Post by: Cromoly on February 05, 2019, 10:26:44 AM
Hello everyone from Quebec’s Estren Township.
Here is THE project that has occupied most of my spare timelately..
This is a work in progress, since it was ridden daily last summer,everything was put on hold.
Even if the project is not quite done, The bike turned out to be a superb ride.
Most of the work was made by me, but i am not afraid to go to professionals if needed. the general idea is set and done, all there is to do now is tidy up.....
This is where it all started....
[ Invalid Attachment ]
Post by: Cromoly on February 05, 2019, 12:11:55 PM
I suggested to roll it into my basement workshop and work on it over winter last year.
Dismantle was a breeze, everything whent off as if it was fastened the day before. [ Invalid Attachment ]
Post by: Cromoly on February 06, 2019, 10:12:32 AM
The back of the frame was cut off also.
Post by: Barry in IN on February 06, 2019, 12:43:38 PM
The back of the frame was cut off also.
Sigh
Post by: The Mighty Gryphon on February 06, 2019, 02:20:09 PM
Sigh
+1 Another brick sentenced to a slow death.
Post by: Cromoly on February 06, 2019, 08:20:30 PM
Post by: Laitch on February 06, 2019, 08:26:52 PM
I would call it a resurrection!When Lazarus was raised from the dead, he didn't come back as Lazbo-man; he came back as Lazarus.
I'd call it a transmogrification.
Post by: Cromoly on February 06, 2019, 08:35:34 PM
Post by: Cromoly on February 06, 2019, 08:53:59 PM
Most of the work was done last winter, and everything else was Zip tye securely in place to be ridden
Until now.
Electrical connections where Good but not to my standards.
I have received good ones from EBay so it is time to replace the crappy ones. [ Invalid Attachment ] [ Invalid Attachment ] [ Invalid Attachment ] [ Invalid Attachment ]
Post by: Cromoly on February 06, 2019, 09:04:02 PM
I think it will be relocated up front, by the radiator.
Post by: Cromoly on February 06, 2019, 09:29:42 PM
I also relocated the ecu, it was bolted in front of the rear tire.
I fabricated brackets out of left overs from the tear down and welded on the frame.
[ Invalid Attachment ]
Post by: Cromoly on February 06, 2019, 09:30:37 PM
Post by: Cromoly on February 06, 2019, 09:39:48 PM
This is the bracket i made last winter for the Motogadjet clock, it did not incorporate any place for a fuel gauge...
[ Invalid Attachment ]
This is the bracket i made for the fuel gauge... its is a very good thing to have a fuel gauge .. ..
Post by: Cromoly on February 06, 2019, 09:42:25 PM
The final product [ Invalid Attachment ]
Post by: Cromoly on February 06, 2019, 09:48:34 PM
I took the air box out,
[ Invalid Attachment ]
These are going on this bike
Post by: Cromoly on February 06, 2019, 09:51:30 PM
Post by: Barry in IN on February 06, 2019, 10:01:31 PM
But i still have to figure it outMe too.
Post by: K1300S on February 07, 2019, 08:02:33 AM
(putting a rubber washer between the ecu and the frame is not vibration insulation)
Post by: Arktasian on February 07, 2019, 09:25:10 AM
C784FCA9-50C7-494E-8A9D-17EFBFCDB5AF.jpeg (51.64 kB . 768x576 - viewed 750 times)
I took the air box out,
These are going on this bike
"But I still have to figure it out"
If you are removing the stock air box to fit individual cone filters on the inlets, how are you going to accommodate the removal of the MAF sensor that resides in the box, and communicates air flow to the ecu? That is not an optional item, assuming you are maintaining the stock ecu.
Post by: Arktasian on February 07, 2019, 09:47:09 AM
Flattened Pins .JPG (20.79 kB . 432x576 - viewed 720 times) Weatherpack.jpg (17.41 kB . 576x576 - viewed 686 times)
Post by: Laitch on February 07, 2019, 11:36:13 AM
If you are removing the stock air box to fit individual cone filters on the inlets, how are you going to accommodate the removal of the MAF sensor that resides in the box, and communicates air flow to the ecu?The K1100 engines don't have a volume air flow sensor in there like 8V engines have. The gizmo in Cromoly's photo is part of the crankcase ventilation system. From what I've read, the Motronic uses air temperature and throttle position as part of fuel mixture calculation. That is part of what Cromoly will need to figure out.
