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1Back to top Go down    K100 restoration cafe-racer style on Sat Jan 18, 2014 4:07 pm

Cossie

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Having spent many months looking for a project I recently purchased a †K100 RT that needs work. †(Built 10-1984)
The seller had inherited it as an incomplete rebuild. It was not running and it was not clear what parts were missing . The price was good so i took a chance.

What i brought home.





I sourced the following missing bits from a local breakers
Injectors
Cam cover bolts
HT leads
HT coil†

I checked the torque on big end bearing and main bearing bolts and they were OK (it was not clear what had been taken apart , what had been put together properly and what had been hastily reassembled by the PO when moving the bike)
I removed spark plugs plugs, squirted oil into the cylinders and onto crank bearings. Left it for a while then pushed the bike in gear and the engine rotated OK.†
I dumped the fuel that was in the petrol tank †and rinsed it a few times with fresh petrol then put more fresh petrol in. Oil and water in the engine. Oil in gearbox and final drive.
From what i have read when starting an engine that has been sitting a long time the important thing is to get it running as promptly as possible to get oil circulating under pressure.
So i tested the injectors separately with a 9V battery and a syringe of alcohol and the all looked good.
I hooked up a battery and turned the engine over with plugs out and was getting a good spark. Also oil pressure light went out which was reassuring.
Time to go for it.†
Connected everything up pressed start and with in less than 10 secs it fired. A few more goes and it was running. Result! It sounded nice and smooth too. There was an awful lot of smoke and a knock that on first guess sounded like †a big end bearing, but it was running.
I left it running for for about 40 mins until the fan cut in.†
I started and ran it a few more times and over time †the smoke disappeared. (the knock did not)
I also carried out a compression test and all 4 cylinders were good.
At that stage I was able to say that the engine was worth stripping down to refurbish.

Initially the plan was a cafe racer style rebuild. This is what i had been looking at













However when i got the bike it looked really good as original so i carried out a few trials to lower the original seat. No matter what i did i was not comfortable sitting on the bike at a stop. The seat is just too wide and too high for me (I am not tall) so back to original plan .
I mocked up †a few seats in cardboard and when i had one i liked i did a prototype in plywood.†
I put this on the bike and with a new battery fitted i took it for a spin up and down the lane (about a mile) This allowed me to test operation of the clutch and gearbox (all good). †It was only a 10 minute spin on the bike but i could not stop grinning all evening.

After the first "Road Trip"








First †the mods to frame
Shorten rear overhang and fabricate new cross brace/Lights and seat support. Two new blanking plugs for rear of frame bonded in with epoxy. New fuel tank mounting cross piece. †Remove redundant brackets from frame.
Then dismantle bike as per Bert's excellent article.

Frame ready to be sent for blasting and priming.





Frame back after blasting and etch primer


Next I applied 3 coats of rattle-can †Simoniz acrylic satin black


Its not perfect but the satin is fairly forgiving and i think it looks well. †Its should allow for easy touch up if and when need in later life. As long as it is durable and does not start to rust i will be happy. Time will tell.
That's all for now.



Last edited by Cossie on Sat Feb 08, 2014 4:02 pm; edited 4 times in total (Reason for editing : Inserting pics instead of links)

    

2Back to top Go down    Re: K100 restoration cafe-racer style on Sat Jan 18, 2014 6:08 pm

MikeP

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Looking good. I'm just finishing off painting another frame. They're a pain to get right without overloading some tubes with paint aren't they?

@Cossie wrote:
Next I applied 3 coats of rattle-can †Simoniz acrylic satin black



If you type in the image tags at either end of your links: the image will appear (as above).


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1992 K1
1993 K1100R (used to be an LT)
    

3Back to top Go down    Re: K100 restoration cafe-racer style on Sun Jan 19, 2014 5:01 pm

GTJos

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Very Happy†Hi Cossie !
Looking good; happy to see you started with a solid base !
In regards to the paintjob: my compliments. I'm lucky enough to have a son who's a pro (makes a living being an allround painter).
I watched him sanding, filling, priming, masking and spraying cars and bikes many times, but I agree with MikeP: it's a hell of a job to get a bike's frame just right ! So: compliments on this one, keep up that good work !
I'll be following this project with interest; thank's for sharing !

