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1Back to top Go down   1989 K100 Teardown & rebuild Empty 1989 K100 Teardown & rebuild on Thu Mar 31, 2016 6:51 am

mikerogers74

mikerogers74
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Hi All,

I bought a cheap 1989 K100LT off of a friend with the intention of pulling it all apart and putting it back together, fixing and cleaning up as I go. I wanted to start this thread to capture the progress and also to hopefully get some advice from you guys on what trouble areas to look at as I go through.

I decided to start with the transmission am working through Chris Harris' 6 part "K100 Spline Lube" videos - very nicely done. So here goes...

    

2Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Thu Mar 31, 2016 6:58 am

mikerogers74

mikerogers74
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So I collected the bike looking like this:

1989 K100 Teardown & rebuild 12516810

First job was to pull off the fairing, damn they weighed a ton. Plus the previous, previous owner had used all kinds of wood screws to hold it together Smile

1989 K100 Teardown & rebuild Img_2110

    

3Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Thu Mar 31, 2016 7:02 am

RicK G

RicK G
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Best advice I can give is use plenty of sandwich bags and a marker pen and take heaps of photos unless you have a memory like an elephant.
If you need bits ask on the forum first as many of us have 3-4 spares bikes
If you want a manual send me a PM


__________________________________________________
"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
    

4Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Thu Mar 31, 2016 7:05 am

mikerogers74

mikerogers74
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Much appreciated. I have already raided the kitchen and stolen the sandwich bags. That lesson I have learned the hard way!

    

5Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Thu Mar 31, 2016 7:09 am

mikerogers74

mikerogers74
active member
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Then I yanked apart the final drive to find this:

1989 K100 Teardown & rebuild Img_2211

and this

1989 K100 Teardown & rebuild Img_2212

Not good. I contacted Brunos in Canada and he suggested that the pinion is fine but the spline is shot and I need a new drive shaft. About $500 here in Aus new. I am trying to source alternatives but if there aren't any other major problems then it's not too bad.

    

6Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Thu Mar 31, 2016 7:13 am

Born Again Eccentric

Born Again Eccentric
Life time member
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An interesting looking bike - judging by the tyres and raised front mudguard the PO used it for some off-roading.

They are reasonably straightforward bikes to work on but it is worth having a good read through the "just bought a K" articles on the portal page. Unless you are going for a show bike or money is no object, don't go looking for problems where there are unlikely to be problems. Stick to the fundamentals of cleaning up electric connectors, oil & lub changes, coolant change (including cleaning up the radiator cap) and filters. Some rubber components and hoses may need changing, but many will not. Stop Press - Ok and perhaps do something about the drive shaft splines and seals....

When you've done the basics, get out and ride and let the bike tell you what else needs attention. I fear that too many bikes get the strip down treatment, with the best intentions in the world, and then just never come back together again.

Enjoy the project


__________________________________________________
1989 K100 Teardown & rebuild Uk-log101989 K100 Teardown & rebuild Sco-lo151989 K100 Teardown & rebuild Eu-log10
Paul 1989 K100 Teardown & rebuild 905546712

"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 Insurancewrite-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)
    

7Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Thu Mar 31, 2016 7:14 am

RicK G

RicK G
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Get the spline from Motobins in UK and weld it on. I have done 3 now for friends. If the uni is suspect you can take your pick of 3 I have here with good unis and shagged splines.



Last edited by RicK G on Thu Mar 31, 2016 7:16 am; edited 1 time in total


__________________________________________________
"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
    

8Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Thu Mar 31, 2016 7:15 am

mikerogers74

mikerogers74
active member
active member
Anyway, so I keep stripping down...

1989 K100 Teardown & rebuild Img_2213


Wow, wonder if these are OEM pine battery planks? Smile

1989 K100 Teardown & rebuild Img_2214

Shock is not OEM, need to look into these IKONs.

