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TECHNICAL MOTOBRICK WRENCHING In Remembrance of Inge K. => Project Custom Motobricks => Topic started by: Boxermann on November 03, 2016, 09:38:59 AM

Title: K100 CAFE FIGHTER
Post by: Boxermann on November 03, 2016, 09:38:59 AM
So I impulse bought an 1987 K100 LT a couple of weeks ago and plan to rebuild it during the winter to a cafe racer/ streetfighter kind of thing. More specifically something with the lines of a classic cafe racer but the more aggressive traits of a streetfighter.

Preliminary plans (updated continuously).
Title: Re: K100 cafe fighter
Post by: MaraudeRS on November 03, 2016, 11:00:19 AM
I'm looking forward to seeing what you come up with. Hoping to do something similar with my 92 K100RS


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Title: Re: K100 cafe fighter
Post by: Boxermann on December 13, 2016, 05:50:02 AM
Wrote a long post, but it disappeared when I clicked "post" because the images was too large. :bang-head:


Anyway. Bike taken apart for cleaning, inspection and painting. Was concerned about the state of things since it had >230k km (ca 140k miles) on the odo, but splines, valves, chain and other expensive things looked good. Bike has apparently been well maintained. I'm replacing clutch plate, voltage regulator, alternator rubbers and a couple of the bearings.

Waiting for parts to arrive this week so I can begin to reassemble. Complete gasket kit, seals, bolts, and so on.

Also decided to swap rear rim for a 3-spoke k1100 18x4.5. Thinking of Pirelli Angel GT tires.

My garage is getting more and more covered in sodium bicarbonate from soda blasting. I think I've used up over 25 kg so far (50+ lbs). At least I'll have a white christmas...
Title: Re: K100 cafe fighter
Post by: Boxermann on December 15, 2016, 04:39:29 PM
Santa came early.


Title: Re: K100 cafe fighter
Post by: MaraudeRS on December 15, 2016, 05:00:54 PM
Soda blasting looks like the way to go. Very nice! I love it when santa comes. I'm hoping he delivers lots of goodies for me this year :)


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Title: Re: K100 cafe fighter
Post by: billday on December 15, 2016, 06:32:19 PM
Why did you strip the engine down?
Title: Re: K100 cafe fighter
Post by: Boxermann on December 19, 2016, 03:54:24 AM
Soda blasting looks like the way to go. Very nice! I love it when santa comes. I'm hoping he delivers lots of goodies for me this year :)

Yeah, soda blasting is awesome. I wish I had covered the rest of the garage before I started though...


Why did you strip the engine down?


Mostly because I had no idea of what has been done to it and and it had over 230k km (ca 140k miles) on the odo. The guy I bought it from had recently got it from an estate, so he knew nothing about its history.


Engine block done painted and gearbox primed. I'm using Hammerite smooth finish. I've used Hammerites alloy primer, but after doing some forum reading I'm unsure if it is necessary? As long as the finish is applied in thin layers.

Title: Re: K100 cafe fighter
Post by: MaraudeRS on December 19, 2016, 12:20:36 PM
That looks fantastic!


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Title: Re: K100 cafe fighter
Post by: nods on December 19, 2016, 08:06:28 PM
Yeah, soda blasting is awesome. I wish I had covered the rest of the garage before I started though...



Mostly because I had no idea of what has been done to it and and it had over 230k km (ca 140k miles) on the odo. The guy I bought it from had recently got it from an estate, so he knew nothing about its history.


Engine block done painted and gearbox primed. I'm using Hammerite smooth finish. I've used Hammerites alloy primer, but after doing some forum reading I'm unsure if it is necessary? As long as the finish is applied in thin layers.


That looks great mate.  As for the primer I reckon it's always a good idea to do a thorough prep first.


Can you please let me know what kit you got to do the soda blasting?  I'm only finding out about this and it looks like a great way to clean up years of gunk before painting.  I want an all black block and tranny, and well, everything, too.


Cheers
nods
Title: Re: K100 cafe fighter
Post by: Martin on December 19, 2016, 08:34:40 PM

Supercheap 4.5 Kg blasting soda $74.97 Gun price starts at $43.97 you will also need a decent compressor. Any of the big tool stores will also stock them.
Regards Martin.
Title: Re: K100 cafe fighter
Post by: nods on December 19, 2016, 08:42:41 PM
Supercheap 4.5 Kg blasting soda $74.97 Gun price starts at $43.97 you will also need a decent compressor. Any of the big tool stores will also stock them.
Regards Martin.
Thanks Martin. And just do it outside, or is there a way to contain the mess? I guess it's a once only use for the media?

It used a bead blaster cabinet years ago when restoring my Bonny at a mates garage.

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Title: Re: K100 cafe fighter
Post by: Martin on December 19, 2016, 09:06:43 PM

Make up a frame out of cheap timber, or a box out of ply wood line it with thick clear plastic sheeting. Cut a couple of holes for your arms, tape a couple of raincoat arms to the hole and wear thick loose rubber gloves that you can tape to the raincoat arms. If you really want to go overboard connect in a industrial vacuum cleaner purchased cheap of Gumtree. You can also screw a sheet of clear acrylic plexiglass to the front it's easier to see through. Most bit's can be scrounged or purchased really cheap, we have a couple of recycle shops that are attached to the local tips (dumps) which are a good source of bits. Salvo shops and the like another good source.
Regards Martin.
Title: Re: K100 cafe fighter
Post by: nods on December 19, 2016, 11:51:30 PM
Awesome thanks mate

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Title: Re: K100 cafe fighter
Post by: Boxermann on December 20, 2016, 03:56:28 AM

That looks great mate.  As for the primer I reckon it's always a good idea to do a thorough prep first.


