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51Back to top Go down    Re: ComberJohn's Ghost on Sun Mar 13, 2016 5:16 pm

Dai


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Two coats of zinc phosphate later. The first coat didn't 'take' in places and I wasn't too sure if that was the result of missed grease streaks or because I hadn't stirred the paint enough (most likely), so I left it overnight to go completely hard (10 hours according to the can, left it for a day). I then rubbed a lot of it back to the original paint/metal and coated the whole lot again. Of course, this time I collected a whole load of runs too as opposed to bugger-all on the first coat  Mad It gets two weeks to go hard this time as that's the earliest I can get back to it and rub it down again before enameling it.

    

52Back to top Go down    Re: ComberJohn's Ghost on Sat Apr 09, 2016 3:08 pm

Dai

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Finally got round to cutting this back:



Just after which the sun was replaced by rain, so it got hung up to drip dry  Very Happy



Not much change from the view above, except that the Guzzi on the bench is my 1000SP which has been sold and I'm now putting it back on the road for the new owner. Another PBS.


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

53Back to top Go down    Re: ComberJohn's Ghost on Sat Apr 09, 2016 3:55 pm

Born Again Eccentric

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Nice work Dai. 
Don't know if I envy your meticulous attention to detail or your manKave (workshop) more!

Keep going, you're doing a grand job there.Very Happy


__________________________________________________
 
                              Paul  

"Heidi" K100LT 1991 (Grey) (VIN 0190172 Engine No. 104EB 2590 2213) - 5th owner. January 2014 (34,000 - 61,000 miles and counting....)
"Gretel" K100LT 1989 (Silver Grey) (VIN 0177324 Engine No. 104EA 2789 2211) - 4th+ owner. September 2015 (58,500miles and counting....). Cat C Insurance write-off rebuild Feb 17
"Donor" K100LT 1990 (Red)  (VIN 0178091 Engine No. 4489 2024) - 6th & final owner (crash write-off now donor bike).   June 2012 (73,000 miles) to November 2013 (89,500 miles)
    

54Back to top Go down    Re: ComberJohn's Ghost on Sat Apr 16, 2016 1:45 pm

Dai

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The enamel didn't come out as well as I'd hoped but that was down to me not cutting the phosphate undercoat back properly. Serves me right.





I can absolutely highly recommend using a zinc-phosphate based undercoat and brushed tractor enamel on top; there's a real delight in watching the brush marks fall out of the paint as it goes on. The enamel dries seriously quickly; within a few minutes there's a distinct colour change as the top layer starts to go off. Although the tin says re-coat within thirty minutes, I found that once the top layer starts to seal any going back will leave brush marks in the new enamel. The real problem was at the rear of the headstock where all the tubes and plates come together; that turned into a slap-it-on-and-get-out session.

I replaced all of the captive nuts too.



I had to laugh; I 'borrowed' a couple of dozen of those from my employer over thirty years ago and never used them until now.


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

55Back to top Go down    Re: ComberJohn's Ghost on Sat Apr 16, 2016 3:11 pm

92KK 84WW Olaf

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Dai

While you were setting up that post I was out on my K having gone down to the local hardware/farming store to see about painting the rear frame on the RT. I work with paints too and zinc phosphate is the business but I had picked up a satin black tractor paint [no it didn't say Made in USA] and it mentioned exactly those properties you have said. Decided to ring someone I knew with lots of off road mud plugging bikes for advice and it was a case of go for it. Extra coats are good and have to let it time to cure fully before putting back cable ties etc.


__________________________________________________
1992 K100LT 0193214 Bertha Alaska Blue 101,000 miles
1984 K100RT 0022575 Brutus Baja Red bought 36,000 now 89,150 miles
1997 K1100LT 0188024 Wotan Mystic Red 58,645 now 84,600 miles
1983 K100RS 0011175 Fricka 29,000 miles Damn K Pox
    

56Back to top Go down    Re: ComberJohn's Ghost on Sun Apr 17, 2016 10:04 am

Dai

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Extra coats = six days between each one if you don't get it within thirty minutes. That's a long time! Very Happy Oh - and use a good quality bristle brush. I forgot to mention that. I used a 30mm Harris Perfection.