Post by: Arktasian on February 07, 2019, 01:25:58 PM
The K1100 engines don't have a volume air flow sensor in there like 8V engines have. The gizmo in Cromoly's photo is part of the crankcase ventilation system. From what I've read, the Motronic uses air temperature and throttle position as part of fuel mixture calculation. That is part of what Cromoly will need to figure out.
I stand corrected. :embarass:
Post by: Cromoly on February 07, 2019, 09:57:06 PM
On your Weatherpack upgrades, you might want to utilize a proper crimp tool as those pins require a folded shape on the fitment, when properly set on the stripped wire. Although that type of connector is rather simple and forgiving, introduced distortion to the male or female side pins may lead to improper "marriage" and electrical behaviour)
You are absolutely right , i was not even aware of this tool!wow.
I did solder every wire to its pin and when inserted I made shire they « clicked » in place .
Good to have tool!!! It makes sense.
Thanks for the info!
I am ordering one. Now.
Post by: Cromoly on February 07, 2019, 10:00:55 PM
suggest you rethink hard bolting the ecu to the frame. ecu's are mounted by the factory with vibration insulation for a reason.
(putting a rubber washer between the ecu and the frame is not vibration insulation)
Thanks, i thought of this, and will reuse grommets from salvage to insolate vibrations. Good call.
Post by: Cromoly on February 07, 2019, 10:43:10 PM
I manage to tuck the headlamp even closer to the fork, and in the process take off even more hardware and brackets.
Here is the « transmogrification« of the headlamp. [ Invalid Attachment ] [ Invalid Attachment ] [ Invalid Attachment ] [ Invalid Attachment ]
As naked as possible!!
Post by: Cromoly on February 07, 2019, 11:00:51 PM
I dont have time to do all the work, so some is contracted out [ Invalid Attachment ] [ Invalid Attachment ] [ Invalid Attachment ]
Post by: Cromoly on February 07, 2019, 11:03:00 PM
Post by: natalena on February 24, 2019, 07:40:05 PM
Which do you prefer? people, with or without the stripes??
If the stripes had a radius at the corners, it'd be truly U-neek. Good luck with the build.
Post by: johnny on February 24, 2019, 08:14:49 PM
need photos of the whole moto from different angles... butts at this point im thinking stripes...
j o
Post by: Laitch on February 24, 2019, 08:56:54 PM
Post by: Cromoly on February 24, 2019, 09:48:21 PM
Post by: Cromoly on February 24, 2019, 09:58:44 PM
I manage to dismantle the leaky front master cylinder with ease an no struggle. A Magura rebuild kit is on the way along with a new throttle cable. The original one being damaged. [ Invalid Attachment ]
Straightforward... [ Invalid Attachment ] broken [ Invalid Attachment ] should be good again with new internals installed
Post by: Cromoly on February 24, 2019, 10:07:01 PM
[ Invalid Attachment ]
Post by: Cromoly on February 24, 2019, 10:16:42 PM
But they have a nice 45deg. elbow... [ Invalid Attachment ]
and smaller pod filters
[ Invalid Attachment ]
[ Invalid Attachment ]
[ Invalid Attachment ]
Post by: Cromoly on February 24, 2019, 10:24:40 PM
I Fitted a hose from the front crankcase breather straight to the injectors tubes, bypassing the collector in the original airbox. [ Invalid Attachment ] [ Invalid Attachment ] [ Invalid Attachment ]
Post by: Cromoly on February 24, 2019, 10:27:10 PM
Post by: Cromoly on February 24, 2019, 10:34:33 PM
Her is the future in battery box!!!
Made a dummy out of cardboard, and will get it reproduced out of aluminum.
The box will be rubber mounted, bolted to the engine.