Can you please let me know what kit you got to do the soda blasting?  I'm only finding out about this and it looks like a great way to clean up years of gunk before painting.  I want an all black block and tranny, and well, everything, too.

Thanks. Yeah, prepping is the key. :)

I bought the soda gun in a local shop here in Norway for ca 80 usd. Nothing fancy, just a blow gun with a screw on container for the soda. If your compressor doesn't have a moisture trap you need to add one. Otherwise the gun keeps clogging up.

I also have one of these cabinets for sand blasting smaller stuff.
Title: Re: K100 cafe fighter
Post by: Boxermann on December 21, 2016, 10:24:33 AM
More cleaning and painting.
Title: Re: K100 cafe fighter
Post by: The Mighty Gryphon on December 21, 2016, 11:47:48 AM
My bricks are beginning to look a little shabby to me now...
Title: Re: K100 cafe fighter
Post by: Glacial on December 21, 2016, 06:09:35 PM
I ride British roads in the winter, there is absolutely no point in me doing such a lovely job to my engine because five minutes later it will be covered in salt-laden mud.
Title: K100 cafe fighter
Post by: Boxermann on December 22, 2016, 03:49:29 AM
I ride British roads in the winter, there is absolutely no point in me doing such a lovely job to my engine because five minutes later it will be covered in salt-laden mud.

At least you can ride in the winter there. Here in Scandinavia it's not really an option. :/

Head cleaned up and painted. Valves removed to be cleaned and for change of valve stem seals (I put one back before deciding to do the rest later).

Next project: throttle bodies.
Title: K100 cafe fighter
Post by: Boxermann on December 30, 2016, 11:37:59 AM
More cleaning and painting. Fitted new voltage regulator. Starter coals checked out ok.

Bought a nice k1100 rim with an as good as new Bridgestone Battlax tire, so I guess I'll keep it instead of the Pirellis I was planning to get. Just need to buy one for the front.

4-1 collector from Cafe4racer.eu



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Title: Re: K100 cafe fighter
Post by: Boxermann on December 30, 2016, 03:31:58 PM
Can't seem to get a decent spray out of three of the injectors. I ran some brake cleaner through them but only one of them seems ok. Will soak them for a while and see if that solves it, otherwise I'm thinking of getting a set of #715's with 4-hole nozzles. Any suggestions/input?
Title: Re: K100 cafe fighter
Post by: Martin on December 30, 2016, 03:53:42 PM

Remove and replace the internal filter screens. Try cycling the injectors while soaking in injector cleaner use a 9v battery and don't keep the battery connected for  long periods.  One of the members cycles the injectors with a pressure pack injector cleaner connected to the injector with the injector open. ( Take extreme care when using a battery around any cleaners, you do not want any sparks which could ignite the cleaner. Use extremely long wires between the injector and the battery and have a fire extinguisher handy.)
Regards Martin.
Title: Re: K100 cafe fighter
Post by: The Mighty Gryphon on December 30, 2016, 04:14:09 PM
You're cleaning the parts that make the bike go with a cleaner for the parts that make the bike stop?!   :mbird

That might be why they aren't getting clean.
Title: Re: K100 cafe fighter
Post by: Markus77 on December 30, 2016, 04:20:13 PM
Looking forward to seeing how your project develops - looks like you're off to a great start! What's your other bike in the garage in one of the first pics?
Title: Re: K100 cafe fighter
Post by: Boxermann on December 30, 2016, 06:17:32 PM

Remove and replace the internal filter screens. Try cycling the injectors while soaking in injector cleaner use a 9v battery and don't keep the battery connected for  long periods.  One of the members cycles the injectors with a pressure pack injector cleaner connected to the injector with the injector open. ( Take extreme care when using a battery around any cleaners, you do not want any sparks which could ignite the cleaner. Use extremely long wires between the injector and the battery and have a fire extinguisher handy.)
Regards Martin.

Thanks! I'll give it a try. :2thumbup:


You're cleaning the parts that make the bike go with a cleaner for the parts that make the bike stop?!   

That might be why they aren't getting clean.

Haha, yeah, you might have a point there.  :eek:


Looking forward to seeing how your project develops - looks like you're off to a great start! What's your other bike in the garage in one of the first pics?

Thanks!

Other bike is a '06 Harley Sportster. Was a ugly orange stock 883 when I bought it. Rebuilt to 1250 now. I'm going to do some changes to it too over the winter: new rear fender, handlebar, tires, new paintjob (still black though), lower the saddle and add drag pipes.
Title: Re: K100 cafe fighter
Post by: Markus77 on December 31, 2016, 07:52:08 AM
Well i hardly ever have occassion to say this - but I like the look of your Harley! Post up some pics of that one as well when you finish up the changes you want to make. Cheers,
Mark
Title: Re: K100 cafe fighter
Post by: The Mighty Gryphon on December 31, 2016, 10:56:25 AM
+1 on the Hardley.  The minimal, naked Sportster is one of my favorite bikes.  Had neighbors when I lived in El Paso who would have built one for me back in the 70's, but stupid me, I wanted an RD350.

Have had several chances to get some really nice examples since then, but never could pull the trigger.  Usually because they were a couple thousand miles away.
Title: K100 cafe fighter
Post by: Boxermann on January 04, 2017, 05:21:53 AM
Well i hardly ever have occassion to say this - but I like the look of your Harley! Post up some pics of that one as well when you finish up the changes you want to make. Cheers,
Mark


Thanks! Will do. Below are some semi-recent pics. It's been under constant change the last year.




+1 on the Hardley.  The minimal, naked Sportster is one of my favorite bikes.  Had neighbors when I lived in El Paso who would have built one for me back in the 70's, but stupid me, I wanted an RD350.

Have had several chances to get some really nice examples since then, but never could pull the trigger.  Usually because they were a couple thousand miles away.