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

57Back to top Go down    Re: ComberJohn's Ghost on Sun Apr 17, 2016 2:53 pm

Dai

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Another one of those small things that irritated the hell out of me on Low Flying Brick is the two brackets that hold the mudguard on and go horribly rusty. Not on Brick2 they won't.



It's the first time I've done any stainless welding and I was quite surprised how much power I had to put through a 1.6mm rod (50 amps) before I started getting decent flow on the weld.


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

58Back to top Go down    Re: ComberJohn's Ghost on Sat May 28, 2016 4:40 pm

Dai

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I snagged a K1100 mainstand off ebay for £30 inc p&p which I was quite pleased with but when it arrived I found this:



It was actually worse than the picture; that was taken after I'd gently hammered the foot back into shape. Originally it was folded almost flat against the leg. So, out came my old friend the SIP Weldmate:



No, that's not serious weld spatter on the left. The foot was worn so thin that even at 50 amps it punched right through and I had to build the hole back up again. I love this welder - I'll swear that you could weld sh!t to a blanket with it. I also ran a bead along the underside of the crack and then ground it flat.



Next up was the sidestand. I took the one off Low Flying Brick's original mainstand assembly (LFB got a K1100 stand a while back); I'd always thought it was a bit loose and expected to find a badly-worn spacer but when the bolt did (eventually) come out, there was no spacer at all. Of all the things that fitted perfectly and just required cutting to size, I wouldn't have expected a rear brake pedal spacer to do the job but here it is:



Finally, I applied a coat of Will's Hammershite to finish them off. I couldn't be bothered with the enamel because hanging down there in the flying crap, they're going to need regular recoats. Given a following wind they should be ready for fitting tomorrow.


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

59Back to top Go down    Re: ComberJohn's Ghost on Sun Jun 05, 2016 4:41 pm

Dai

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Last Sunday I did mount the repainted mainstand and also the exhaust pipe; finally, it seemed, light at the end of the tunnel.



New feet, clean exhaust system and a missing plenum chamber. Read on... Sad

The light turned out to be a train. First up was a faulty back brake on Low Flying Brick. That was a bit of a peculiar one: the brake pedal was hard but the action was suspect. Then the reservoir ran dry (!!) but there were no signs of a hydraulic leak anywhere. While bleeding the system I heard a slurp-slurp-slurp from underneath; I peeled back the boot on the master cylinder and was promptly showered with hydraulic fluid. But the system pumped up perfectly...! And stayed that way. And worked properly. Until the reservoir ran low again and the boot filled up with hydraulic fluid again. Evil or Very Mad

Conclusion: the seal was leaking but such a tiny amount that I couldn't see it and only prolonged pressure (braking) was forcing fluid passed the seal. Bugger. New seal kit: £54. However, as this was a Sunday, the nearest seal kit was in Brick 2's master cylinder. Ten minutes later the entire rear brake system was off Brick 2 and mounted on LFB. I mount the rear hydraulic reservoirs directly to the footrest hangers so there's no messing about removing the battery, FICU etc. when taking the rear hydraulics off. So now Brick 2 is missing a rear brake. Sigh.

Second up was the nice new throttle cable I'd just made. It worked perfectly with the throttlebodies on the bench, but just wouldn't go onto the throttlebodies on Brick 2. That was when I discovered the two different sizes of cable brackets, but only after I'd removed the airbox and plenum chamber to try and see what was wrong. Okay... so it did do me a sort-of favour because I found that the inlets from the plenum chamber to the throttlebodies were starting to perish. Add another £34 for new inlets. While I was that far into stripping the fuel system (again!) I took the inlet spigots off and checked those too. No signs of splitting at all (hooray), so I bolted them back to the engine with a bit of Threebond to seal them.