Post by: Cromoly on February 24, 2019, 10:37:19 PM
Post by: johnny on February 24, 2019, 10:45:40 PM
use the photo gallery...
canadicans are whack...
http://www.motobrick.com/index.php/topic,10242.msg103981.html#msg103981
j o
Post by: Martin on February 24, 2019, 11:02:24 PM
Regards Martin.
Post by: Cromoly on February 24, 2019, 11:12:20 PM
Haha 😂
Photo's are wack because you have your camera set for the southern hemisphere.
Regards Martin.
Post by: Laitch on February 24, 2019, 11:16:08 PM
Why are my pictures upside down??This might be why (https://iphonephotographyschool.com/iphone-photos-upside-down/).
Post by: Laitch on February 24, 2019, 11:30:17 PM
I also manage to find information on what to do with the crankcase breather hosesI can't decipher your photos. Does this mean you are introducing oil vapor and crankcase fumes directly into the air/fuel mixture? What is the purpose of an oil separator and why do racers use catch cans?
I Fitted a hose from the front crankcase breather straight to the injectors tubes, bypassing the collector in the original airbox.
Post by: boardjnky4 on February 25, 2019, 10:18:25 AM
Post by: Cromoly on February 25, 2019, 10:28:54 AM
Where did you get the radiator catch tank? All of the ones I'm seeing are a little too big for my liking.[ Invalid Attachment ]
Got it from eBay, i searched for (ruckus catch tank) for a bog 33$ can.
Post by: Cromoly on February 25, 2019, 10:32:25 AM
I can't decipher your photos. Does this mean you are introducing oil vapor and crankcase fumes directly into the air/fuel mixture? What is the purpose of an oil separator and why do racers use catch cans?Yes indeed, i don't know if it will work, the k1200 is setup like that, [ Invalid Attachment ]
This is what i got and the ONLY info i found.
Any other suggestions?
Post by: boardjnky4 on February 25, 2019, 10:43:19 AM
Got it from eBay, i searched for (ruckus catch tank) for a bog 33$ can.
You rock, thanks
Post by: Laitch on February 25, 2019, 12:32:48 PM
This is what i got and the ONLY info i found.I suggest that modifying a K1100 with a schematic for modifying a K1200 could bring unsatisfactory results because the tuning, fuel intake and emission controls of the two motos differ. Please keep us updated concerning its performance.
Any other suggestions?
Do you have a sight window on the radiator reservoir? Will the coolant transfer tube opening always be submerged?
Post by: Cromoly on February 25, 2019, 02:55:15 PM
I suggest that modifying a K1100 with a schematic for modifying a K1200 could bring unsatisfactory results because the tuning, fuel intake and emission controls of the two motos differ. Please keep us updated concerning its performance.No sight windows and yes, the hose hole is at the bottom of the can.
I took the info on the k11 owners group page, it has been done on k1100 and working fine for them.
Do you have a sight window on the radiator reservoir? Will the coolant transfer tube opening always be submerged?
Post by: Cromoly on February 25, 2019, 03:23:19 PM
Someone must had to deal with this issue before, i cant find any more info?
I’ll give it a shot, pay close attention and see if i get sludges in the throttle body.
From what i can see, it must be mostly fumes coming out of the crankcase beather hose.
Beeing mixted withe fuel/air mixture, i belive thath the system will compensate.
Anyway what do i know, îm just a basement moto mechanic triyng to undo what a bunch of verry well paid German engeineers worked hard to achieve! [ Invalid Attachment ]
Îll give it a shot, will keep posted next summer. I can always go back to the original aibox if all else fail.
Post by: boardjnky4 on February 25, 2019, 03:59:12 PM
Anyone else has put pod filters on a k1100?
Someone must had to deal with this issue before, i cant find any more info?
I’ll give it a shot, pay close attention and see if i get sludges in the throttle body.
From what i can see, it must be mostly fumes coming out of the crankcase beather hose.
Beeing mixted withe fuel/air mixture, i belive thath the system will compensate.
Anyway what do i know, îm just a basement moto mechanic triyng to undo what a bunch of verry well paid German engeineers worked hard to achieve! [ Invalid Attachment ]
Îll give it a shot, will keep posted next summer. I can always go back to the original aibox if all else fail.
