Author Topic: Das Brick: 93 K75 S Renovation  (Read 31930 times)

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #50 on: March 07, 2020, 11:39:24 AM »
So shims have no discernible numbers on them, but they measure 2mm each. I reinstalled the wheel with one shim and can slide the other two between the tire and the driveshaft housing with only a tiny amount of drag, so close to 4mm clearance. Once I get new tires I'll experiment with shims but don't see reinstalling all three. I'll be going with the T30 or T31 Battlax 150/70ZR-17 like RC and RBM so shouldn't have clearance issues.

Now to go take some pics of the violated Brick...
  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #51 on: March 07, 2020, 07:31:55 PM »
Productive day, got lots done. Finally got her nekkid:



Ignore the Camaro Green GL1000 lurking in the background!
  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #52 on: March 07, 2020, 07:43:24 PM »
Clutch time:



Bought a small jack to use on the lift, and the handle was just the thing to pop off the stubborn pressure plate. Just took a small amount of leaverage in the right place!



Couldn't really tell till I cleaned this up:


Chewed up and enough lateral play so I'm replacing it.
  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #53 on: March 07, 2020, 08:06:08 PM »
Just needs cleaning:



The in-famous pilot shaft bushing in its unmolested position:



Awaiting munkee nutz and starter o-rings:

  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #54 on: March 07, 2020, 08:43:38 PM »
Almost forgot the primary reason I pulled the tranny with only 16k miles on it:



Yar, the wünderbar grub screw. It was maybe a full turn loose.



  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #55 on: March 07, 2020, 08:48:30 PM »
Installing:





Actually able to get my sissy little girl fingers in there:



Done. I did wipe off the excess Loctite.

  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #56 on: March 07, 2020, 09:08:51 PM »
Ready to reinstall the cover. I looped a small piece of wire around the shift drum lever, instead of knocking out the plug in the cover and inserting a bolt to hold it out of the way while the cover went on.



Good thing I ordered a new switch assembly since it was cracked. It disintegrated when I unscrewed it:



So all in all a lot accomplished today, even if no riding was involved.
  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #57 on: March 07, 2020, 09:11:37 PM »
Forgot to post a pic of the tranny splines:



I'll post another when they're clean and ready to install. They're in pretty good shape, with a slight narrowing taper as you move front to rear.

Final drive splines in very nice shape:


  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

Offline Martin

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Re: Das Brick: 93 K75 S Renovation
« Reply #58 on: March 07, 2020, 09:31:43 PM »
It's pretty common for the GPI switch cover to disintegrate. If the internal mechanism is intact a new cover can be made and then waterproofed.
I just pulled mine for a bit of maintenance clean and lube and the 20 year old Plasti Dip waterproofing was still fine.
Regards Martin
  • North Lakes Queensland Australia
  • 1992 K75s Hybrid, Lefaux, Vespa V twin.

Offline The Mighty Gryphon

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Re: Das Brick: 93 K75 S Renovation
« Reply #59 on: March 07, 2020, 10:12:16 PM »
Nice job on the grub screw!

Did you change the o-ring on the output shaft?  I guarantee it's dried out and is going to leak one of these days, and if you have even a tiny bit of bad karma, that oil is going straight for the clutch friction disc.

On the gear position switch, chip out all of the old broken up potting compound, be fussy and get every little bit out, then wash well with brake cleaner. 

After it's good and dry, mix up enough epoxy(don't use the quick stuff, you want it to flow into all the spaces) to fill the end where the potting was.  Work the epoxy into all the nooks and under the wires with a toothpick.  Be careful not to get a lot of air bubbles.Let it sit until it's fully cured.  Tip: Clamp the switch body in vise grips to keep it from flopping around while you fill with epoxy.

After the epoxy has fully cured, take the switch apart(carefully!  there's some small springs and other easily lost stuff that wants to escape).  Clean all the metal surfaces and bits in a rubbing alcohol soak, dry for a day and shoot everything with Deoxit.  Then you can put it all back together.