Yeah, It is a really nice bike. I will probably get a bigger Harley at some point, but I don't think I ever will sell the sporty.
Title: Re: K100 cafe fighter
Post by: Boxermann on January 04, 2017, 05:27:01 AM
Back to the beemer.


New valve stem seals installed and I'm finally beginning to put the motor back together. I managed to break one of the threaded rods for the camshaft brackets because of a crappy and unreliable torque meter though. Anyone know what grade steel they are? 8.8? I need to make a new one.
Title: Re: K100 cafe fighter
Post by: Boxermann on January 06, 2017, 06:53:09 PM
I replaced the snapped rod with a grade 8.8 one.


Main seal... Forgot to do my homework and installed it flush at first. Took the sump off and took it out and installed it again. Went slow and steady and thought I was far from .5 mm, but no. Ended up at .3 mm. Question is if I should take it apart again an redo it, or if I'm over analyzing?
Title: Re: K100 cafe fighter
Post by: Laitch on January 06, 2017, 07:22:27 PM
Question is if I should take it apart again an redo it, or if I'm over analyzing?
It appears that you're under-analyzing while you install it. :giggles
You know what it takes to install it again. Why not leave it in for scientific purposes and let us know how well it works after a few thousand kilometers? That will both benefit the community and give the slackers some hope.
Title: Re: K100 cafe fighter
Post by: jc55 on January 07, 2017, 09:19:50 AM
Yes, re-do it...these things add up in your mind later on down the road. I don't know Beemer internals or the amount of machine work you've done, but moving a seal on a crank can mean the difference in a leak or not in some instances.
Title: Re: K100 cafe fighter
Post by: Markus77 on January 07, 2017, 10:47:50 AM
I can't imagine there is much difference between the specs you listed in the real world - but then again JC55 makes a good point . . . knowing it's off would be in my mind and bother me. Better to re-do if for no other reason than your own piece of mind:) Thanks for the Harley pics - very cool bike!
Title: Re: K100 cafe fighter
Post by: The Mighty Gryphon on January 07, 2017, 12:28:11 PM
No one really knows why BMW wants the seal installed this way, but IMHO the purpose of the seal offset is to have the actual sealing lip positioned on a fresh point on the clutch hub to avoid any wear caused by the original seal.. 

Since you have already screwed with it once, I would be concerned that screwing with it again will be worse than leaving it 0.008" further in than BMW recommends.

Check the surface of the clutch hub where the seal touches it.  Does it have a groove worn into it?  If not, I would leave the seal alone.  If there is, pull out the seal and put a new one in and be careful to get it positioned properly.
Title: Re: K100 cafe fighter
Post by: Boxermann on January 07, 2017, 05:28:46 PM
Thanks guys!


I think I'll go with Gryphons suggestion. Not because it is that much work to take it apart again, but I don't think I want to screw more with the seal. Clutch hub looks like new, so I don't think the fit will be a problem.
Title: Re: K100 cafe fighter
Post by: mw074 on January 07, 2017, 05:39:54 PM
The factory service bulletin explains the new seal installation how and why.    K Models - Sealing Ring on Output Shaft  (http://hrsbstaff.ednet.ns.ca/bvogel/K100/download/K100-service-bulletins-and%20special-tools/2798%2Epdf)
Title: Re: K100 cafe fighter
Post by: The Mighty Gryphon on January 08, 2017, 12:08:02 AM
That service bulletin is interesting.  So the seal position is to move the lip away from the chamfer at the end of the clutch hub to prevent leakage.  The cause of the leak is an unfavorable stack up of part tolerances.  I see it is dated 10 years after your motorcycle was manufactured.  Sounds to me like the problem was noticed in later model K bikes(K1100's?) probably because of a lot of warranty claims.

So the first question is if the original seal was leaking excessively.  Hard to tell because the o-ring will probably leak before the seal.  I would guess that if the lip of the original seal was on the chamfer the leakage would have resulted in a warranty claim a long time ago. 

The bulletin also mentions that the original seal position was .4mm below the engine case surface.  Assuming the original seal location did not trigger a warranty claim because of leakage I would think that having the new one .3mm proud or .7mm away from the original seal location is enough to avoid any problems. 
Title: Re: K100 cafe fighter
Post by: Boxermann on January 08, 2017, 03:40:23 PM
Thanks. Yes, I came to the same conclusion.

I went down to the garage earlier today to bolt up the sump, and while doing it obsessing about dropping a piece of hardware or the bit down the open exhaust holes, but to lazy to cover them. So... of course I dropped the bit down in one of them, and of course the valve was open since the garage gnome apparently had rotated the camshaft. Yeay..  :swear:

Hopefully it falls out when I flip the engine over.


EDIT: It came out easily with the help of a magnet.  :yippee:
Title: Re: K100 cafe fighter
Post by: Boxermann on January 11, 2017, 03:26:32 AM
Installed timing chain and new front crank seal.

Oil/water pump seal looked far from great.. New seal, impeller etc. going in later this week.
Title: Re: K100 cafe fighter
Post by: Boxermann on January 14, 2017, 05:21:43 AM

Found a cheap grommet kit containing grommets for the coils and injector rail. Had to buy two though, since it only comes with three of the ones for the coils.

http://www.ebay.com/itm/125-Rubber-Grommet-Firewall-Hole-Plug-Set-Electrical-Wire-Gasket-Assortment-Kit-/361288150009 (http://www.ebay.com/itm/125-Rubber-Grommet-Firewall-Hole-Plug-Set-Electrical-Wire-Gasket-Assortment-Kit-/361288150009)


Found out that the swing arm bearings probably has seen better days. One hardly moves, and the other sounds like it's filled with sand. Any tips for extracting them? I'm going to try filling up with grease behind them then stick a rod in the same size of the hole and whack on it and hopefully the pressure pushes them out.

