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TECHNICAL MOTOBRICK WRENCHING In Remembrance of Inge K. => Project Custom Motobricks => Topic started by: Max on September 21, 2018, 04:29:04 AM

Title: K100 GSXR conversion questions
Post by: Max on September 21, 2018, 04:29:04 AM
Hi all how is every one doing?. I have been building a 1985 k100 rs since March this year and have been messing around trying to get a GSXR 750 front end to fit and have a few questions. I have turned down and pressed in the original BMW stem tube into the GSXR tree and just wondered if this will be safe enough to take the load or should I get a solid bar made up?. Also with the GSXR front wheel what would be my options regarding tires as I want the old cafe style look. I was told having the GSXR front wheel will limit my choice in tires but do not understand why? Can any one help answer this or give a suggestion on tires. I am a great mechanic/fabricartor/painter but know nothing about tires and am struggling to get a definitive answer, even my local bike shop could not help. Any advice would be greatly appreciated
Title: Re: K100 GSXR conversion questions
Post by: Laitch on September 21, 2018, 09:51:22 AM
Considering the effects upon me of age, gravity and observation of human behavior, I'm doing pretty good. How long did it take you to attain greatness as a mechanic?
Title: Re: K100 GSXR conversion questions
Post by: Max on September 21, 2018, 09:54:35 AM
3 years at collage and a further 10 years in the trade 👍 Thanks for asking
Title: Re: K100 GSXR conversion questions
Post by: Laitch on September 21, 2018, 10:34:03 AM
Part of the instruction in university and trade was to machine a part—for example, a BMW stem tube— to a spec that you want so it can be used in an assembly of your choice then determine afterward by asking around on the Internet whether it would be safe enough to take the load?
Title: Re: K100 GSXR conversion questions
Post by: Max on September 21, 2018, 10:45:58 AM
You must have gone to a different university than me then but am happy to take on any advice from you as you seem so knolagable. I did not realise I would be tested in my knolagable and skill from simply coming onto this site but I guess there is always one that feels threatened by other people's skill set. I agree that stating I am great was the wrong use of word, competent would have been a better word to use, I apologise and bow to to you greatness if you could answer my questions?
Title: Re: K100 GSXR conversion questions
Post by: Barry in IN on September 21, 2018, 11:54:32 AM
I only spent two years in college then the next 31 as an aircraft mechanic.  I wish I could be “knolagable” enough, whatever that is, to achieve greatness too.   
Maybe I could get there by stripping pieces and parts off of perfectly good motorcycles.   That’s OK, I’ll do without. 

Why am I being so harsh? 
Because you took a vital structural part and reduced its thickness and therefore strength.   Doing it without knowing how much difference that will make is one thing.   What makes it worse is you did this to a hidden area, where it won’t be apparent to the next owner.   The only way they will know is if you tell them.  Maybe you plan to do that.  Maybe you will drop dead tomorrow and the bike will be sold by someone else. 

Start trimming on the steering knuckles of a 35 year old car, then go on a car forum and ask opinions.  See how well that goes over.

And this was all done as part of making the motorcycle look different to meet a style fad.   Well, that makes it all worth it. 
Title: Re: K100 GSXR conversion questions
Post by: Max on September 21, 2018, 12:01:54 PM
Fine I will turn down a solid bar to fit, can any one answer the tire question?
Title: Re: K100 GSXR conversion questions
Post by: Barry in IN on September 21, 2018, 12:06:54 PM
Lots of tire threads here.   I like the Michelin Pilot Activ. 
Since you want tires based on “that old cafe look” rather than performance, I’m not sure if you’ll find the info you want here. 
Title: Re: K100 GSXR conversion questions
Post by: Max on September 21, 2018, 12:14:50 PM
But why will I be limited to what tire will fit the rim, size is obvious but I was told radial tires will not fit the rim but could not be given an answer as to why?. This is all becoming to much of a headache and am just going to refit the standard front end at this rate
Title: Re: K100 GSXR conversion questions
Post by: K1300S on September 21, 2018, 12:29:32 PM
"But why will I be limited to what tire will fit the rim".  huh?   maybe there is an english translation issue here, but of course you are limited to what tire will fit the rim.  if it doesn't fit, you can't put it on.