The "accumulator" in the stock airbox is essentially an oil catch can. So, ideally, you would replace the stock configuration with an aftermarket catch can.
Post by: Cromoly on February 25, 2019, 04:20:45 PM
The "accumulator" in the stock airbox is essentially an oil catch can. So, ideally, you would replace the stock configuration with an aftermarket catch can.
[/quote]
I guess i could make a small catch tank similar to the cooling one, out of aluminum or anything really...
Post by: Laitch on February 25, 2019, 05:13:11 PM
I guess i could make a small catch tank similar to the cooling one, out of aluminum or anything really...A juice box probably won't be as durable as aluminum. I think you're headed in the right direction though.
Post by: boardjnky4 on March 01, 2019, 11:58:54 AM
Anyone else has put pod filters on a k1100?
Someone must had to deal with this issue before, i cant find any more info?
I’ll give it a shot, pay close attention and see if i get sludges in the throttle body.
From what i can see, it must be mostly fumes coming out of the crankcase beather hose.
Beeing mixted withe fuel/air mixture, i belive thath the system will compensate.
Anyway what do i know, îm just a basement moto mechanic triyng to undo what a bunch of verry well paid German engeineers worked hard to achieve! [ Invalid Attachment ]
Îll give it a shot, will keep posted next summer. I can always go back to the original aibox if all else fail.
I dug into this a little bit last night. You inspired me.
I actually ran my bike with the airbox and all breather hoses removed and observed air flow (BTW, it ran perfectly).
1. The rear breather hose had a steady stream of air venting from the crankcase.
2. All other hoses have no air movement at all. Both at idle, acceleration and holding RPMs. That indicates to me they are just returns for the positive pressure from the rear vent.
3. I noted that the hose running along the throttle body connects into the TBs BEFORE the butterfly valve. That indicates to me that it would never present a vacuum to the hoses that connect to it. It really is just an air re-circulation. As such, I really don't actually think it's necessary.
With that in mind, I have the following thoughts:
I would not put the rear crankcase breather directly to the TB hose like that picture. That is just asking for oil to enter the system. Either keep it with just a breather, or run a catch can. Putting just a breather does introduce the potential for some oil to leak out of the filter if it spits some out. I'd rather have it dripping/leaking than to have it enter the intake.
I'm planning on doing what you're doing. Just going to run a breather filter. If you look at pictures of the La Dini k1100, you can see that he also just has it venting to the side of the bike with a pod filter.
From the front crankcase hose, I did what you did and just jumped that over to the Y-fitting that is on the TB hose. I don't actually think any air flows FROM the front, so I don't think you'll ever get any oil spitting entering the TB (might want to monitor it, though). I also believe that you could probably plug it up, with zero consequence.
Post by: Cromoly on March 02, 2019, 10:07:54 AM
I dug into this a little bit last night. You inspired me.Thanks for your interest, late response, real work got me busy...
I actually ran my bike with the airbox and all breather hoses removed and observed air flow (BTW, it ran perfectly).
1. The rear breather hose had a steady stream of air venting from the crankcase.
2. All other hoses have no air movement at all. Both at idle, acceleration and holding RPMs. That indicates to me they are just returns for the positive pressure from the rear vent.
3. I noted that the hose running along the throttle body connects into the TBs BEFORE the butterfly valve. That indicates to me that it would never present a vacuum to the hoses that connect to it. It really is just an air re-circulation. As such, I really don't actually think it's necessary.
With that in mind, I have the following thoughts:
I would not put the rear crankcase breather directly to the TB hose like that picture. That is just asking for oil to enter the system. Either keep it with just a breather, or run a catch can. Putting just a breather does introduce the potential for some oil to leak out of the filter if it spits some out. I'd rather have it dripping/leaking than to have it enter the intake.
I'm planning on doing what you're doing. Just going to run a breather filter. If you look at pictures of the La Dini k1100, you can see that he also just has it venting to the side of the bike with a pod filter.
From the front crankcase hose, I did what you did and just jumped that over to the Fitting that is on the TB hose. I don't actually think any air flows FROM the front, so I don't think you'll ever get any oil spitting entering the TB (might want to monitor it, though). I also believe that you could probably plug it up, with zero consequence.