Question are if they can be saved.. I see they are somewhat expensive. Buying a used swing arm online is not really an option because of the costly shipping to Scandinavia. I don't think I'll find one locally.
Title: Re: K100 cafe fighter
Post by: Laitch on January 14, 2017, 09:53:51 AM
I'm going to try filling up with grease behind them then stick a rod in the same size of the hole and whack on it and hopefully the pressure pushes them out.
Question are if they can be saved
That has been done successfully as described in this K100 forum post (http://www.k100-forum.com/t2361-what-s-the-proper-way-to-pack-the-swingarm-bearing#45980), as you might already know. Why would you not replace seized and grinding bearings after having taken an engine down to its component parts? That doesn't seem a good location to compromise quality.
Title: Re: K100 cafe fighter
Post by: Boxermann on January 14, 2017, 11:09:51 AM
That has been done successfully as described in this K100 forum post (http://www.k100-forum.com/t2361-what-s-the-proper-way-to-pack-the-swingarm-bearing#45980), as you might already know. Why would you not replace seized and grinding bearings after having taken an engine down to its component parts? That doesn't seem a good location to compromise quality.


Thanks for the link. Yes, most parts of me had already come to that conclusion when I wrote the last post, but sometimes it takes a little more time to convince the part that's in charge of the money...
Title: Re: K100 cafe fighter
Post by: Boxermann on January 16, 2017, 06:45:32 AM
Grease trick worked like a charm. I used a 1/2" extension bar wrapped with a little electric tape and it popped right out. Ordered new bearings.


Also ordered a BEP 3.0, Motogadget Pro and Breakout box B, aero cas cap kit, BT45 front tire, RS belly pan, Shorai Lithium-Iron battery and a whole lot of other things. Going to the post office will be like christmas every day the next couple of weeks.  :clap:

Serviced rear master cylinder. I don't think it was that long since its been done before, but I like that new part smell. Also started servicing the calipers, but need to wait for parts.
Title: Re: K100 cafe fighter
Post by: Laitch on January 16, 2017, 10:33:54 AM
. . .  I like that new part smell.
That's what BMW depends upon. It's good for the economy, too. :giggles
Title: Re: K100 cafe fighter
Post by: nods on January 17, 2017, 06:36:26 AM
Grease trick worked like a charm. I used a 1/2" extension bar wrapped with a little electric tape and it popped right out. Ordered new bearings.


Also ordered a BEP 3.0, Motogadget Pro and Breakout box B, aero cas cap kit, BT45 front tire, RS belly pan, Shorai Lithium-Iron battery and a whole lot of other things. Going to the post office will be like christmas every day the next couple of weeks.  :clap:

Serviced rear master cylinder. I don't think it was that long since its been done before, but I like that new part smell. Also started servicing the calipers, but need to wait for parts.


Are you going to wire in a Motogadget m-Unit as well as the Motoscope Pro?
Title: Re: K100 cafe fighter
Post by: Boxermann on January 17, 2017, 06:57:57 AM
That's what BMW depends upon. It's good for the economy, too. :giggles


Yeah ... except for my personal economy  :dunno2:


Are you going to wire in a Motogadget m-Unit as well as the Motoscope Pro?


I'm considering it, but haven't decided yet. Can't really see the big upgrade except for it being sexy..? (which of course is as good a reason as any).

I'm planning to use a K9 alarm as ignition and alarm, so I won't be needing that functionality. And I'm going to slim down and relocate the stock relay box to over the engine where the stock air box was so it will be out of sight anyway.


EDIT: I read up a little more on the m.unit and the part of me that's in charge of the money is already beginning to soften to the idea...
Title: Re: K100 cafe fighter
Post by: Boxermann on January 17, 2017, 02:41:54 PM
Rear shock: my initial plan was to use a 13.25" Harley shock that I have a pair of in good shape (I'm also lowering the bike 1-2 inches in the front), but now I'm starting to think maybe I should buy a new 14" one. Maybe Progressive 412? RAM? YSS? Hagon? Any suggestions? (preferably below $300).
Title: Re: K100 cafe fighter
Post by: duckytran on January 17, 2017, 03:07:58 PM
Rear shock: my initial plan was to use a 13.25" Harley shock that I have a pair of in good shape (I'm also lowering the bike 1-2 inches in the front), but now I'm starting to think maybe I should buy a new 14" one. Maybe Progressive 412? YSS? Hagon? Any suggestions? (preferably below $300).


I was using Progressive 412 and it perform just fine. You can also find YSS shock for under $300. BSK SpeedWorks has RAM shock for $279 pounds and Hagon for $299 pounds. Not a whole lot of options for <$300. I think these are all pretty comparable in performance. It kinda comes down to aesthetics.


http://www.bskspeedworks.co.uk/ram-rear-shocks.html (http://www.bskspeedworks.co.uk/ram-rear-shocks.html)
http://www.bskspeedworks.co.uk/hagon-rear-shocks.html (http://www.bskspeedworks.co.uk/hagon-rear-shocks.html)
Title: Re: K100 cafe fighter
Post by: The Mighty Gryphon on January 17, 2017, 05:26:08 PM
+1 on aesthetics. 

The lower weight of a cafe bike, and the chances it won't get too many kilometers and will mostly be used in town makes me think almost anything will work back there.  I would go with whatever looks the coolest and fits in the budget.
Title: Re: K100 cafe fighter
Post by: Boxermann on January 19, 2017, 05:18:19 PM
Thanks ducky and Gryphon! Good points.

Inspired by Martin I put a grease zerk on the clutch arm.