is the tire thing a trick question?  why wouldn't whatever size tire that came on the gsxr fit the gsxr rim?  there must be a zillion tires for that bike.  you aren't looking for a tire to fit an old k bike, you are looking for a gsxr tire.  or did i miss something?
Title: Re: K100 GSXR conversion questions
Post by: Max on September 21, 2018, 12:39:38 PM
I want an old style cafe tire fitted onto a modern rim, I was told this cannot be done and had no explanation why. I just wanted to know the reason is all but starting to wish I never asked
Title: Re: K100 GSXR conversion questions
Post by: Barry in IN on September 21, 2018, 01:08:45 PM
I don’t know what size rim you have, but I know many BMW K-series ones are in a size that radials aren’t made in.  That may be part of it.
Title: Re: K100 GSXR conversion questions
Post by: Laitch on September 21, 2018, 07:29:31 PM
I want an old style cafe tire fitted onto a modern rim, I was told this cannot be done and had no explanation why.
If by old style you mean narrow, one reason might be the Gixxer rims are too wide for narrow tire beads to seat securely on them. The Gixxer is designed with radials in mind—wide ones, especially the rear tire. An additional reason might be the diameter of old style tires tends to be greater than Gixxer rims.

The early K model tires look more like the BSA and Triumph tires of yore.
Title: Re: K100 GSXR conversion questions
Post by: johnny on September 21, 2018, 09:12:30 PM
greetings...

before f-ing with tiors you oughtta square away that bung... proally will fixt the handling...

click on this link... perhaps you can getts you that hemorrhoid hanging off the bung of that blue 750... that will offset that abortion of a head job you performed on that hundert rs... (http://www.motobrick.com/index.php/topic,11721.0.html)

j o
Title: Re: K100 GSXR conversion questions
Post by: Laitch on September 21, 2018, 11:48:40 PM
Maybe it's time to head out for bratwurst with espresso and gelato chasers.
Title: Re: K100 GSXR conversion questions
Post by: Max on September 22, 2018, 03:53:36 AM
I thought that the wheel rim was too shallow to take the tire to seal onto but they are exactly the same, the GSXR rim is slightly wider but still do not understand why this will be a problem as tires can stretch or get a slightly wider tire.
Title: Re: K100 GSXR conversion questions
Post by: Max on September 22, 2018, 03:58:06 AM
I'm just going to re fit the standard front end and address the GSXR front end at a later date, I like a challenge but also want to use the bike before winter hits
Title: Re: K100 GSXR conversion questions
Post by: Barry in IN on September 22, 2018, 06:38:35 AM
Well at least you planned it out well.   
Title: Re: K100 GSXR conversion questions
Post by: johnny on September 22, 2018, 07:32:13 AM
greetings...

i guess you learnt everything except common sense... guess common sense aints all that common...

j o
Title: Re: K100 GSXR conversion questions
Post by: Laitch on September 22, 2018, 08:05:45 AM
I thought that the wheel rim was too shallow to take the tire to seal onto but they are exactly the same, the GSXR rim is slightly wider but still do not understand why this will be a problem as tires can stretch or get a slightly wider tire.
There is data available that a uni-educated person should have found before now even using a clapped-out Mac in need of an upgrade it can't support.

Here's a table (http://kawtriple.com/mraxl/tire_rim.htm) that shows minimum to maximum rim width for sizes of tires. This isn't the only table on the Web but its color caught my eye. Gixxers have rims typically 1.5 inches or more than the maximum width for narrow tires, despite what you might think. Although these tires might have been called balloon tires when they had tubes in an earlier and simpler motorcycle age, they are not balloons.
Title: Re: K100 GSXR conversion questions
Post by: NickHeijman on September 22, 2018, 03:23:37 PM
My plan was to follow this topic, because i'm planning to do a USD swap over winter or beginning of next year. The GIXXER 750 front had my attention, however it looks like every one here is giving Max a roast.

@Max, I looking over the internet and it seems that the ZX7R front end will fit with the original ZX7R Triple and triple top. The length of the stem is about the same. So you will be on the safe side in that case. Furthermore google around, several guys have done the R1 fork and a GIXXER750 front swap and left some nice details and information.

Hope you will figure it out before I do so I can take your notes as well :)

Cheers and best luck,
Nick
Title: Re: K100 GSXR conversion questions
Post by: CG_3D on September 22, 2018, 07:52:14 PM
Don't use the BMW stem you turned down. You have thinned out a hollow tube which takes a shear load on the front of the bike.  I don't remember the exact difference from a 750 to a 1000 if any (google 'gsxr fork matrix') but Cognito Moto make a GSXR to K100 stem. For $140 save yourself a headache.