You are right, the front breather should not do much, the rear breather is the on i am concerned about.
Others have build a hose assembly that joins the vent to the front of the TB via calibration holes using a one way valve (from other source).
From what i understand, the engine needs this negative pressure to work properly,
So by plugging under the butterfly, It solves this issue.
Monitoring will be done often... [ Invalid Attachment ]
Post by: Cromoly on March 02, 2019, 10:10:57 AM
THATS exactly what i thought!!
Haha 😂
This might be why (https://iphonephotographyschool.com/iphone-photos-upside-down/).
I AM LEFTHANDED , that is why my pics are upside down, i was pressing the camera button of my phone with my ... left hand.
Turned my phone around 180deg and voila...
Post by: boardjnky4 on March 02, 2019, 03:32:56 PM
Thanks for your interest, late response, real work got me busy...
You are right, the front breather should not do much, the rear breather is the on i am concerned about.
Others have build a hose assembly that joins the vent to the front of the TB via calibration holes using a one way valve (from other source).
From what i understand, the engine needs this negative pressure to work properly,
So by plugging under the butterfly, It solves this issue.
Monitoring will be done often...
To me, I don’t think it really needs a vacuum in order to properly vent the crankcase. And again, doing so, you risk sucking oil into your intake.
Post by: Laitch on March 02, 2019, 06:30:17 PM
To me, I don’t think it really needs a vacuum in order to properly vent the crankcase. And again, doing so, you risk sucking oil into your intake.Post photos of your moto's setup, boardjnky4.
Post by: Cromoly on March 02, 2019, 07:58:02 PM
To me, I don't think it really needs a vacuum in order to properly vent the crankcase. And again, doing so, you risk sucking oil into your intake.You may be right, i have a small pod filter on order and a one way valve on order as well, i can do both and test. I guess i can put the filter on the breather for now and see. The setup would be the cleanest and most
« naked »
You did mentioned you ran your bike with the hoses unplugged, did you get any oil residue ?
It is the main reason i wanted to put a one way valve on the hose line.
Post by: Cromoly on March 02, 2019, 08:22:02 PM
All of the rear of the bike is to my liking, everything was taken out of there, wires were tucked away and securely fastened.
[ Invalid Attachment ]
Red gaz line on the way
Post by: Cromoly on March 02, 2019, 08:28:56 PM
This is the next project before it leaves the shop. The bike is scheduled to get a nice handmade custom exhaust system.
I need to figure out how to hook this BEP 3.0 up to the Motogadjet clock...
Post by: billday on March 03, 2019, 07:43:58 AM
Red gaz line on the way
Make sure that fuel line is up to the pressure of the K bike system.
Post by: boardjnky4 on March 03, 2019, 07:46:12 AM
You may be right, i have a small pod filter on order and a one way valve on order as well, i can do both and test. I guess i can put the filter on the breather for now and see. The setup would be the cleanest and most
« naked »
You did mentioned you ran your bike with the hoses unplugged, did you get any oil residue ?
It is the main reason i wanted to put a one way valve on the hose line.
No actual residue, but I’m sure the air contains lots of oil vapors.
Post by: Laitch on March 03, 2019, 10:49:46 AM
No actual residue, but I’m sure the air contains lots of oil vapors.My experience is that wherever there is oil vapor, there will be oil residue. Post some photos of your set up, boardjnky4.
Post by: boardjnky4 on March 03, 2019, 10:52:18 AM
My experience is that wherever there is oil vapor, there will be oil residue. Post some photos of your set up, boardjnky4.
Exactly! This was less than 5 minutes of runtime.
I’ll get some pics up soon when I’m not on mobile. My bike is coming along nicely.
Post by: Laitch on March 03, 2019, 01:35:41 PM
I’ll get some pics up soon when I’m not on mobile. My bike is coming along nicely.Be sure to start your own thread in either the Custom or Restoration projects section—whichever applies to your work. Explain how long you've had the moto, how much riding you've done on it, etc..
Now, we'll return to Cromoly's thread.
Post by: Cromoly on March 03, 2019, 11:00:14 PM
Post by: boardjnky4 on March 03, 2019, 11:02:58 PM
More work and tidying up was done.