Also trying to decide if I should replace the water pump shaft or not... Opinions please?
Title: Re: K100 cafe fighter
Post by: Laitch on January 19, 2017, 06:37:28 PM
Also trying to decide if I should replace the water pump shaft or not... Opinions please?
If you are feeling lucky, you could try smoothing the surface with cyanoacrylate; otherwise, replace it.
Title: Re: K100 cafe fighter
Post by: The Mighty Gryphon on January 19, 2017, 07:39:20 PM
Even my bad eyes can see the wear on that shaft.  If it was my bike and I was doing as much work as you, I'd replace it.
Title: Re: K100 cafe fighter
Post by: Filmcamera on January 19, 2017, 07:57:11 PM
Replace it - the rest is looking immaculate, why would you put that back in?
Title: Re: K100 cafe fighter
Post by: Laitch on January 19, 2017, 07:58:47 PM
Replace it - the rest is looking immaculate, why would you put that back in?
It would be like a time capsule, or time bomb—take your pick.
Title: Re: K100 cafe fighter
Post by: Mike Flores on January 19, 2017, 08:13:12 PM
That water pump shaft definitely needs to be replaced.
Title: Re: K100 cafe fighter
Post by: Boxermann on January 21, 2017, 12:33:13 PM
Thanks for the input. Will replace it.

Installed new clutch boot, removed the eyes from the tank and tried on my sexy new gas cap from flatracer.com. It will probably be the only thing not black on the bike when I'm finished.
Title: Re: K100 Cafe Fighter
Post by: Boxermann on January 28, 2017, 04:33:57 PM

Still waiting for a couple of crucial parts to arrive before I can assemble the rest of the engine and driveline and begin working on the frame.


I got my Shorai lithium-iron battery a couple of days ago, and I must say I'm impressed! Tried it in my 1250cc Harley and it fired up easily. Half the size and 1/10th (!) of the weight of the gelbattery that came with the bike, still it delivers more CCA and should be able to deliver a lot more Ah than a lead-based battery with the same number Ah (because of higher usable capacity).


I've read that lithium batteries require to be warmed up (f.ex. by turning on the lights for a couple of minutes) before being able to provide full cranking power when its cold so I'm thinking of placing the heating elements from a set of grip warmers on the battery and connect them to a thermostat that kicks in below 10 °C (50 °F) when the ignition is on. Warming from the outside and the "inside" at the same time should speed up the process. I thinks. Thoughts?


Title: Re: K100 Cafe Fighter
Post by: jc55 on January 28, 2017, 06:42:02 PM
Cool, can I trouble you for the dimensions of that new battery? My old one was 25Ah, and your new one is 14Ah. I'm curious on how it'll work out.
Title: Re: K100 Cafe Fighter
Post by: jc55 on January 28, 2017, 06:42:26 PM
Cool, can I trouble you for the dimensions of that new battery? My old one was 25Ah, and your new one is 14Ah. I'm curious on how it'll work out.
Title: K100 Cafe Fighter
Post by: Boxermann on January 28, 2017, 07:57:42 PM
Cool, can I trouble you for the dimensions of that new battery? My old one was 25Ah, and your new one is 14Ah. I'm curious on how it'll work out.

Length 4.45" Width 2.28" Height 3.50". Weight 1.46 lbs/0.66 kg.
http://shoraipower.com/lfx14l2-bs12-p78 (http://shoraipower.com/lfx14l2-bs12-p78)

As I have understood it you can't really compare the Ah rating of a lithium-based battery with a lead-based. A lithium battery have a larger usable capacity; it retains the same Ah rating in a larger spectrum of the battery's charge. Meaning it provides 13+ volts until it is flat more or less, while a lead battery can't provide enough volts to crank after it has passed 50% discharge or so. And a lithium also recharges a lot faster.

My guess (based on limited knowledge though) is that a 14 (PbEq) Ah lithium is more than enough for a K. If you don't have a lot of power draining accessories It's just needed to crank it up anyways. The alternator takes care of the rest.

(https://www.victronenergy.com/blog/wp-content/uploads/2015/02/Usable-energy.png)
Title: Re: K100 Cafe Fighter
Post by: jc55 on January 28, 2017, 08:01:36 PM
Those are good points. And you know, you're right. with a fuel injected bike, it's either going to start right away or it isn't. It's not like cranking away on a quad carb cold blooded bike like my Goldwing's.


Thanks for the dimensions!
Title: Re: K100 Cafe Fighter
Post by: The Mighty Gryphon on January 29, 2017, 02:41:33 AM
Just for a reference, the normal start takes about 1% or less of a 14AH battery's capacity.

At a starter cranking current of 225 amps a fully charged 14AH battery should theoretically be able to crank the engine for about 2 minutes.
Title: K100 CAFE FIGHTER
Post by: Boxermann on February 17, 2017, 11:02:36 AM
New swing arm bearings installed. Destroyed the cups behind the bearings when I hammered out the old bearings so I cut the bottom out of a pair of empty brake fluid bottles and made new ones.

Gear sensor plastidipped and reinstalled with Allen screws.

Also fabricated mounting brackets for the rear sets out of 10mm aluminum. Will be painted black later.
Title: Re: K100 CAFE FIGHTER
Post by: jc55 on February 17, 2017, 11:04:22 AM
Nice brackets! Good job!
Title: Re: K100 CAFE FIGHTER
Post by: MaraudeRS on February 17, 2017, 11:18:58 AM
Looks great


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Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on February 20, 2017, 03:42:34 AM
Thanks Marauder & jc!


Made a jig inspired by Mike Flores and cut the frame. Made a template out of cardboard for the shock mount placement.