Also look at the tire size you have on the GSXR wheel you have. The GSXR wheel isn't that unusual. If it's say a 180/55-17, then you look for tires the same size to start. - 17 being the wheel diameter. 180 is the section width in mm and the 55 is the sidewall height as a percentage of the width. Therefore you could look for all available tires at that size. You could look at 190 wide perhaps. Maybe a 60 sidewall...Depends on the look and what is available.
Title: Re: K100 GSXR conversion questions
Post by: CG_3D on September 22, 2018, 07:58:43 PM
Re-read above and want to add, not sure what exactly you are thinking as being a 'cafe racer style' tire, but most vintage style tires are tube type vs modern sport or touring type tires which are most commonly tubeless.... you can technically run a tube type tire on a 'tubeless' rim (like the gsxr). There are mixed opinions on running a 'tube only' tire without an inner tube on a 'tubeless' (sealed) rim. You can, of course run an inner tube on a tubeless rim... Google is your friend. ....
Title: Re: K100 GSXR conversion questions
Post by: johnny on September 22, 2018, 08:08:12 PM
greetings...

here is a 6 ply with nice steering tread...

 [ Invalid Attachment ]

j o
Title: Re: K100 GSXR conversion questions
Post by: Barry in IN on September 22, 2018, 09:42:08 PM
“Like” ^
Title: Re: K100 GSXR conversion questions
Post by: Max on September 24, 2018, 11:22:46 AM
Nickheijman 👍Cheers bud. I am still going ahead with the GSXR front as I have come this far. Be careful with what brakes you put on as I have looked into upgrading my master cylinder to a k1100 as the diameter is 20mm but this then means I have to change the controls, throttle etc and this is not cheap. What I am going to do is use the gsxr600 twin pot calipers as this will work fine with the standard 13mm set up on the BMW.

Google is your friend if you like computers and the Internet. I don't! Infact I hate computers because I cannot see how they work. Trial and error and having the balls to give things a go is what I find works but thank you for all the constructive comments. The thing that got me was being told the GSXR wheel cannot take the tire but without any explanation why?

The pic is the Firestone classics I want to buy in a 17" tire. I'm sure they will work but only way to know is to try. If not I have other bikes I can put them on, it's only money.
Title: Re: K100 GSXR conversion questions
Post by: NickHeijman on September 24, 2018, 11:47:04 AM
The tire looks good !

I’m planning to change the controls also, so I will buy a brembo master and clutch set this winter when I do the USD fork swap.
Regarding the K1100 brake cylinder, i’m using one now on my k75 and it works like a charm bro!
Here is a picture.

I used the throttle cable of the k1100 with a custom braket on the k75 throttle body.
Title: Re: K100 GSXR conversion questions
Post by: Max on September 24, 2018, 02:11:24 PM
I'm struggling to find a k1100 set up second hand and its around $500 new, might be cheaper to buy a k1100 complete. Love the intake on the k75 bud, bet she sucks like a prostitute.
Title: Re: K100 GSXR conversion questions
Post by: Laitch on September 24, 2018, 02:19:39 PM
Love the intake on the k75 bud, bet she sucks like a prostitute.
Don't try that with it at home, Max.  :nono
Title: Re: K100 GSXR conversion questions
Post by: NickHeijman on September 24, 2018, 02:57:24 PM
For me the k1100 is just temporary since I borrowed it from a friend. The female banjo is thread is worn out on my k75 master cylinder. As mentioned I will go for a brembo set with also a usd swap so for now its okay. For you it will be a good solution to use the 4 pod calipers with the usd form and oem handlebar controls. How come they are so expensive if you want we have these k1100 local for not more then 100€ used in good shape.
Title: Re: K100 GSXR conversion questions
Post by: johnny on September 24, 2018, 03:54:52 PM

* tior01.png (93.21 kB . 366x437 - viewed 4174 times)
Title: Re: K100 GSXR conversion questions
Post by: robotradio on September 26, 2018, 12:29:13 PM
I'm doing a GSXR conversion myself on a '91 K100 LT.  Purchased donor fork from 2008 GSXR 600, cognito moto conversion stem and cognito moto gsxr machined upper triple, allballs bearings same for top and bottom (99-3521-5) , front brake calipers from 2009 Yamaha R6r paired with venhill brake lines, mswitch 3 button control / munit blue / master brake cylinder / clutch controls from amazon.  I will be reusing the bmw rim on the gsxr front with some tbd spacers. Ditched the choke.