Regards
Jos


__________________________________________________
Ich bin enge KirchrŲatsjer jong; adieŽ wa ?!†
† † † † † † † † † † † † † † † † 1992 †K1100LT†6458188
† † † † † † † † † † † † † † † † 1986 K100RS 0085647 + sidecar Velorex 562
† † † † † † † † † † † † † † † † 1985 †K100RT †0027026
    

4Back to top Go down    Engine output shaft rivets on Tue Jan 28, 2014 6:34 pm

Cossie

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Thanks for the comments.†
I have opened the engine to get a look at the output shaft as it seemed the most likely source of nasty noise. I found that the rivets were indeed loose.†
I sourced a replacement from a motor breakers on E bay (from a 1987 K100 LT)

Yesterday I got the lend of some bearing pullers and was able to get a better look at the original and "new" shaft†
These pictures are the original shaft†





It appears to me that over time the hole in the anti-backlash spring that engages with the pin on the narrow gear wears and †opens up. As this happens the spring can move outwards and starts to hit the sides of the Rivets. In my case the three leftmost rivets are loose (i can rotate them easily)and 2 have been marked on the side where the spring has been hitting them.†


In contrast, the newer type spring which is fitted to the 87 shaft is much smaller and even if it wears a bit it is never going to impact the rivets.†
That is the one i think i should be fitting.

    

5Back to top Go down    New output shaft on Sat Feb 08, 2014 4:10 pm

Cossie

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Output shaft ready to go in. I got this second hand on E-Bay and fitted a new bearing and new spring in the anti-backlash gear.

    

6Back to top Go down    Re: Engine output shaft rivets on Sat Feb 08, 2014 9:05 pm

GTJos

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Very Happy†Fine pictures, thanks for that !†
Always good to have this kind of documentation, as 1 picture "says" more than 100 words.
Cheers !
Jos.


__________________________________________________
Ich bin enge KirchrŲatsjer jong; adieŽ wa ?!†
† † † † † † † † † † † † † † † † 1992 †K1100LT†6458188
† † † † † † † † † † † † † † † † 1986 K100RS 0085647 + sidecar Velorex 562
† † † † † † † † † † † † † † † † 1985 †K100RT †0027026
    

7Back to top Go down    Re: K100 restoration cafe-racer style on Sat Feb 08, 2014 9:08 pm

Oldgoat

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Beautiful work on the frame! †Do you mind if I ask what you payed for the OP shaft on Fleabay?

OG

    

8Back to top Go down    Output shaft on Sun Feb 09, 2014 5:41 am

Cossie

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Thanks guys
I got it for £20.00 plus £10.00 for shipping which i think was very reasonable.
This is the store
http://stores.ebay.co.uk/moto-partz?_trksid=p2047675.l2563

    

9Back to top Go down    Re: K100 restoration cafe-racer style on Thu Mar 27, 2014 4:51 pm

Cossie

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Finally starting to put things back together!

    

10Back to top Go down    Re: K100 restoration cafe-racer style on Mon Mar 31, 2014 5:39 am

floyd

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@Cossie wrote:Finally starting to put things back together!

Oooooh I cant wait til I put my frame back on!

Looking good mate!


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K100 with lots of K1100 bits - mongrel of a thing...
    

11Back to top Go down    Re: K100 restoration cafe-racer style on Mon Mar 31, 2014 7:07 am

charlie99

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lots of potential ...good work


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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
    

GTJos

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@Cossie wrote:Output shaft ready to go in. I got this second hand on E-Bay and fitted a new bearing and new spring in the anti-backlash gear.

Smile†Hi Cossie !
Congrat's; hope you get her back together before this season ends ? Thumbs up !
And also: thank's to your earlier remark about the 'anti-backlash gear' I'm now pretty sure of the sound-source coming from my engine ! Since a few weeks, mostly right after a cold start, I hear a kind of 'hickup' -accompanied by a split-second drop of the idle-. No problem on higher than idle-revs, she's running as smooth as she ever did but the 'hickup' at idle stays.
Seams to me that I'm in for some rebuilding, coming winter ! (Sorry for hijacking your threath a little... †Very Happy

Keep on the good work !

Jos


__________________________________________________
Ich bin enge KirchrŲatsjer jong; adieŽ wa ?!†
† † † † † † † † † † † † † † † † 1992 †K1100LT†6458188
† † † † † † † † † † † † † † † † 1986 K100RS 0085647 + sidecar Velorex 562
† † † † † † † † † † † † † † † † 1985 †K100RT †0027026
    

13Back to top Go down    Re: K100 restoration cafe-racer style on Sun Apr 27, 2014 9:02 am

Cossie

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Thanks for the comments guys.
I now have the bike back together enough to start her up and take for a spin up the road
Feels great.†


    

14Back to top Go down    Re: K100 restoration cafe-racer style on Sun Apr 27, 2014 9:27 am

Inge K.