Just need to buy a tube bender now.. Because I really need more tools floating around in my garage. I love order and everything in its place, but I can never seem to make time for it. Instead I spend my time looking for stuff... :dunno  Working on 10+ multiple projects at the same time does not help either.
Title: Re: K100 CAFE FIGHTER
Post by: jc55 on February 20, 2017, 08:34:16 AM
I hear ya. I have a JD squared manual bender but have known people to pack sand in tubing, weld the ends shut(although I would leave a tiny relief hole(especially if you apply any heat), and bend it around Olympic style bench weights placed flat on a layout table. If you were closer, I'd love to help!
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on February 21, 2017, 04:32:42 AM

I hear ya. I have a JD squared manual bender but have known people to pack sand in tubing, weld the ends shut(although I would leave a tiny relief hole(especially if you apply any heat), and bend it around Olympic style bench weights placed flat on a layout table. If you were closer, I'd love to help!


I was thinking of welding the ends and filling with sand, but I couldn't think of anything at home to bend it around... Until I read this. I have a gym room full of olympic weights next to the garage, but never managed to think that far. Thank you! :)

Started to put together the frame last night. I'm reusing the parts where the tank mounts where, lengthened with a couple of inches of tube from the rear part of the frame. I'm putting 25mm tubes inside to strengthen the welds.

Also started to make a linkage for the gear lever. Need to paint it and find some better hardware, and adjust a little so it stays clear of the swing arm adjustment screw.
Title: Re: K100 CAFE FIGHTER
Post by: jc55 on February 21, 2017, 08:19:40 AM
That'll be nice and strong with the inserted tubes you're using. Aside from the weld you can drill a hole on either side of the weld and fill with weld to catch that inner 25mm pipe as an extra measure. I apologize if you knew that, just a tip.


I ordered that battery last night so I thank YOU for that!
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on February 21, 2017, 08:32:12 AM
That'll be nice and strong with the inserted tubes you're using. Aside from the weld you can drill a hole on either side of the weld and fill with weld to catch that inner 25mm pipe as an extra measure. I apologize if you knew that, just a tip.


I ordered that battery last night so I thank YOU for that!


Thanks for the tip!


I hope the battery works fine. Since my bikes are in pieces still I haven't had a chance to try it out properly.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on February 27, 2017, 04:17:44 AM
Rear frame welded up. Just need to add the shock mount.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on March 01, 2017, 02:16:14 PM
Had a plate made to mount the motoscope pro on top of the triple tree. I think I'm going to lower the button down the nut, so it is flush with the top of the nut. The plate will be painted black. I just have to decide if it should be matte or glossy.
Title: Re: K100 CAFE FIGHTER
Post by: jc55 on March 01, 2017, 02:28:42 PM
Whoa! Where'd you get that?
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on March 01, 2017, 02:35:30 PM
I drew it in Adobe Illustrator and ordered it from eMachineShop.com.


EDIT: the speedo is from motogadget.com
Title: Re: K100 CAFE FIGHTER
Post by: jc55 on March 01, 2017, 02:50:18 PM
I want one!!! Without the center cut out. You should sell them on eBay, I want one bad!
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on March 01, 2017, 03:00:14 PM
I want one!!! Without the center cut out. You should sell them on eBay, I want one bad!

PM me your email address and I'll send you a DXF file you can send to a machine shop.
Title: Re: K100 CAFE FIGHTER
Post by: stellarkyle on March 01, 2017, 03:13:57 PM
How much did ordering that from eMachineShop.com set you back?
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on March 01, 2017, 03:15:22 PM
How much did ordering that from eMachineShop.com set you back?

Ca 90 usd + shipping.
Title: Re: K100 CAFE FIGHTER
Post by: Filmcamera on March 01, 2017, 03:28:52 PM
Pretty good price for a one off machined piece of kit that will look super cool and really raise the level of the bike
Title: Re: K100 CAFE FIGHTER
Post by: Elipten on March 01, 2017, 04:39:58 PM
 That is fantastic.  Even an old dog can learn new tricks.


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Title: Re: K100 CAFE FIGHTER
Post by: milq on March 01, 2017, 07:04:28 PM
Pretty good price for a one off machined piece of kit that will look super cool and really raise the level of the bike
Agreed! I'd be hard pressed to make it for that money. If I wanted to make money anyway.
Title: K100 CAFE FIGHTER
Post by: Boxermann on March 02, 2017, 02:19:16 AM
Agreed! I'd be hard pressed to make it for that money. If I wanted to make money anyway.

If you team up with somebody the price drops pretty fast though. If you make two at the same time they cost $50 each, three $35 each and so on.

You can opt to powder coat, anodize, bead blast, etc for a little addition in cost too. I chose 6061 grade aluminium, but they also have steel, brass, titanium... I think even silver or gold if you want.
Title: Re: K100 CAFE FIGHTER
Post by: nods on March 02, 2017, 02:42:53 AM
What a great business idea, well done to them.

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Title: Re: K100 CAFE FIGHTER
Post by: milq on March 02, 2017, 07:20:29 AM
If you team up with somebody the price drops pretty fast though. If you make two at the same time they cost $50 each, three $35 each and so on.

You can opt to powder coat, anodize, bead blast, etc for a little addition in cost too. I chose 6061 grade aluminium, but they also have steel, brass, titanium... I think even silver or gold if you want.
No, I meant as a machinist, I would likely charge more than that for a one time part. But I don't have a water jet, so I would make that part with wire EDM...which gets $100/hr to run.
Title: Re: K100 CAFE FIGHTER
Post by: MaraudeRS on March 02, 2017, 10:21:12 AM
I want one!!! Without the center cut out. You should sell them on eBay, I want one bad!
If you team up with somebody the price drops pretty fast though. If you make two at the same time they cost $50 each, three $35 each and so on.

You can opt to powder coat, anodize, bead blast, etc for a little addition in cost too. I chose 6061 grade aluminium, but they also have steel, brass, titanium... I think even silver or gold if you want.