https://www.allballsracing.com/99-3521-5.html

https://cognitomoto.com/collections/fork-conversion-parts/products/gsx-r-fork-on-bmw-r50-r60-r75-r90-frame-conversion-stem?variant=3724295241768
Title: Re: K100 GSXR conversion questions
Post by: robotradio on September 26, 2018, 12:31:16 PM
What's keeping you from using the BMW rim? Aesthetic?
Title: Re: K100 GSXR conversion questions
Post by: Max on September 26, 2018, 01:22:54 PM
Fair point! I thought trying to make to BMW wheel fit would be a nightmare in itself, as in disk alignment to the calipers, disk size etc. I am going to play around and see if I can make it work. Where do these spacers go? Between the disk and wheel or disk and fork?. I have a complete GSXR front end and just tried like for like but you have got me thinking now.
I have ordered the cognito stem and top yoke, just waiting on delivery to continue
Title: Re: K100 GSXR conversion questions
Post by: Max on September 28, 2018, 01:26:06 PM
Ok so I have the original BMW wheel fitted to the GSXR forks with spacers and now have an issue with caliper alignment as the BMW disks are too small a diameter. I have 1998 GSXR forks with 90mm hole centres for the caliper mounts, r6 calipers have 100mm mounting points so they won't work. Either I find larger disks to fit the BMW wheel or find calipers with 90mm mounting points that sit at an angle to fit the BMW disks.
Title: Re: K100 GSXR conversion questions
Post by: NickHeijman on September 28, 2018, 01:34:51 PM
What about the GSXR calipers? Will they do the job?
Title: Re: K100 GSXR conversion questions
Post by: Max on September 28, 2018, 01:40:05 PM
Got them on at the mo, the GSXR disks are a larger diameter than the BMW disks so the brake pads are only just on the outer edge of the BMW disks. I have a set of BMW rr wheels that would work but I don't like the off set on the rear wheel as its about an inch off centre and looks pants.
Title: Re: K100 GSXR conversion questions
Post by: Max on September 28, 2018, 01:44:09 PM
Next challenge
Title: Re: K100 GSXR conversion questions
Post by: Max on September 28, 2018, 02:14:51 PM
I have also solved the issue regarding the GSXR wheel with a cafe style tire on. I spoke to a TT racer and he explained the difference in radial and crosply tires and said I could put a crosply onto the GSXR rim with the use of an inner tube but this would make the front end twitchy and dangerous. I can use a radial on the rear BMW rim no problem but this is not the look I am going for, So once again it's back to the drawing board.
Title: Re: K100 GSXR conversion questions
Post by: NickHeijman on September 28, 2018, 03:58:00 PM
Ah okay I see you need bigger rotors, however it must work because a lot of people did it before :)
I'm going for the ZX9R or ZX7R fork, this is interchangeable and also the BWM K rims will go in easy with the stock Nissin callipers.

Good luck, looking forward on your end result.
Title: Re: K100 GSXR conversion questions
Post by: Max on October 11, 2018, 12:57:37 PM
Ok so I have decided to carry this on for future Frankenstein minded people. The cognito moto trees are fitted, I'm not overly impressed with the trees as for a polished finish they are covered in machining marks and has a score running across the top tree. I will have to anodise or paint these now, also the steering stops are rubbish and I had to grind down on the inner lip to clear the steering tunnel, even with spacers on the stem, then add a 4mm rubber pad as there was not enough adjustment on the stops.
The tire issue has been solved by running a 110/70/17 on the GSXR rim and a 140/60/17 on the k1100 rim. I know I could have gone to a 160 on the rear but you will gain much more in height than you would width because of the narrow rim and this would change the geometry even more. In reality the bike has been lowered a total of 46.6 mm front and back with the the aid of the adjustable rear shock, not ideal but best I can get it, the test will be in the ride. I am interested to see how this effects the side stand issue too, should help if any thing and better than attaching a big block on the end of it.

