Author Topic: K100RS parked for four months outside in all weathers  (Read 88700 times)

Offline Filmcamera

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Re: K100RS parked for four months outside in all weathers
« Reply #25 on: October 05, 2016, 02:12:56 PM »
great thanks
  • San Jose, Costa Rica
  • 1991 K100RS 16v ABS1, 2018 Triumph Street Triple RS 765
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Offline Filmcamera

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Re: K100RS parked for four months outside in all weathers
« Reply #26 on: October 11, 2016, 08:14:48 PM »
The extractor set has finally arrived - and it would be the week I cannot do anything to the bike until the weekend...

Fingers crossed for Saturday
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Offline stokester

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Re: K100RS parked for four months outside in all weathers
« Reply #27 on: October 11, 2016, 08:23:04 PM »
The extractor set has finally arrived - and it would be the week I cannot do anything to the bike until the weekend...

Fingers crossed for Saturday
Looks just like my MATCO set with left-hand drill bits and the extractors to fit.

Take it easy and be patient.  Breaking off an extractor brings all kinds of trouble.
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Offline Inge K.

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Re: K100RS parked for four months outside in all weathers
« Reply #28 on: October 11, 2016, 08:54:28 PM »
The extractor set has finally arrived -

Not really needed, as you just could have drilled the head of the screw.

Be aware that it's a special screw with a shallow head, if using a ordinary allen screw you
need to grind down the head.
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Offline Filmcamera

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Re: K100RS parked for four months outside in all weathers
« Reply #29 on: October 11, 2016, 09:06:36 PM »
OK I will remember that thanks. It is an M8 right or is it M10? I can't seem to find the part number or see it on the fiche but do see it in Clymer, though it just says allen screw without specifying the size.
  • San Jose, Costa Rica
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Offline Inge K.

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Re: K100RS parked for four months outside in all weathers
« Reply #30 on: October 11, 2016, 09:08:56 PM »
M8
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Offline Filmcamera

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Re: K100RS parked for four months outside in all weathers
« Reply #31 on: October 11, 2016, 09:17:47 PM »
Ty
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Offline Inge K.

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Re: K100RS parked for four months outside in all weathers
« Reply #32 on: October 11, 2016, 09:30:10 PM »
Sorry, did first have the older type fork in mind.....on your fork it was a change in 08/91.

On early version seems to be M10, late version M8....both is special bolt, which you gonna need
the OEM part.....especially if you have the early version which have a integrated valve.
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Offline Filmcamera

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Re: K100RS parked for four months outside in all weathers
« Reply #33 on: October 11, 2016, 09:43:14 PM »
The fiche on MaxBMW for my bike does show the integrated valve -

 31 42 2 310 804

but to be honest it isn't very clear

just my luck it is a $65 part and the later on is $8...

I guess I will take it out and see

The set switches from one size extractor to another at M9 so I might play is safe and use the one for M8 just in case..
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Offline Inge K.

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Re: K100RS parked for four months outside in all weathers
« Reply #34 on: October 11, 2016, 09:52:52 PM »
Best wishes for the job.
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Offline Filmcamera

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Re: K100RS parked for four months outside in all weathers
« Reply #35 on: October 16, 2016, 09:58:00 PM »
Soooo...

A largely but not totally successful weekend to report.

I had discovered a total of six wrung out allens on the bike when I started to work on it.  This weekend I managed to get five of them undone using the extractor kit.  The one that got away... yep the bottom of the fork leg.   I cannot get it undone.  I have drilled a decent hole and the extractor bites great using the tap wrench I have but it just will not turn.  I have so far avoided getting all butch and putting some kind of extension bar on the tap wrench because I don't want to break the tool off in the fork.  For now I think I will take both forks to a specialist BMW shop near me and let them have a try...

I DID manage to get the second fork off the bike (there was a threaded nut in the lower triple tree). I also got the rear brake off and gave it an overhaul - there is a hole in the pipe from the master cylinder hence zero back brake.  I also took the discs off the front wheel so I can swap them round and mount the wheel the right way. I took off the rear wheel so I can prepare it and the front for powder coating.

Lastly I tackled the fuel tank, to get it ready for a respray.

I drained it and was going to dismantle it when I saw how the filler looks.

I guess I am going to have more work with the extractor but they are such small screws i wondered if I should do anything different?

The inside of the tank doesn't look too bad but isn't great and the electrics have been hacked about (of course).  The sender unit for fuel level is a total wreck but we run ethanol free gas here so the rubber etc seems ok.  I can almost guarantee the hoses inside the tank are the wrong ones but wanted to get some input before messing the filler cap up to get everything out and check.

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Offline kennybobby

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Re: K100RS parked for four months outside in all weathers
« Reply #36 on: October 16, 2016, 10:56:20 PM »
i suppose you applied heat to the bolt to melt the thread locking compound, and use an adjustable torque wrench so you can control how much you using--it may take at least whatever the tightening torque value is to get it loose.

A small carbide drill bit should open up the gas cap screws--hopefully you can get in there to get it squared away.
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Offline Filmcamera

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Re: K100RS parked for four months outside in all weathers
« Reply #37 on: October 16, 2016, 11:02:20 PM »
Yeah I did use heat on the Allen in fork. To be honest if I just got braver with some sort of lever on the tap wrench it might break free. The issue is that since it is JUST a tap wrench that the extractor connects to I don't know how much force it or the extractor can take  and survive.