When you install the gear position switch use allen screws.  They are a lot easier to turn than the hex heads that are there now.  A new gasket will help keep the crap out.

  • In my garage in Marilla, NY
  • '91K100RS White/Blue
Current:
'91 K100RS16V "Moby Brick Too"

Past:
'94 K75RT "Ilsa, She Wolf of the SS"
'92 K100RS16V "Moby Brick" (RIP, deceased in a vehicular assault)
'94 K75S Special Edition Dakar Yellow "Cheetos"
'89 K100RS Special Edition "Special Ed"

Offline billday

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Re: Das Brick: 93 K75 S Renovation
« Reply #60 on: March 08, 2020, 01:43:31 PM »
Great posts, great pictures, thanks for making the effort.
  • New York State, USA 10977
  • 1985 K100

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #61 on: March 08, 2020, 03:24:08 PM »
It’s easy when you know how: cut the damn o-ring off and the clutch housing basically just falls off:

  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

Offline Rcgreaves

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  • "I'd rather be flying, but this will do nicely"
Re: Das Brick: 93 K75 S Renovation
« Reply #62 on: March 08, 2020, 10:37:44 PM »
Excellent progress- imaging what you must be capable of with two good mits.  Thanks for grub screw images- new to me.  Hopefully you will soon run out of novel new items in need of sorting.  I grinned every mile this weekend- it will be worth it!
  • Livingston in Southwest WI. USA-"With the good earth all around."
  • 94' K75S, 85' GL1200 Aspencade, 96' VFR750F, 01' GL1800. Restoring: 95' K1100RS, 83' R80RT NEW: Motorvation Formula II
Doing “better than I deserve"

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #63 on: March 08, 2020, 11:15:33 PM »
Stitches come out a week from Monday, then it's just trying not a break it on anything the rest of my days:



Titanium: it does a body good!
  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #64 on: March 09, 2020, 11:44:19 PM »
Progress for today: mostly waiting for parts but made a repair to the gear position switch.




Yup, that's a screw top to a quart oil bottle, filled with epoxy. We'll see how it works.

Was the plastic collar supposed to come out with these? I bet that's where the o-ring goes...



New friction plate came, along with new coolant hoses and clamps, new clutch release boot, new seals for the starter, new munkie nutz for the alternator. All installed except the friction plate, waiting on the jeezuss nut that holds the clutch housing on. Spieglers should be here tomorrow.
  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

Offline The Mighty Gryphon

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Re: Das Brick: 93 K75 S Renovation
« Reply #65 on: March 10, 2020, 08:44:41 AM »
Looks nice with that cap.  Were you able to get all the bubbles out of the epoxy around the wires?  How much does the cap add to the height of the switch?  As I recall, there isn't a lot of room between the switch and the swingarm.

Is that injector cap still in the head?  They aren't supposed to come off like that.  There is a plastic ring that goes above the o-ring.  Do you have it?
  • In my garage in Marilla, NY
  • '91K100RS White/Blue
Current:
'91 K100RS16V "Moby Brick Too"

Past:
'94 K75RT "Ilsa, She Wolf of the SS"
'92 K100RS16V "Moby Brick" (RIP, deceased in a vehicular assault)
'94 K75S Special Edition Dakar Yellow "Cheetos"
'89 K100RS Special Edition "Special Ed"

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #66 on: March 10, 2020, 09:47:14 PM »
Looks nice with that cap.  Were you able to get all the bubbles out of the epoxy around the wires?  How much does the cap add to the height of the switch?  As I recall, there isn't a lot of room between the switch and the swingarm.

Is that injector cap still in the head?  They aren't supposed to come off like that.  There is a plastic ring that goes above the o-ring.  Do you have it?

