Trash Hauler’s first K100 Cafe Racer Project

[Trash Hauler]

Disassembly

I started the disassembly last week after cleaning out the garage. The biggest challenge was working out how best to work on the engine once I have removed it from the frame. With the clutch gearbox arrangement being similar to a car, I could see an automotive engine stand would work nicely. So I purchased the cheapest stand I could get ($117) and the photos below show the progress.

I also made up a steering lock and left the front end on while I separated the frame. This way I could sit the rear seat frame on a bench and the bike was stable while removing the gearbox and engine.

1. Bike before the project (I bought the bike sans the fairings and luggage)

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2. Initial disassembly 

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3. Steering lock

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4. Seat frame on bench for gearbox / engine removal

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5. Gearbox removed

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6. Engine removed and on stand

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7. Frame with front end and loom still to be removed.

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TH

(Edited to correct orientation of images)

[volador]

Looking good you're off to a good start. Where did you get the engine stand?

[Trash Hauler]

Supercheap Auto Parts - Sydney Australia

Engine Stand. https://www.supercheapauto.com.au/p/sca-sca-engine-stand-560kg/219511.html

[Martin]

 
Regards Martin.

[volador]

Supercheap Auto Parts - Sydney Australia

Engine Stand. https://www.supercheapauto.com.au/p/sca-sca-engine-stand-560kg/219511.html

Crikkey, was thinking Sydney Nebraska not another downunder bloke

there's a tribe of you'll here you just met chief 'Regards Martin'

[volador]

Bonzer engine stand

Can you give us a piccy of stand mounting to intermediate housing.
Just an observation I would be concerned to exert to much force on that intermediate housing maybe a support under the oil pan would alleviate some of the engine weight

[Trash Hauler]

Regards Martin.

Thanks Martin - good to be here

[Trash Hauler]

Bonzer engine stand

Can you give us a piccy of stand mounting to intermediate housing.
Just an observation I would be concerned to exert to much force on that intermediate housing maybe a support under the oil pan would alleviate some of the engine weight

[Trash Hauler]

Frame and engine disassembly complete ready for blanking, degreasing and glass blasting.


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[Trash Hauler]

I have ordered an Injector Pulser Tester from AliExpress to go with my ultrasonic cleaner. $26 USD.

I will post a review once I have used it.

https://www.aliexpress.com/item/33008882556.html?spm=a2g0s.9042311.0.0.3a854c4dPKo9W9


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TH

[Martin]

You might want to get a 250 ML graduated vessel to compare injectors. Home brew supply shops have them. I built an air powered test unit set to 35 PSI due to not wanting to blow up my workshop. On the advice of a local injector workshop I use lacquer thinners to clean the injectors which is a lot cheaper and more effective. The vapours however do melt some types of plastic for example the lid of my sonic cleaner which did eventually solidify. I would remove the pintle caps, filter screens and "O" rings if using thinners. The thinners did however restore a set of Ford injectors that nothing else would clean and had been rejected by another injector shop.
Regards Martin.

[Trash Hauler]

Thanks Martin - great advice.

[Martin]

TH see here http://www.motobrick.com/index.php/topic,12153.msg107177.html#msg107177 The test unit has changed a bit since it's inception the plastic bottle has been changed to a graduated vessel and I'm now using a Sun test pulser.
Regards Martin.

[Trash Hauler]

Thanks Martin - I like your setup. I am going to build one the same. I think I have an old fire extinguisher in the shed that may work as the container.

TH