Author Topic: 1985 K100 Repairs (Read 17760 times)

DirtyDR · « **on:** October 31, 2016, 10:54:06 AM »

Now that Winter will hopefully be settling in soon I decided to roll the K100/EML sidecar rig in the shop and start on some much needed repair work. The final drive has been leaking so bad I can barely keep lube in it long enough to run to the store with it. It still has the original 16 spline drive and shaft so I have purchased a good low mileage 20 spline final drive and drive shaft to replace them with. The grub screw in the transmission has backed out so it will be repaired also. With 150,000 on the bike I am also wondering if I should keep going and replace the output shaft with a 12 rivet shaft also since I am that far in to it and from what I have heard from a couple of friends that have pretty much the same setup you really do not want to have to pull the transmission and such any more than necessary because of that EML frame. I am sure somewhere along the way I will be confused and in need of support but you never know it could all just go peachy.

A few pictures of the start.

DirtyDR · « **Reply #1 on:** October 31, 2016, 11:02:31 AM »

After a couple of evenings work I now have this in the shop.

That last is a pretty good shot of the EML frame and the others you can kind of see the nice dual sided swing arm and leading link front end I also have to deal with. When I get back over there next weekend I will try to remember to get some good pictures of that swing arm and front end for those who are curious about how to do rude things to a nice old motobrick.

TrueAce · « **Reply #2 on:** October 31, 2016, 09:38:12 PM »

Thanks for taking pics and sharing.............this will be an interesting series. :euro

sj2000 · « **Reply #3 on:** November 02, 2016, 01:36:29 PM »

Wow, this is nice.

DirtyDR · « **Reply #4 on:** November 07, 2016, 11:53:32 AM »

I did not get much done with the bike this weekend since I had house and yard stuff to deal with before Winter hits and I am only over at the house on weekends. Nice thing is once Winter does finally get here I will nothing else to do there except work on the bike.

I took a bunch of pictures of the sidecar mounting and the EML frame on the bike, in case anyone is interested they are all here; https://dirtydr.smugmug.com/Motorcycles/K100-EML-Frame/
I may need these to remember how things go back together also since it will undoubtedly be a few months before I am at that stage.

A few pictures to tease:

DirtyDR · « **Reply #5 on:** December 31, 2016, 10:36:45 AM »

Things have been progressing slowly since working for a ski resort things have been understandingly busy. I have not been spending a lot of time at the house in Hotchkiss but I am slowly making progress.

They sure do cram a lot of stuff in there.

I am guessing the labels did not come from BMW but I have been wrong before.

TrueAce · « **Reply #6 on:** December 31, 2016, 02:59:03 PM »

How deep are you prepared to dive? This could be more that "one" winter project! :euro

DirtyDR · « **Reply #7 on:** December 31, 2016, 03:37:05 PM »

I am going deep. The transmission needs to come out so I can fix the grub screw and I am pretty sure I need a clutch since it was slipping real bad in the 100 degree heat in L.A. when I rode it out there last year. It drips a little oil so I am not sure if it is the seal leaking oil on the clutch or the clutch is just gone but either way I will put new seals and a clutch in it while I am this far. The engine has over 150,000 so I am tempted to pull the output shaft out to look at it. I have a new water pump out of a real low mileage K1200 that got wrecked so I will put that in. Have newer driveshaft and final drive so those will go in on the way out.

With that EML frame in the way disassembly is not a pleasant task so I do not want to go back in any sooner than I have to. Still trying to figure out how to get the radiator out since it is between the stock K100 frame and the down tubes on the EML frame.

The radiator is leaking fluid somewhere but the scoop will not come out without pulling the front end off so I think I will just cut it into two pieces at the bottom and then the halves will come out each side. If I do it correctly I can make a tab on it so it will bolt back together to make things easier the next time I need to get in there.

I am seeing quite a few low mileage newer K100s fairly cheap that would make perfect donors to just replace everything with but I hate to buy a nice low mileage bike and tear it up for a drive train donor.

If anyone is sitting on a bike with front end damage but a good engine and tranny I am always up for a deal.

DirtyDR · « **Reply #8 on:** February 17, 2017, 09:44:21 AM »

Had some time to run over and get a little more done on the bike this weekend. Slowly getting there.

:neener:

Filmcamera · « **Reply #9 on:** February 17, 2017, 10:51:51 AM »

I have a quick question. I was rummaging though a box of bits I got from the PO and came a cross a plastic part which I had no idea where it came from.

I just saw it in one of your pics so now I know where to put it but still don't know what it's purpose is. Do you know?

The Mighty Gryphon · « **Reply #10 on:** February 17, 2017, 11:00:21 AM »

That is the vent overflow for the fuel tank. The spigots on the rear of the tank drain into it, and a hose from the bottom of it takes the gas down behind the rear master cylinder. The alternative is to have two hoses running down there or having the fuel leak onto the frame and wiring.