1989 K100 Teardown & rebuild Img_2215

Exhaust removal was easy. But 2 of the header pipe clamps were missing SadLots of dirt down there too

1989 K100 Teardown & rebuild Img_2216

    

9Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Thu Mar 31, 2016 7:16 am

mikerogers74

mikerogers74
active member
active member
@RicK G wrote:Get the spline from Motobins in UK and weld it on. I have done 3 now for friends. If the uni is suspect you can take your pick of 3 I have here with good inis and shagged splines.
Thanks again Rick - I have just sent an email through to them. I think the UNI is ok but I'm not 100% sure what to look for - I believe that they get 'notchy'?

    

10Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Thu Mar 31, 2016 7:20 am

RicK G

RicK G
VIP
VIP
Hold the shaft in one hand and push down on the uni and rotate it and any wear will become apparent.


__________________________________________________
"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
    

11Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Thu Mar 31, 2016 7:21 am

mikerogers74

mikerogers74
active member
active member
@Born Again Eccentric wrote:An interesting looking bike - judging by the tyres and raised front mudguard the PO used it for some off-roading.

They are reasonably straightforward bikes to work on but it is worth having a good read through the "just bought a K" articles on the portal page. Unless you are going for a show bike or money is no object, don't go looking for problems where there are unlikely to be problems. Stick to the fundamentals of cleaning up electric connectors, oil & lub changes, coolant change (including cleaning up the radiator cap) and filters. Some rubber components and hoses may need changing, but many will not. Stop Press - Ok and perhaps do something about the drive shaft splines and seals....

When you've done the basics, get out and ride and let the bike tell you what else needs attention. I fear that too many bikes get the strip down treatment, with the best intentions in the world, and then just never come back together again.

Enjoy the project

Sounds advice. I plan on checking the clutch plate then doing the spline lube and cleaning and sealing it all back up. Then I will focus on exactly the type of things you are talking about. Hoses are in reasonable condition but clutch boot is shot and some other grommets have been torqued to hell. Touch wood - i have not had a single seized bolt.

    

12Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Thu Mar 31, 2016 7:33 am

mikerogers74

mikerogers74
active member
active member
So I got the swing arm off and the bell housing. Now I noticed something odd. In the Chris Harris video he pulls off the clutch boot, removes a spring and a "puck" and then a bearing. I did not seem to have one of these bearings...

In this video https://www.youtube.com/watch?v=YCnQE4vQTcsat 5:43 he removes the 'puck' and then pulls out a bearing.

All that came out of mine was

1989 K100 Teardown & rebuild Img_2311

Nothing else in there...

1989 K100 Teardown & rebuild Img_2312

I might be as thick as 2 planks though and missing something obvious...

    

13Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Thu Mar 31, 2016 9:31 am

RicK G

RicK G
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The little piston is the bearing and sometimes (well most of the time) it falls apart and comes out like Harris pulls it out. When they do that just put them back in and all is fine.


__________________________________________________
"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
    

14Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Thu Mar 31, 2016 11:21 am

Inge K.

Inge K.
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@mikerogers74 wrote: Now I noticed something odd. In the Chris Harris video he pulls off the clutch boot, removes a spring and a "puck" and then a bearing. I did not seem to have one of these bearings......

The video shows the early version alu piston where the bearing was a separate part.
In your picture is the later plastic piston where the bearing is integrated.


__________________________________________________
Inge K.
K100RS -86. (first owner), K1100LTSE -94.
    

15Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Sat Apr 02, 2016 10:37 pm

mikerogers74

mikerogers74
active member
active member
So I got the transmission off. I have a thin coat of black oil in the clutch area and on the transmission block. This is not 'normal' no? Is it likely to be coming from the transmission? Should I replace the transmission gasket?