All of the rear of the bike is to my liking, everything was taken out of there, wires were tucked away and securely fastened.
Red gaz line on the way
Is that a cafe4euro collector? Did it fit pretty snug for you? Mine doesn’t seem to fit snugly and leaks pretty bad.
Post by: Cromoly on March 03, 2019, 11:39:36 PM
Is that a cafe4euro collector? Did it fit pretty snug for you? Mine doesn’t seem to fit snugly and leaks pretty bad.
[/quote]
I got the 4 into one in England, a speed shop called BSK Spees Works,
http://www.bskspeedworks.co.uk/k-throttle-bodies.html
I got the rear set ansn rear master there too.
They do fit nicely, they are snug, there is probably lots of leak, i wouldn’t know !
The almost non existent exhaust is SOOO LOUD ....sorry i don’t know.
It is the main reason why we are changing the exhaust.
[ Invalid Attachment ] we found a master exhaust welder who can build anything!
Will keep posted.
Post by: boardjnky4 on March 04, 2019, 08:51:16 AM
Is that a cafe4euro collector? Did it fit pretty snug for you? Mine doesn’t seem to fit snugly and leaks pretty bad.
I got the 4 into one in England, a speed shop called BSK Spees Works,
http://www.bskspeedworks.co.uk/k-throttle-bodies.html
I got the rear set ansn rear master there too.
They do fit nicely, they are snug, there is probably lots of leak, i wouldn’t know !
The almost non existent exhaust is SOOO LOUD ....sorry i don’t know.
It is the main reason why we are changing the exhaust.
Will keep posted.
Good to know. I have a muffler that I like, which isn't too loud.
If you want to sell the collector, let me know.
Post by: Cromoly on March 04, 2019, 09:06:15 PM
The new finish on the gas tank is done and on the way.
Just brushed aluminium, raw ...
Post by: Cromoly on March 04, 2019, 09:14:58 PM
Post by: Cromoly on March 04, 2019, 09:16:54 PM
Aluminum battery box is good to go!!
Post by: Barry in IN on March 04, 2019, 09:20:36 PM
We are currently looking for a replacement gas cap, something slick and keyless.
Post by: Cromoly on March 04, 2019, 09:25:15 PM
Post by: DJEwen on March 05, 2019, 04:00:28 AM
Is that a cafe4euro collector? Did it fit pretty snug for you? Mine doesn’t seem to fit snugly and leaks pretty bad.
You need to coat the inside of the collector with exhaust putty, coat the pipes up too then I mated up the surfaces, tightened the exhaust to its final position, wiped away any excess then initially heated it dry with the heat gun before running the bike to make sure I didn’t blow any out on start which would remove the seal - works perfect.
Post by: boardjnky4 on March 05, 2019, 06:36:18 AM
You need to coat the inside of the collector with exhaust putty, coat the pipes up too then I mated up the surfaces, tightened the exhaust to its final position, wiped away any excess then initially heated it dry with the heat gun before running the bike to make sure I didn’t blow any out on start which would remove the seal - works perfect.
You rock! Thanks for the tip
Post by: Laitch on March 05, 2019, 07:36:29 AM
You rock! Thanks for the tipHow about starting a thread of your own with photos of your project, boardjinky4, instead of hijacking this one. :giggles
Post by: boardjnky4 on March 05, 2019, 08:24:13 AM
How about starting a thread of your own with photos of your project, boardjinky4, instead of hijacking this one. :giggles
I thought my comments were relevant to the discussion?
Post by: Cromoly on March 05, 2019, 04:03:24 PM
Pics of today's work
The tank is here, battery box as well,
I think it looks good just aluminum color.
Half of the motogadjet instrument is hooked up.
I have a magnet speed sensor to install, it came with the instrument gauge, I will use the rear ABS sensor bracket to hold it in place since the ABS SECTOMY it is useless
So far so good. Close to schedule, if only the snow could melt so i can get the bike outside and test start.
Post by: Cromoly on March 08, 2019, 07:57:31 AM
I striated plugging in to the BEP 3.0, pretty straightforward so far.