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Looks like you got the genuine factory mounted shock absorber,
and it's mounted upside down.


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

15Back to top Go down    Re: K100 restoration cafe-racer style on Sun Apr 27, 2014 2:02 pm

Cossie

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@Inge K. wrote:Looks like you got the genuine factory mounted shock absorber,
and it's mounted upside down.
Thanks Inge
I shall attend to that.

    

16Back to top Go down    Re: K100 restoration cafe-racer style on Sun Apr 27, 2014 5:07 pm

floyd

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does the red alternator go faster? Wink

good luck with the start


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K100 with lots of K1100 bits - mongrel of a thing...
    

17Back to top Go down    Re: K100 restoration cafe-racer style on Sun Apr 27, 2014 5:39 pm

Cossie

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@floyd wrote:does the red alternator go faster? Wink

good luck with the start
Nice one †Floyd
The red alternator was the previous owners attempt at detailing.
I have removed red paint from the starter, as well as engine mounting bolts and various other bits and pieces. The alternator has yet to be done.†
I see you are in Marrickville. I have great memories of a year I spent a †working at Unilever (Edinburgh Rd) back in the 90's. Met some really sound people.

    

18Back to top Go down    A few more photos on Sun May 25, 2014 8:30 am

Cossie

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Front headlight fitted
Front indicators fitted
Front brakes working
Back brakes working (sort of)
Drives and runs well
I have had it up and down the road a few times now and am starting to get used to the weight of it.
I am treating the seat as a "Revision 1" as i suspect it may not be that comfortable for long journeys (or even short ones)
There is a bump from the front going over rough spots on the road †so i think will need to readjust the steering bearings

















    

19Back to top Go down    Re: K100 restoration cafe-racer style on Sun May 25, 2014 2:33 pm

Comberjohn

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Taking shape.
I notice you have left the 'snorkel' off the air box.
Seem to remember a while ago on a thread. Someone remarked that air passing over the hole in the air box when going faster, could cause negative or low air pressure in the air box.
While the snorkel isn't pretty, it does give a bit of a ram effect at speed.
The stock silencer looks enormous when the rest of the bike is stripped down!


__________________________________________________
Life is not a rehearsal.
2010 VFR 1200F DCT†
2010 R1200GS(gone)
1986 K100 Silver(gone)
2012 K1600GT(gone)
1984 K100RT Madison Silver(gone)
1989 K100LT Stratus Grey(gone)
1984 K100 Red(gone)
http://www.johnsdrivingschool.co
    

20Back to top Go down    Re: K100 restoration cafe-racer style on Mon May 26, 2014 3:28 am

Tenox

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I do not have that snorkel and the bike performs very well without it too. Standing mile (naked bike, large pilot) with my humble acceleration skils with end speed 197km/h and bike would have continued to accelerate but the runway ended.

I do have a little home made shield on it.

Like this:†
https://www.dropbox.com/sh/wso2wf0jajx9dju/Us9IpM3PD1#lh:null-PC13_01.JPG

and from airport:
https://www.dropbox.com/sh/wso2wf0jajx9dju/Us9IpM3PD1#lh:null-1stRun.jpg


__________________________________________________
BMW K100RT Scrambler (86)
    

21Back to top Go down    Re: K100 restoration cafe-racer style on Tue May 27, 2014 3:20 pm

bryandarragh

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Excellent, I envy your skills


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BMW K100RS 8 valve
1986
    

22Back to top Go down    Re: K100 restoration cafe-racer style on Sun Jul 05, 2015 3:58 pm

Cossie

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Well finally got the bike on the road. A small matter of getting a licence had to be overcome. Insurance was sorted on Friday . So far 160 Kms (Small local trips). Am very happy indeed. I have to say a big thank you to †all the contributors to this forum as without it †I could never have completed this project . Thanks again.

    

23Back to top Go down    Re: K100 restoration cafe-racer style on Mon Jul 06, 2015 5:03 am

Comberjohn

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Congratulations on getting on the road at last.
Was down your way weekend before last after coming down the coast from Sligo.
You have some great scenic roads around you, but try to keep her between the hedges until you get used to it.
Plenty of tourists in hire cars!


__________________________________________________
Life is not a rehearsal.
2010 VFR 1200F DCT†
2010 R1200GS(gone)
1986 K100 Silver(gone)
2012 K1600GT(gone)
1984 K100RT Madison Silver(gone)
1989 K100LT Stratus Grey(gone)
1984 K100 Red(gone)
http://www.johnsdrivingschool.co
    

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