Filmcamera · « **Reply #11 on:** February 17, 2017, 11:03:25 AM »

I would never have guessed that in a million years - especially since mine has no hose! Thanks

DirtyDR · « **Reply #12 on:** March 16, 2017, 08:05:40 PM »

Been awhile but I really am making progress. The weather is getting nice so I spent the weekend, Thursday and Friday are my Winter weekend, getting some things done on the k100/EML.

That EML subframe is a pain and to remove it you need to pull the front end off since the front of the frame is mounted to the steering head.

The accepted way to remove the transmission is to use a strap to pull the subframe down so the transmission will clear.

DirtyDR · « **Reply #13 on:** March 16, 2017, 08:08:03 PM »

On a side note isn't there supposed to be a bolt hole in the middle of this thing to make it easier to get the swing arm pivot out?

DirtyDR · « **Reply #14 on:** March 16, 2017, 08:16:22 PM »

The transmission is out, all cleaned up and ready to open up so I can fix the grub screw.

Still need to pull the clutch pack and see what all I need to get ordered so I can start putting it back together. Rear main is leaking from the looks of things since there is a lot of oil in there and the clutch pack is oily so I know I need at least the rear main and I will probably just order a clutch since I am in this far and I do not want to do this again any time soon.

Filmcamera · « **Reply #15 on:** March 16, 2017, 09:48:52 PM »

"On a side note isn't there supposed to be a bolt hole in the middle of this thing to make it easier to get the swing arm pivot out?"

Yes - mine has one anyway - maybe it was a later addition....

I'll take hot cam in trade for that any day

DirtyDR · « **Reply #16 on:** March 19, 2017, 09:48:16 AM »

Hackers is fine. I started it before we had the Hackers section so I suppose this is where it rightly should be now.

K_grendell · « **Reply #17 on:** June 03, 2017, 08:05:12 AM »

Dirty I love the bike! While it's apart would you mind letting me know what your sidecar wheel lead and track is?

We just took our k75/Velorex rig from central mass to Montreal and back last week. It was a blast but we quickly found out it's limitations. I've always wanted a krs/eml rig and now have the wife's blessing, so I'm sourcing the bike and bits now. I'll probably end up with an ezs and have to make my own subframe, so I'm looking for a good baseline of numbers to start with. I really like the solid bottom mounts that can pivot but don't have any front to rear adjustments, it makes the connection simpler and with less to go wrong.

DirtyDR · « **Reply #18 on:** June 19, 2017, 10:31:26 AM »

I know this is dragging on but with the K bike being at the house in Hotchkiss and me still having to work for a living in Vail it does not leave a lot of time for wrenching. Unfortunately when I get to Hotchkiss for the weekend the house comes first, mowing, weeding, general house maintenance and such.

At any rate I got the transmission sorted out but I did not have any gasket goop and I ran out of time so I will have to seal it up when I get back to Hotchkiss this coming weekend. I went to test fit the grub screw and the threads were all mangled in the housing so I had to pull the shifter out and run a tap through the offending orifice. Had to pull all of this apart to get part number 88 out so I could run a tap through the threads so part number 84, grub screw, would screw back in. Ample red Loctite and we should be good for another 150,000 miles.

DirtyDR · « **Reply #19 on:** June 19, 2017, 10:33:56 AM »

As far as wheel lead and such I am going to have to wait until I get the sidecar frame connected back to the bike before I can check any of that.

The Mighty Gryphon · « **Reply #20 on:** June 19, 2017, 04:49:12 PM »

That grub screw is a pain in the ass. Had to do mine in the RT. Of all the dumb places Motorad put that damn red Loctite, and then NOT use it on the friggin' grub screw. :swear:

DirtyDR · « **Reply #21 on:** August 28, 2017, 03:24:38 PM »

Just a note to let those who care that progress is being made. I got the water/oil pump off and the new one ready to go on.

Since I am here I may as well pull the radiator and make sure what the fan looks like. It seems to work fine but the way the rest of this has been I am going to look just to be safe.

johnny · « **Reply #22 on:** August 28, 2017, 06:06:45 PM »

greetings...

i care... may not seem like it cause im a bully... butts i do care...

keep us informed...

ride dangerously...

j o

K_grendell · « **Reply #23 on:** August 28, 2017, 06:50:09 PM »

I'm glad you're making progress! Hopefully you'll get to enjoy it this season. With all the trips I've been taking I wish I swapped mine out with a spal unit last winter. It's a good piece of mind when you're 500 miles away from home.

DirtyDR · « **Reply #24 on:** May 13, 2018, 01:32:59 PM »

Finally done and on the road. I rebuilt the transmission and it shifts so nice now, like warm butter. Updated water/ oil pump from a k1200, driveshaft and final drive from same K1200 low mileage wreck. Brand new clutch kit from Bob's with all of the associated goodies. It took about seven months but it was worth it. Think I will go for a ride and harass town with it.

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Author Topic: 1985 K100 Repairs (Read 17760 times)