I'd be in for one too (without the cutout) if you want to order one JC. Lmk


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Title: Re: K100 CAFE FIGHTER
Post by: jc55 on March 03, 2017, 03:56:10 PM
Yes I do. And we need to give Boxermann the chance to make some money on this idea.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on March 03, 2017, 04:37:03 PM
Yes I do. And we need to give Boxermann the chance to make some money on this idea.


No worries. Just glad to help. I only need to know what shape you want it on the top side. Flat like the illustration below to cover the fairing mounts?


Painted mine glossy black, and I couldn't be happier with the result.



Title: Re: K100 CAFE FIGHTER
Post by: jc55 on March 03, 2017, 04:39:38 PM
That's gorgeous. I'd like one notched like yours...not straight.
Title: Re: K100 CAFE FIGHTER
Post by: Mike Flores on March 03, 2017, 10:07:37 PM
Boxermann, you're bike is coming along nicely! That motoscope pro is looking really good too!
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on March 06, 2017, 04:03:44 AM
That's gorgeous. I'd like one notched like yours...not straight.

Thanks! Just PM me your email address and I'll send you the file.


Boxermann, you're bike is coming along nicely! That motoscope pro is looking really good too!

Thanks Mike!



Still working on the frame. Needs a little more sanding, but soon ready for paint. Also started making a mold for a fiberglass cowl.

(... and yes, my garage is a complete mess right now)
Title: Re: K100 CAFE FIGHTER
Post by: MaraudeRS on March 07, 2017, 09:54:34 AM
Yea the notched looks really good. I'll PM you my email address too and JC and I'll will get together on this. Thanks!


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Title: Re: K100 CAFE FIGHTER
Post by: jc55 on March 07, 2017, 09:59:19 AM
It's looking good. You're making quick progress. The frame shooting is coming along.
Title: K100 CAFE FIGHTER
Post by: Boxermann on March 11, 2017, 03:39:31 AM
Made the center hole in the nut a little bigger so I could fit the control button for the motoscope inside rather than on top. Happy with the result so far. I probably should have covered the holes for the forks before painting the trees though.. 

Fabricated a mount so I can place a cone air filter on the AFM. Paint finish didn't turn out great since I managed to drop it on the dusty floor, but I don't care. Its barely visible when mounted anyway.
Title: Re: K100 CAFE FIGHTER
Post by: jc55 on March 11, 2017, 10:19:18 AM
Your pictures are way too big...I can hear the bandwidth sucking through my phone!
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on March 11, 2017, 10:33:02 AM
Your pictures are way too big...I can hear the bandwidth sucking through my phone!


Sorry, I've shrunk them now. I blame Tapatalk. :)
Title: Re: K100 CAFE FIGHTER
Post by: jc55 on March 11, 2017, 10:37:33 AM
Oh that's much better! So, no details on the MAF adaptor fabrication? That looks great. I have an edge roller, but I never tried to put a bead in the end of tubing yet.  :2thumbup:
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on March 11, 2017, 10:57:10 AM
Oh that's much better! So, no details on the MAF adaptor fabrication? That looks great. I have an edge roller, but I never tried to put a bead in the end of tubing yet.  :2thumbup:

Not that much to it. Just made a plate in aluminum (I had it cut out at the same time as the triple tree plate) and attached a piece of 60mm tube on it. I was planning on using brazing sticks, but I couldn't get that to work properly so I ended up using a strong epoxy instead. The aluminum didn't look that great after my failed brazing experiment and the epoxy job was kind of messy, that's why I painted it.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on March 11, 2017, 11:02:51 AM
Found pics.
Title: Re: K100 CAFE FIGHTER
Post by: jc55 on March 11, 2017, 11:28:08 AM
That really looks great, man. I need to expand my horizons and get into more machining. Thanks for sharing!
Title: K100 CAFE FIGHTER
Post by: Boxermann on March 11, 2017, 11:32:01 AM
Thanks.


If you want to use a 3" cone filter you could probably make one of these fit after some lighter modification:
http://www.ebay.com/itm/88-92-Golf-Jetta-1-8-2-0-Mass-Air-Flow-Sensor-Adapter-/140522647308
Title: K100 CAFE FIGHTER
Post by: Boxermann on March 13, 2017, 03:36:40 AM
Making an intake manifold and doing the last touches on the mold for the cowl before glassfiber. I've ordered a custom led strip from Radiantz that is going to go in the groove in the frame.

(https://uploads.tapatalk-cdn.com/20170313/f0dcf6f7758db49bd44319119c5464c0.jpg)

(https://uploads.tapatalk-cdn.com/20170313/98898d4476d7d8c3bbf0e69233c3efff.jpg)
Title: Re: K100 CAFE FIGHTER
Post by: jc55 on March 14, 2017, 09:36:55 AM
Keep the pics coming!
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on March 16, 2017, 06:30:06 AM
Finished the intake manifold. The design was inspired by the Impuls K100 build. I folded the box from a plate of aluminum and glued the tubes (38mm) with epoxy, then metal filler and sanding. Painted flat black.

The weather suddenly allowed for driving this week so I had to scramble together the Harley so I could take it to work. Damn it feels good to sit on a motorcycle again.  :clap:
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on March 22, 2017, 04:43:34 AM
Made a compartment under the tank where I'm planning to put the necessary electrical parts (yes, I know my welds aren't the prettiest..) I couldn't resist ordering the new m.unit blue from motogadget so it will replace the fuses and relays except the starter relay and fuel injection relay. The temp.switch unit and BEP also goes there under the tank.

The m.unit is controlled by Bluetooth; alarm, log, diagnostics and the sexiest part is that I should be able to use the phone as an ignition key. Just walk up to the bike with the phone and it unlocks and lights up automatically. I will put a key switch somewhere just in case though. I was planning to achieve this through a k9 car alarm but this is a lot smoother. 