At least the handlebars are finished with (I hope). They're fitted with Triumph Sprint switchgear, a Moto Guzzi California EV adjustable clutch lever and a Suzuki Bandit 1200 master cylinder with fully adjustable lever.



Homemade clutch and fast idle fittings and cables.



Homemade throttle fittings and cable.



All those nice new brass fittings led to one conclusion; I'm going to be in deep shit if a cable breaks on the road. The idea is to make three clutch cables, two throttle cables and a fast idle cable and keep the lot secreted in the lunchbox at the back of the bike.


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

60Back to top Go down    Re: ComberJohn's Ghost on Fri Jun 17, 2016 2:53 pm

Dai

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Nice new brass bits:



Unfortunately I ran out of 6mm tube after making the second throttle cable. A new lot arrived yesterday, so no excuse not to finish the job. I didn't dare try to cut a 6mm thread into an 8mm hex bar (I don't have the tools to drill to that sort of accuracy) so I bottled out and used 10mm bar instead. The top throttle cable is using an adjuster scavenged from a Honda CB250N throttle cable.

After throwing some more money at Motorworks, I replaced the split throttle body inlets and put the plenum chamber back on. At the same time I overhauled LFB's rear master cylinder and mounted it on Brick2. That's the easiest m/c overhaul I've ever done. Try doing Guzzi master cylinders for a bit of amusement one day...


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

61Back to top Go down    Re: ComberJohn's Ghost on Sat Jul 02, 2016 4:27 pm

Dai

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Engine finally back in one piece:



I still have to check/do the tappet clearances. Now, here's a shock for those of you that are familiar with my bikes....

CLEAN WHEELS!!!!!!! Shocked Shocked 



(See avatar to see what they're normally like). I started off with a citrus-based cleaner to remove as much of the dirt as possible but had to resort to an abrasive nylon wheel, followed by 240 grade wet'n'dry lubicated with a colour restorer. Not again. Never again. They're actually the wheels that used to be on LFB but both tyres needed replacing. It was easier to take both of Brick2's wheels in the back of the car, then swap them over when I got home. I should have taken a picture of both bikes with no wheels...

Ringfad pointed me to a Givi mounting kit on ebay. I snaffled it, but found when it arrived that it was specifically for the 4-valve model. Bugger. Two out of the three required mounting points weren't difficult to relocate, but the last one was a sod. There should be a bridge mounted under the plastic mudguard that takes the place of the existing clamp, but because the 2v and 4v frames have different rear loops, it wasn't gonna fit. Oddly enough, the final bodge consisted entirely of Givi parts! Very Happy Oh yeah - and it proves that I did do the back wheel too.



Eventually the rusty bolts will be replaced with stainless steel, but I just don't have any of the right size in stock.


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

62Back to top Go down    Re: ComberJohn's Ghost on Sat Jul 02, 2016 9:08 pm

blaKey

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Coming together nicely Dai.

Good work!


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Neil
K100RS 1986 RED!

Dress for the ride and the potential slide.
    

63Back to top Go down    ComberJohn's Ghost on Sat Jul 02, 2016 9:32 pm

Tom FKR

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G'day Dai, Nice work like that is indeed very hard to ignore.....


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1993 K75 Slightly Modified
2010 BMW F650GS Twin
1992 R100R
    

64Back to top Go down    Re: ComberJohn's Ghost on Sat Jul 02, 2016 10:41 pm

Garyk100

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Good post Dai enjoyed reading it, have owned my k for 18 years.
after reading this post, I think it's time to do some of the serious maintenance, since 1998 I have only done fluid and oil changes and filters, I do all the maintenance myself. Never been game to do the spline lube but it's time to learn how, new fork springs would be nice, I am sure it used to sit higher at the front. Thank you for the inspiration 
Cheers Gary


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The early bird catches the worm, but the second mouse gets the cheese

1991 K100rs16v
1993 K1100LT
    

65Back to top Go down    Re: ComberJohn's Ghost on Sun Jul 03, 2016 12:14 am

RicK G

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Doing a spline lube on a paralever is a bit different Gary. The thing to watch for is the phaseing of the two halves of the shaft.