I have also upgraded the rear disk and pads to brembo as the front now has 6 pots. Side exit exhaust fitted and just the electrics and hook up the koso dl-03sr speedo to work out.
NickHeljman thanks for the offer on mastercylinder bro but I'm going to buy the k1100rs master new, I have gone this far with it and can't cheap out now.
Title: Re: K100 GSXR conversion questions
Post by: robotradio on October 12, 2018, 06:43:44 PM
Thanks for the update! I went with the black anodized gsxr -> bmw conversion top triple.  I also noticed the machine marks, but gives it more character :P  So your analysis is that the bmw brake rotors won't fit with the gsxr calipers? I personally have 2006-7 GSXR 600 front end, so the sizings are probably a little diff than your 98(?) gsxr front. 
Title: Re: K100 GSXR conversion questions
Post by: Max on October 13, 2018, 04:37:02 AM
It was not the machining marks that bothered me so much as the score down the middle of the top tree, this is a machining line where the two surfaces are slightly different heights.
Regarding the rotors I worked out if I used a k1100 rs front wheel as the spindle size is the same, rotor dimensions are 300mm then did some reading into what Suzuki runs a 300mm rotor. The closest I could find was a 305 rotor on a Suzuki ( can't remember which ) this would mean there would be a difference in cercumfrance of 2.5 mm and would mean I would have to purchase another set of calipers, as well as the k1100 wheel and disks. You just need to look to find what will work for your set up and then get a master cylinder to fit, but then in changing the mastercylinder you also will need to change the controls,throttle etc.
What I am looking into now is a BMW r1100s front wheel, the spindle size is smaller but wonder if I can press bigger I/d bearings into it to fit the larger spindle. Disk rotors are the same 320mm as the Suzuki so it should work.
Title: Re: K100 GSXR conversion questions
Post by: NickHeijman on October 16, 2018, 03:35:05 PM
Looks good Max !

Go for a nice black look on the lower and upper triple. I'm sure it will looks amazing on it.
How did you end up with the break callipers ?

I have the ZX7R fork ready now. Bearings just arrived OD 52 ID 34 H12mm Need to grind the stem down 1mm and make 2 rings of 4mm to cover the 12mm height of the bearings to the 16mm height in the frame.

Needed to make 2 spacers to fit the stock K75 rim in. Rest is fits like a glove.

Looking forward to see your master cylinder and all on the bike !
Title: Re: K100 GSXR conversion questions
Post by: Max on October 17, 2018, 01:19:55 PM
Thanks Nick 👍 Get some pics of yours up 👍👍 saying about turning your stem down I only took off 1mm to my old one before I went cognito. The bearings cognito supplied me were 30/52/16. I used one 4mm spacer and had too otherwise the top nut would have not seated on the top tree, there was clearance without the spacer otherwise
.
So I have put the R1100s wheel on stop For the time being and sticking with the GSXR wheel, disks and callipers. The mastercylinder arrived today as well as the throttle housing, I went for a k100rs 16v as its a 20mm bore and can use my original switchgear. The draw back is I also needed to buy a brake leaver and brake switch and throttle cable as they are all different to the 8v. I had to modify the throttle cable as there was just not enough adjustment on the throttle to take up the slack, added a small spacer ( pics attached ) and works like a dream. It's all coming together nicely, should be finished just in time for winter 👉😞
Title: Re: K100 GSXR conversion questions
Post by: Max on October 21, 2018, 11:54:34 AM
Ok, so next problem is.... The cognito trees are wrong for my forks, the trees hold the forks 7mm closer together than the standard 98 GSXR set up. I cannot mount the brake Callipers as they foul on the disks being so much closer together. I'm not sure why this is yet and have contacted cognito, I notice there are a few variations of the GSXR usd forks ranging from 98-2003. I can cure this by filing down 3mm from the calliper mounting points, 1.5mm from each side of the mounting point should not hurt, or find the right forks for the trees, unless cognito has messed up?. Another unexpected problem to solve, so far I am not overly impressed with going the cognito route.
Title: Re: K100 GSXR conversion questions
Post by: rbm on October 21, 2018, 08:03:59 PM
Max, if you don't get satisfaction from Cognito and are forced to modify the parts yourself, I'd recommend getting the work done at a local machine shop.  You need precision and you won't achieve that by hand filing.
Title: Re: K100 GSXR conversion questions
Post by: Max on October 22, 2018, 02:30:28 PM
You are exactly right rbm, but hopefully won't come to that. Cognito have been great and turns out it was my mistake. The GSXR 600/750 1996-99 have a fork width ( centre to centre ) of 214mm, the later models as in last of the 99s went to a 207mm fork centre. The k1 GSXR 2000-03 have 207 mm and is what cognito sent me. As I live in the uk it would cost a bomb to return the trees so just sucking it up and getting the right forks for the trees. I need GSXR 1000 forks and brakes, the wheel is the same. I actually prefer the look of the k1 forks so selling my 98 forks and callipers and upgrading.

If life was easy it would be boring!
Title: Re: K100 GSXR conversion questions
Post by: Max on October 22, 2018, 02:36:01 PM
The fork matrix for Suzuki if any one needs it