The epoxy I used came from another project and mixes up nicely, no bubbles and flowed well into all the spaces. Clearance-wise, there appears to be enough, as I temp-installed the swingarm to see how deep the pivot pin goes in. I'm thinking the PO neglected to heat the pin up when he removed it and bollocksed up the threads where the lock nut rides. It jams right where it needs to lock the pin so gonna make it tres dificíle to get an accurate torque on it. Merde.

So yeah, all the injector caps stayed in the head. I'm conflicted on doing anything about it at the present.

Here's the epoxy I used for the switch:
  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

Offline The Mighty Gryphon

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Re: Das Brick: 93 K75 S Renovation
« Reply #67 on: March 10, 2020, 10:24:17 PM »
Are the injector caps in the head with the o-rings?  I just went through a similar thing with the injectors on an '89 K100RS.  Stuck the damn things in with old hard o-rings, and when I pulled them out two of the o-rings stayed in the head, and one stuck in the rail. 

I dug them out and replaced all of them with new ones.  Now everything goes together easily.
  • In my garage in Marilla, NY
  • '91K100RS White/Blue
Current:
'91 K100RS16V "Moby Brick Too"

Past:
'94 K75RT "Ilsa, She Wolf of the SS"
'92 K100RS16V "Moby Brick" (RIP, deceased in a vehicular assault)
'94 K75S Special Edition Dakar Yellow "Cheetos"
'89 K100RS Special Edition "Special Ed"

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #68 on: March 10, 2020, 10:59:33 PM »
The caps stayed in the head, held by those ole swole o-rings. I have to order the pivot pin anyway so might as well get those, too.
  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

Offline Rcgreaves

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Re: Das Brick: 93 K75 S Renovation
« Reply #69 on: March 14, 2020, 04:24:52 AM »
Injector o rings - check!
  • Livingston in Southwest WI. USA-"With the good earth all around."
  • 94' K75S, 85' GL1200 Aspencade, 96' VFR750F, 01' GL1800. Restoring: 95' K1100RS, 83' R80RT NEW: Motorvation Formula II
Doing “better than I deserve"

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #70 on: March 16, 2020, 01:27:54 AM »
Made progress today getting things back together. New o-ring, compression ring and nut came in so clutch housing installed:



Don't know if it will stay but noted the install date:



Clutch installed and bolts torqued:



Shaft lubed with Staburags, ready to mount:

  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #71 on: March 16, 2020, 01:39:30 AM »
Transmission installed, bolts torqued:



New clutch arm boot, alternator and starter installed, clutch cable and actuating arm adjusted, battery tray snafu:



Left footpeg plate, battery tray snafu unsnafued, coil cover, ABS blitzenmöter installed:



Right ABS blitzenmöter , center and side stands installed:

  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

Offline Rcgreaves

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  • "I'd rather be flying, but this will do nicely"
Re: Das Brick: 93 K75 S Renovation
« Reply #72 on: March 16, 2020, 06:25:22 AM »
We be rolling down that mountain - soon and very soon! 112350
  • Livingston in Southwest WI. USA-"With the good earth all around."
  • 94' K75S, 85' GL1200 Aspencade, 96' VFR750F, 01' GL1800. Restoring: 95' K1100RS, 83' R80RT NEW: Motorvation Formula II
Doing “better than I deserve"

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #73 on: March 17, 2020, 11:42:03 AM »
Yesterday’s work:
Final drive installed



Rear shock. Guess I should look for something newer to support my whopping 155 lbs:

  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

Offline Bon Jon Bovi

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Re: Das Brick: 93 K75 S Renovation
« Reply #74 on: March 17, 2020, 01:16:22 PM »
Anybody recognize what bike this came from?




I recall now the PO replaced this as part of the resurrection he did to get it running. At least it's BMW?
  • Cloudcroft, New Mex
  • '93 K75s-'05 R1200GS-'08 R1200RT-'88 XR600R-'74 GT80
63 years. Don't they go by in a blink...

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