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"Every normal man must be tempted, at times, to spit upon his hands, hoist the black flag, and begin slitting throats."  from Mencken's 1919 Prejudices

Bikes 1993 K1100 LT, 1998 K1100 LT, 1993 K75 RT, 1996 K75RT, 1986 K75 GS, 1979 Z1300 Kawasaki X 2 for now
    

66Back to top Go down    Re: ComberJohn's Ghost on Sun Jul 03, 2016 2:53 am

Garyk100

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Thanks Rick, I will research the procedure, where do I get a phaser:-c: think I have a mate who could help he is a Star Trek fan,


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The early bird catches the worm, but the second mouse gets the cheese

1991 K100rs16v
1993 K1100LT
    

67Back to top Go down    Re: ComberJohn's Ghost on Sun Jul 03, 2016 2:55 am

indian036

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Make sure it is only set to stun, not kill. 


Bill


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1985 K100RT  VIN 0028991  My original Very Happy   (Historic rego)
1985 K100RT  VIN 0029036  BOB the Blue Old Bike  (Historic rego)
1990 K100LT  VIN 0190452  Work in progress
1984 K100RT  VIN 0023022  Work needing lots of progress

1986 K100RT  VIN 0090542  Work needing lots and lots of progress
1993 K1100LT  VIN 0183046  Work in progress
1993 K75S  VIN 0213045  Newest toy, slightly non-original
    

68Back to top Go down    Re: ComberJohn's Ghost on Sun Jul 10, 2016 5:14 pm

Dai

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One step closer...



and one step back. See the pile of lower fairing parts on the bird food boxes upper middle of the pic? They looked silver in the ebay pictures but turned out to be Sea Foam Green (or whatever it is) when they arrived. The upper fairing isn't silver either, but I could have lived with respraying such a large flat piece of plastic. Not the lowers - too many nooks and crannies and some things I get really lazy about. Plus one of the lowers (leftside) was far more scratched than the pictures made it out to be. Bugger. I should have asked about the colour; have only myself to blame for that one.

I made my own mounts for the Givi topbox. No amount of squinting at ebay pics was able to tell me if the Givi mounting kit used the existing BMW rack holes, so I decided not to chance it. The standoffs were made from 14mm aluminium rod; the rear ones were drilled and tapped so that I could secure them from inside the seat hump but the front ones were just drilled straight through as spacers. Figuring out the angle so that they'd mount vertically on the seat hump was interesting...

So, I actually got round to doing the wiring test yesterday. No.1 fuse kissed its ass goodbye as soon as I turned the ignition on. After a couple of simple tests and a couple more blown fuses, I walked off and left it for the day. I came back to it this morning and disconnected the instrument panel. No blown fuse. Next thought - what have I cross-wired? Answer - nothing. I've rewired the bloody connectors the wrong way round, so sockets 1-12 went into pins 13-24 and vice versa. Just at the moment I don't have any spare sockets, so a Stanley knife was brought in to relieve the tongues that ensure correct location and that was followed by a permanent marker that scribed 'LEFT 1-12' and 'RIGHT 13-24'  in BIG LETTERS on the relevant connector.

Problem solved with a first-class bodge Shocked Very Happy


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

69Back to top Go down    Re: ComberJohn's Ghost on Mon Jul 18, 2016 9:49 am

Dai

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Oops! Anyone spot the typo above?





Checked the valve clearances (which I wasn't looking forward to) and whaddya know? They were all okay!





Lastly, gut and overhaul the fuel tank. I checked the resistance while I was at it and got reading of between 4ohms and 113 ohms. Good enough, I hope.





Today was also bite the bullet day. Add fluids and sneak up on the starter button... I'd love to say it fired up first time but it didn't, just sat there and churned. Putting the fuel lines on the right way round helps a lot Very Happy Then no.4 injector started spewing fuel from the fuel rail, so off came the whole assembly for a check and reseat. This time the garage was filled with a cloud of blue smoke - never been so happy to run out of a cloud of choking fumes!!!!