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Offline Martin

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Re: K100RS parked for four months outside in all weathers
« Reply #38 on: October 16, 2016, 11:20:15 PM »
Try heating with a hot air gun on the fork leg, also try a 50-50 mix of acetone and ATF fluid. As far as the filler screws I would try removing with a screw removal bit, they come in a set and are different than Eziouts. If this doesn't work drilling the heads off the screws carefully with a counter sink drill bit could be an option. You need to keep it centred and square ( helper is handy to make sure you are drilling square) and only go deep enough to just remove the head. Hopefully with the heads and filler removed and with a bit of heat and penetrating fluid they will come out. If they don't you will have to drill them out, if you have drilled the head off and it is centred and square you could use this as a guide to centre and drill out the screws. It is a tricky and daunting task go slowly and carefully. If you are not confident try out the techniques on a bit of scrap material drill, tap and countersink, fit some screws and try drilling them out with the extractor, try countersinking and drilling and retaping. It is better to stuff up a bit of scrap than stuff up the tank.
Regards Martin
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Offline rbm

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Re: K100RS parked for four months outside in all weathers
« Reply #39 on: October 17, 2016, 05:44:22 AM »
...  My fuel gauge doesn't work but at $200 the gauge in the tank can wait.
The sender must just need some refurbishment to bring it back from the dead.  Check my article on K100-forum for the process.
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Offline kennybobby

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Re: K100RS parked for four months outside in all weathers
« Reply #40 on: October 17, 2016, 09:40:40 AM »
Get a square, or triple-square, socket of the correct size and then you can use a torque wrench (e.g. 4,8 or 12 pt socket)
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Offline Martin

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Re: K100RS parked for four months outside in all weathers
« Reply #41 on: October 17, 2016, 02:11:38 PM »
Make sure you have thoroughly flushed the tank before applying heat. Also be careful if you use the the Acetone ATF mix it is highly flammable and will remove paint. Before attempting to use the screw extractor you could try alternating between heat and cold (freeze spray) then apply the Acetone ATF mix and let it soak for a few hours or days.You might want to replace your existing screws with stainless steel allen screws and a bit of Koppercote once they are out.
Good luck Martin.
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Offline Filmcamera

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Re: K100RS parked for four months outside in all weathers
« Reply #42 on: October 23, 2016, 09:47:01 AM »
So the good news is - the allen is OUT!

The bad news is it is a mess in there.

The seals seem to be very well stuck in there and before I just hack at them with a screwdriver or something I wanted to ask if there is a specific method used to get them out?

They also seem different from the replacements I brought from MaxBMW.  It seems the ones in there are part number 31 42 2 312 928 which MaxBMW says were superseded by 31422310345 which are the ones I got as replacements.  That makes it hard for me to work out exactly what is going on under all that old grime and grit etc.

So can anyone tell me the best way to get the old ones out?
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Offline The Dude

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Re: K100RS parked for four months outside in all weathers
« Reply #43 on: October 23, 2016, 07:37:13 PM »
So the good news is - the allen is OUT!

The bad news is it is a mess in there.

The seals seem to be very well stuck in there and before I just hack at them with a screwdriver or

So can anyone tell me the best way to get the old ones out?

Should be easy enough with a screwdriver working round.I seem to remember puting two blue seals in mine and original BMW gaiters many miles ago.
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Offline Laitch

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Re: K100RS parked for four months outside in all weathers
« Reply #44 on: October 23, 2016, 07:47:30 PM »
So can anyone tell me the best way to get the old ones out?
When the springs and seal circlip have been removed, on my K75 I use the absorber tube as a slide hammer and bang the seal out of there.  at 10:00. I can't say whether that's the best way on a K100RS but it works on a K75.
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Offline Filmcamera

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Re: K100RS parked for four months outside in all weathers
« Reply #45 on: October 23, 2016, 08:18:27 PM »
Well that is exactly what has me confused.  I cannot for the life of me see any kind of circ clip or retaining ring holding it in...

Yet it is very well stuck in there



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Offline kennybobby

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Re: K100RS parked for four months outside in all weathers
« Reply #46 on: October 23, 2016, 08:33:44 PM »
That dark brown wet rusty bit above the seal is the internal snapring--i can see the extraction hole in the ring at the 3 oclock position in your 3rd photo (073606) in the prior post.

google snapring and snapring pliers to see pictures.

A pick can be used in the hole to pry the ring out and a small screwdriver to work the edge around to get it oot if you don't have the right pliers.
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Offline Filmcamera

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Re: K100RS parked for four months outside in all weathers
« Reply #47 on: October 23, 2016, 08:52:40 PM »
Yep just after posting  the last post I saw it myself and with a pick and some grunting me and my son got it out . Thanks for the help.  I am beginning to realize that the easiest task on this bike is a challenge. I have never seen seals such a mess. Still progress is progressing- we have had a great day

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  • 1991 K100RS 16v ABS1, 2018 Triumph Street Triple RS 765
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Offline Filmcamera

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Re: K100RS parked for four months outside in all weathers
« Reply #48 on: October 27, 2016, 08:09:02 AM »
I am nearly ready to send some parts for paint and powder coating.  I have the front wheel off and the disc brakes removed etc. All I need to do now is take the bearings off and Clymer's mentions needing a special BMW tool to do this.  Is that the only way or can it be done without buying the special tool?  I know there are posts on how to do it if you are replacing the bearings but unless they are terrible I was hoping to reuse them, I just wanted to take them off before the powder coating process.
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Offline kennybobby

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Re: K100RS parked for four months outside in all weathers
« Reply #49 on: October 27, 2016, 09:27:42 AM »
It's difficult to remove them without smacking the inner raceway, and that will damage (brinnel) the bearing.  You don't want powder coat in the bore of the outer race anyway, so it would need to be taped off well--it won't matter if the bearing is in or out when taping, actually may be easier to do a good tape job with bearing in place.  Cut a piece of cardboard to fit in the outer bore and trim the tape at the edge--no paint will get into the bearing.
Ridin' 87 K75S vin 1334,
Renchin' 86 75S vin 0061

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