1989 K100 Teardown & rebuild Img_2319
1989 K100 Teardown & rebuild Img_2318
1989 K100 Teardown & rebuild Img_2317

    

16Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Sat Apr 02, 2016 11:48 pm

RicK G

RicK G
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VIP
Wow that clutch spline looks like you have got there just in time. How are the splines on the shaft, in the pic they look OK but its hard to tell.
The gearbox oil will have a very acrid sulphury smell to it. It looks to me like the oil will be coming from the engine output shaft seal because there is no oil on the clutch yet.
You will need to remove the clutch plates and carrier to get to it. Take care removing the 6 clutch bolts, the hex hole is shallow and easily rounded out. If that does happen use an 8mm or 5/16 drill and dril the head off and the remainder will come out easily. I replace them with hex head bolts from REPCO and usually need to cut them down to the correct length so next time its easy. In behind the nut on the shaft is a big O-ring use a sharpened 3mm screwdriver to cut it into 4-5 pieces which makes it very easy to get out.
If you buy a seal locally get a viton seal to stand up to the heat and when they try to charge $80 for it squeel like a stuck pig and say you only paid $32 for the last one and usually they will give in. The seal is 80 x 50 x 8 which works well but OEM is 80 x 50 x 10. I have used the 8mm seals many times and never had an issue.


__________________________________________________
"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
    

17Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Sun Apr 03, 2016 12:14 am

mikerogers74

mikerogers74
active member
active member
@RicK G wrote:Wow that clutch spline looks like you have got there just in time. How are the splines on the shaft, in the pic they look OK but its hard to tell.
The gearbox oil will have a very acrid sulphury smell to it. It looks to me like the oil will be coming from the engine output shaft seal because there is no oil on the clutch yet.
You will need to remove the clutch plates and carrier to get to it. Take care removing the 6 clutch bolts, the hex hole is shallow and easily rounded out. If that does happen use an 8mm or 5/16 drill and dril the head off and the remainder will come out easily. I replace them with hex head bolts from REPCO and usually need to cut them down to the correct length so next time its easy. In behind the nut on the shaft is a big O-ring use a sharpened 3mm screwdriver to cut it into 4-5 pieces which makes it very easy to get out.
If you buy a seal locally get a viton seal to stand up to the heat and when they try to charge $80 for it squeel like a stuck pig and say you only paid $32 for the last one and usually they will give in. The seal is 80 x 50 x 8 which works well but OEM is 80 x 50 x 10. I have used the 8mm seals many times and never had an issue.

Thanks Rick. It does not smell sulphury so I guess not transmission. Attached are pics. Hopefully they are ok...

1989 K100 Teardown & rebuild Img_2320
1989 K100 Teardown & rebuild Img_2321

    

18Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Sun Apr 03, 2016 4:03 am

RicK G

RicK G
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The gearbox input spline looks OK but not the spline in the friction plate.
To lube the splines I use Rocol GA50 you can get it from Blackwoods. There are quite a few brands with 50% or more moly, Honda make one and Staburags is what factory use but I am not sure if you can get it in Oz apart from a Dealer
Also check the steel plates by puting a straight edge across the flat surface and check if they are dished.


__________________________________________________
"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
    

19Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Sun Apr 03, 2016 5:36 am

mikerogers74

mikerogers74
active member
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@RicK G wrote:The gearbox input spline looks OK but not the spline in the friction plate.
To lube the splines I use Rocol GA50 you can get it from Blackwoods. There are quite a few brands with 50% or more moly, Honda make one and Staburags is what factory use but I am not sure if you can get it in Oz apart from a Dealer
Also check the steel plates by puting a straight edge across the flat surface and check if they are dished.

So you reckon I should replace that clutch plate?

I bought some of this to lube:http://www2.munichmotorcycles.com.au/product_info.php?products_id=515

Boy was it a mission to get the clutch out! Hex hole is indeed shallow but I stripped none. Pulling the clutch was a different story - tapping with rubber hammer, swearing at at, sweating, begging. Stopping for a beer did the trick.

    

20Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Sun Apr 03, 2016 8:12 am

RicK G

RicK G
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Yeah that Optimol is the good stuff. Definately replace the clutch plate you are lucky there is no real damage to the input shaft of the gearbox.