So, I'm left with a couple of niggles. The alternator seems to be bolloxed as the blue wire has 12 volts on it but the charging light is not going out. Voltage across the battery is just the battery voltage; no charge at all. The other annoyance is the fuel light is not going out. I tried wiggling the float but no joy. The first problem is easy to fix as I have two spare alternators but the second one... I'm not sure where to start.


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

70Back to top Go down    Re: ComberJohn's Ghost on Tue Jul 19, 2016 12:16 pm

Dai

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Charging problem fixed - I swapped the alternator for another 50amp verison. I checked the brushes in both alternators and found that the 'original' one had better brushes than the replacement. The unproven conclusion is that the regulator had failed.

Anyone any ideas on the fuel level light?


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

71Back to top Go down    Re: ComberJohn's Ghost on Thu Jul 21, 2016 12:08 pm

Dai

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Dammit - the fuel level sensor is buggered. I pulled it out again this morning and dismantled it according to the word of Robmack. No dirt or corrosion on the inside but there's a definate break in the track. Sad No idea what I was measuring before..!

WTB inserted in the appropriate forum... Very Happy


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

72Back to top Go down    Re: ComberJohn's Ghost on Fri Jul 22, 2016 1:17 pm

Dai

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Problem fixed. I found a not very good solder joint under a thin rubber tube in the tail from the fuel tank, so I chopped the connectors off both the new loom and the tank tail (I'd reused the OEM connector on the new loom) and crimped on two new Molex connector blocks. Must have been a broken wire in the OEM connector as this time the fuel gauge responded almost immediately when I pulled the float up but the fuel low light still remained on. After a few minutes of faffing about, I turned away from the bike and when I turned back, the light was out. I thought I'd imagined it, so I turned the ignition off and went through the test procedure again. Light on. Turn away, come back a bit later and light off. Then the remaining grey cells sputtered into action and I finally figured out that there's an RC network in the instrument panel damping the input from the float.

Well now - time to bolt the bike back together, put two new tyres on it and pass it on to the new owner.

Yes, it's sold. I told you I wanted that Guzzi Nuovo Falcone... Very Happy


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

73Back to top Go down    Re: ComberJohn's Ghost on Fri Jul 22, 2016 9:01 pm

RicK G

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Oh No Doc I think we're losing him, someone has been feeding him anyiKpox vacine in his loffee.


__________________________________________________
"Every normal man must be tempted, at times, to spit upon his hands, hoist the black flag, and begin slitting throats."  from Mencken's 1919 Prejudices

Bikes 1993 K1100 LT, 1998 K1100 LT, 1993 K75 RT, 1996 K75RT, 1986 K75 GS, 1979 Z1300 Kawasaki X 2 for now
    

74Back to top Go down    Re: ComberJohn's Ghost on Fri Jul 22, 2016 11:35 pm

Holister

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Been reading this with interest Dai. Good job.
A bit of Guzzi fever coming on I think. Take a couple of Panadol® and have a lay down. It'll pass. Laughing


__________________________________________________
1988 K100RT     VIN No.  0094680
1989 K100RT     VIN No.  0097367 (naked)  
1996 K1100RS   VIN No.  0451808
     Fuel:  95 Octane
Engine Oil: Nulon Full Synthetic 15W50
Gear Box Oil:  Nulon Synthetic 75W90
    

75Back to top Go down    Re: ComberJohn's Ghost on Sat Jul 23, 2016 6:56 am

Dai

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In my defence I have to add that I also sold a Guzzi to fund the Guzzi. I'm still looking to sell the Suzuki to finish funding the Guzzi. It's funny; I sold the 1000SP to a guy for whom I'd built an 850-T3 from the proverbial six boxes of bits about eight years ago. His son has an MV Augusta Brutale but was looking for a boxer for an easier commute. I knew where there was an R100RS for sale but as soon as his father told him I was selling Brick2, he jumped, even though I pointed out that he could most likely get a K100 cheaper than the price I was asking. Even so, it was still only half the price of the boxer.