__________________________________________________
"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
    

21Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Mon Apr 04, 2016 6:53 am

mikerogers74

mikerogers74
active member
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Hi Guys,

Do these clutch plates looked too dished? I'd say about .5mm, maybe less...

1989 K100 Teardown & rebuild Img_2322
1989 K100 Teardown & rebuild Img_2323

    

22Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Mon Apr 04, 2016 7:28 am

RicK G

RicK G
VIP
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The first plate is definately had it and the other is not as bad but on the way out.

With both plates like the first one you only get about 6mm at the edge of the friction plate that holds. I have probably 10 maybe 12 plates like that. I repaired a pair about 5 years ago for my K1100 but it took hours to set them up and grind them so it really isn't worth doing. I have put a few back together with a friction plate that matched and they kept going well but with your plate in that condition it's not a proposition worth considering.


__________________________________________________
"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
    

23Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Mon Apr 04, 2016 8:19 am

mikerogers74

mikerogers74
active member
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Thanks Rick. Sigh... I guess it's time to hit up beemer boneyard or motorworks...

    

24Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Thu Apr 07, 2016 8:03 am

mikerogers74

mikerogers74
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I'm going to go out on a limb here and say my main seal is indeed busted

1989 K100 Teardown & rebuild Img_2324
1989 K100 Teardown & rebuild Img_2325

    

25Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Fri Apr 08, 2016 12:17 am

mikerogers74

mikerogers74
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My new guts arrived courtesy of Munich Motorcycles. Super fast delivery from Perth to Sydney.

1989 K100 Teardown & rebuild Img_2326

    

26Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Fri Apr 08, 2016 5:40 am

mikerogers74

mikerogers74
active member
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So I had to get the seal out. First I tried the old screws, sledgehammer and wire trick.

1989 K100 Teardown & rebuild Img_2327

And ended up with broken wire.

1989 K100 Teardown & rebuild Img_2328

Then I tried my own variation. The patented vice-grips-on-a-rope-to-a-sledgehammer-tug. I ended up with a vice grip in the shins.

1989 K100 Teardown & rebuild Img_2329

So finally I bought a tool called a seal remover. To remove the seal. It removed the seal.

1989 K100 Teardown & rebuild Img_2330

    

27Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Fri Apr 08, 2016 8:15 am

mikerogers74

mikerogers74
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So I decided to remove the air box to see what was under there. A lot of oil muck. What other expensive seal could possibly be broken to allow this crap to exist?

1989 K100 Teardown & rebuild Img_2331

    

28Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Fri Apr 08, 2016 10:00 am

RicK G

RicK G
VIP
VIP
Nothing to be concerned about there, it's fairly normal and this is quite possible the first time it's been cleaned or seen in 30 years.


__________________________________________________
"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
    

29Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Mon Apr 18, 2016 7:17 am

mikerogers74

mikerogers74
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So I think I have a filthy plenum. Is it just me or do you all have filthy plenums?

1989 K100 Teardown & rebuild Img_2411

    

30Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Mon Apr 18, 2016 9:12 am

Dai

Dai
Life time member
Life time member
We're all dirty buggers around here Very Happy . Seriously though, that one looks like a lack of air filter.


__________________________________________________
'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)
    

31Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Mon Apr 18, 2016 12:31 pm

mikerogers74

mikerogers74
active member
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Just found a thread here http://www.motobrick.com/index.php?topic=4408.0which suggests this is 'normal' due to oil from crankcase breather hose. Will clean and maybe get a hose filter.

    

32Back to top Go down   1989 K100 Teardown & rebuild Empty Re: 1989 K100 Teardown & rebuild on Mon Apr 18, 2016 9:28 pm

RicK G

RicK G
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Oil sludge build up is fairly normal but there is a dust build up there as well. Make sure the filter is working as intended and seals well on the outer edge and there is no splits in the paper. If you have a reuseable filter like K&N get rid of it as that is where the dust is getting in. I have found and the US military also found that K&N usually dont even stop fine sand.


__________________________________________________
"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
    

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