So I find myself in the odd position of building bikes for father and son.


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

76Back to top Go down    Re: ComberJohn's Ghost on Tue Jul 26, 2016 5:19 pm

88

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Dai - did you take any final pics of the finished bike - I was sure cleaning up nicely!


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88....May contain nuts!

"The world is a book and those who do not travel read only one page." - St. Augustine from 1600 years ago & still true!

Bike: K100LT 1988. 0172363. AKA the Bullion Brick! Mods: k1100 screen and stands.
K1: 1990. 6374189. Custom Stealth Black paint.
    

77Back to top Go down    Re: ComberJohn's Ghost on Tue Jul 26, 2016 9:04 pm

Dai

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Hi Will! It's not quite finished yet, so don't worry about that. More pictures to follow.


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

78Back to top Go down    Re: ComberJohn's Ghost on Wed Aug 10, 2016 8:01 am

Dai

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Finished - apart from not having plugged in the Tom-Tom. I switched the navsat power from the leftmost switch in the crashpad. At the new owner's request I also fitted heated grips, a clock and fuel gauge in the fairing and two power take-offs (USB and Hella) mounted on the ignition coil cover.



Surprisingly, he (or rather his father!) wasn't too fussed about the colour mismatch saying that his son would get it resprayed when he could be bothered.





The additional light on the back of both bikes is a foglight.

On Monday Brick2 passed its MoT on the first attempt, not bad considering I took it straight from home to the testing station with no other checking - but it shouldn't have done. The speedo died within a hundred yards of home. Somewhat pissed off, I decided that at least I could find out if I'd missed anything and the cost of a re-test is less than booking a new one. However, the tester missed it and I wasn't going to tell him! Twisted Evil The new brakes and swingarm/headstock bearings tester is great for getting someone to scrub-in brand new tyres too .

Yesterday morning I sat down to troubleshoot the speedo. I started by checking the drive sensor but that was pulsing fine, then replaced the entire speedo but still no joy. That just left the drive board; a quick root through a pile of buggered speedos turned up a replacement board and sure enough, that was the problem. It's just taken you ten seconds to read what took me two hours to sort out!

Now for the interesting bit - a back-to-back comparison with LFB. If you recall, LFB has had K1100 TBs fitted and the timing advanced by six degrees. I'd always been curious as to how much difference this had really made and I found out.

LFB made Brick2 feel like a slug. Oops. lol!


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

79Back to top Go down    Re: ComberJohn's Ghost on Wed Aug 10, 2016 8:55 am

Gaz

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Great job Dai, always things to learn watching guys like yourself do these builds.

Is your choice of using non-BMW handlebar switchgear based on personal preference and/or cost and availability?

Thanks


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Gaz
95 K1100LT 0232224; 90 K75 6427509; 87 R80G/S PD 6292136
    

80Back to top Go down    Re: ComberJohn's Ghost on Wed Aug 10, 2016 1:14 pm

Dai

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It's based on teenage injury affraid  . I have only half the normal range of movement in both wrists and both thumbs which makes the standard BMW paddles somewhat painful to operate.

Well, I thought it was finished anyway... only today when I went to fine-tune the throttlebodies Brick2 pissed all over the garage floor. It didn't take long to track the leak to the brand-new(!!) clutch boot. I was absolutely not amused to find that the reinforcing ring (where the clutch arm pushes against the boot) was only bonded to the rubber for about a 30-degree arc. I've ordered two this time, just in case  



Last edited by Dai on Wed Aug 10, 2016 6:16 pm; edited 1 time in total


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81Back to top Go down    Re: ComberJohn's Ghost on Wed Aug 10, 2016 4:45 pm

mike d


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Do they check the actual speedo in your MOT? Over here the UK MOT test doesn't check its operation, only that any illumination bulbs are working.

Mike

    

82Back to top Go down    Re: ComberJohn's Ghost on Wed Aug 10, 2016 6:14 pm

Dai

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You're right, but a non-functioning speedo is frequently caught under the catch-all of 'tester's discretion as to whether something affects the roadworthiness of the vehicle'. Also, it's difficult to miss that it's not working when doing the brake and suspension test on the rollers. Personally, I'd class a defective speedo as potentially dangerous but... This might be of interest:

https://www.gov.uk/government/uploads/system/uploads/attachment_data/file/510388/mot-inspection-manual-classes-1-2.pdf


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'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

83Back to top Go down    Re: ComberJohn's Ghost on Thu Aug 11, 2016 7:12 am

Dai

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New clutch boots arrived from Motorworks today so I gave them a close inspection. Turns out that the leaky one was completely screwed. The reinforcing ring is molded into the rubber - or at least, it should be. On the original one the internal molding that the ring bonds into was thin to non-existent in places. The reinforcing ring must have parted company with the rubber boot the very first time I pulled the clutch lever in. The red outlines show where the rubber molding is missing - sorry about the poor picture but I had to wind the brightness and contrast right up to get the missing bits to display.



No wonder it leaked.


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

84Back to top Go down    Re: ComberJohn's Ghost on Thu Aug 11, 2016 7:32 am

92KK 84WW Olaf

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Dai

When did you put the previous one in? I have a similar issue and mine was replaced April 2014, wondering was there a bad batch of stock out there....!


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1992 K100LT 0193214 Bertha Alaska Blue 101,000 miles
1984 K100RT 0022575 Brutus Baja Red bought 36,000 now 89,150 miles
1997 K1100LT 0188024 Wotan Mystic Red 58,645 now 84,600 miles
1983 K100RS 0011175 Fricka 29,000 miles Damn K Pox
    

85Back to top Go down    Re: ComberJohn's Ghost on Thu Aug 11, 2016 7:53 am

Dai

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It arrived here on Sept. 29th last year.


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

86Back to top Go down    Re: ComberJohn's Ghost on Thu Aug 11, 2016 1:53 pm

Dai

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Well, that was an interesting hour. I found that if you hang a 14lb weight, a 7lb weight and a Guzzi swingarm off the end of the silencer you get just enough room to slide the clutch arm pivot rod through. After that, it's just a case of growing another hand to push the pivot rod back again while your original two hands hold the clutch arm, spring and boot in place.

Actually, I used the clutch cable to hold the clutch arm almost in place. That in itself held the boot and spring together while I wiggled the pivot rod through. Once that was back in again, I pushed the boot over the gearbox spigot and clamped the securing clip back up. The advantage of doing it this way is that you don't put any pressure on the boot from the big spring. Not a difficult job but just awkward because of the confined space. Next time I think I'll take the back wheel off for better access.


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

87Back to top Go down    Re: ComberJohn's Ghost on Fri Aug 12, 2016 9:46 pm

Dai

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It's a wrap!!!!




Brick2 went to its new home this morning. Well, halfway house in Portaferry. Next stop is Rugby across the water.


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

88Back to top Go down    Re: ComberJohn's Ghost on Sat Apr 14, 2018 4:21 pm

charlie99

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don't know how I missed this
but great write up and work Dai
many good tips and ideas

cheers mate


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cheezy grin whilst riding, kinda bloke ....oh the joy !!!! ...... ( brick aviator )

'86 K100 RT..#0090401 ..."Gerty" ( Gertrude Von Clickandshift ) --------O%O
    

89Back to top Go down    Re: ComberJohn's Ghost on Sat Apr 14, 2018 5:54 pm

Dai

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Thanks Charlie! Very Happy


__________________________________________________
'83 K100 upgraded to K100RS spec
Others...
'78 Moto Guzzi 850-T3, '79 Moto Guzzi 850-T3 California,'93 Moto Guzzi 1100ie California,
'03 Suzuki Blandit GSF600SK3 (NFS any more because wifey has claimed it)
    

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