I got a message from FedEX while writing this telling me that a package from motogadget will be delivered today.   :clap:

Ordered m.switches, m.blaze discs and some other goodies from them at the same time. Also waiting for an YSS shock and a new Shorai battery since I put the one I had in the Harley.


I never seem to be able to remember if its "measure twice, drill once" or the other way around so that's why there are three holes for the fuel tank overflow instead of two...
Title: Re: K100 CAFE FIGHTER
Post by: nods on March 22, 2017, 05:42:56 AM
Very cool! I hadn't heard about the new Bluetooth m-unit. Good things come to those who wait!

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Title: Re: K100 CAFE FIGHTER
Post by: pablooo on March 23, 2017, 06:06:49 PM
I'm glad I hadn't purchased the M-unit yet then! I'll go ahead and get that now and add it with the m-lock I have now.
Title: Re: K100 CAFE FIGHTER
Post by: stomatomoto on March 30, 2017, 04:17:41 PM
I'm so stoked on this thread, this is awesome. Totally inspired to make my own intake manifold now!
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on April 01, 2017, 04:50:29 AM
Very cool! I hadn't heard about the new Bluetooth m-unit. Good things come to those who wait!
I'm glad I hadn't purchased the M-unit yet then! I'll go ahead and get that now and add it with the m-lock I have now.


It's awesome! I just hope they release the mride app for iPhone soon.


I'm so stoked on this thread, this is awesome. Totally inspired to make my own intake manifold now!


Thanks! Go ahead! It was my first try at doing something like this and it was easier than I first thought. Aluminium is easy to work with. And there's always metal filler...




Frame finally primed! 2K epoxy primer/filler. Thinking of doing on one more layer.



Other bits and pieces:
Rear cowl mostly finished, just need a little more sanding. I received the custom Radiantz LED strip for tail/brake/indicators a couple of days ago and it looks great.
Made a bracket to mount the MAF to the frame.
Bought another Shorai battery since I put the first one in the HD.
Bought an YSS shock.
Reinstalled the water/oil pump and added a sensor for oil temperature (from motogadget). I'm actually really looking forward to start the electrical work as soon as I'm finished painting the frame.
Title: Re: K100 CAFE FIGHTER
Post by: nods on April 01, 2017, 04:54:46 AM
Do you mean a water temperature sensor? I think the top sensor is the oil pressure switch and the bottom one is the coolant temp sensor. Love this thread!

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Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on April 01, 2017, 05:12:12 AM
Do you mean a water temperature sensor? I think the top sensor is the oil pressure switch and the bottom one is the coolant temp sensor. Love this thread!


Yeah, you are right... I didn't think that one through properly. It will act as an optional water temp sensor then. I see now the only option for an oil temp sensor is to replace the filling cap?
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on April 22, 2017, 04:05:31 AM
Finally found time to paint and coat the frame so I can start to reassemble.


Installed the Radiantz LED strip and started placing the electrical components. Also found a place for a coolant overflow tank. I'm using a 500ml car oil catch tank.

Title: Re: K100 CAFE FIGHTER
Post by: jc55 on April 22, 2017, 08:33:58 AM
It's looking good man. I like the extra long turn signal idea and the clean electrical layout.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 05, 2017, 10:00:25 AM
It started up nice and clean at least... I'm going to tidy it up now that I've got everything working properly.

(https://uploads.tapatalk-cdn.com/20170505/d4af14441fca965fbaada1ebfc693c8f.jpg)
Title: Re: K100 CAFE FIGHTER
Post by: MaraudeRS on May 05, 2017, 10:34:22 AM
I'm lovin what you're doin. Keep the updates coming!


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Title: K100 CAFE FIGHTER
Post by: Boxermann on May 06, 2017, 03:07:16 PM
Thanks!

Mostly finished with the wiring. The red cable on the outside is to a button acting as a temporary ignition switch. I've ordered a small key switch which I'm going to hide somewhere as a backup for the m.unit Bluetooth keyless go.
(https://uploads.tapatalk-cdn.com/20170506/77071e41b26480c0d3b9103b036a587b.jpg)

40 amp main fuse switch under the tank. Very annoying that I cut the cable just a little too short so it's not straight. Will probably fix that soon. 
(https://uploads.tapatalk-cdn.com/20170506/77754aff36ac1344053a5b0826f8371b.jpg)

Made a little compartment under the triple tree for the m.button and cables for the switches.
(https://uploads.tapatalk-cdn.com/20170506/e4f85b39593843d875aee3a781d564b0.jpg)


(https://uploads.tapatalk-cdn.com/20170506/c5ae015066b5c55d7e99bb5fef7a7e06.jpg)

(https://uploads.tapatalk-cdn.com/20170506/c9e9b6d865afeefb09ad86a64a8a6f07.jpg)
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 08, 2017, 06:01:49 PM
Itsy bitsy tiny backup ignition key switch installed.

(https://uploads.tapatalk-cdn.com/20170508/1a4562b8a8e559a759c19ccf004867a5.jpg)
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 10, 2017, 04:19:27 AM
Wheel bearings came out pretty easily at the expense of a small chisel. New ones are in the freezer and are going in today.
Title: Re: K100 CAFE FIGHTER
Post by: stomatomoto on May 10, 2017, 03:36:44 PM
Probably a dumb question but am nooblet for sure, but why the freezer exactly? Also awesome work man, always excited to get a notification for this thread's updates! How do you plan on wrangling those wires under the seat, bunch of zip ties or something? Another question I had was, is there any risk of oil blowing up into the air filter given the custom design of the intake manifold? I was always cautioned against similar designs on other bikes because of that for some reason, not exactly sure of how that all works though.
Title: Re: K100 CAFE FIGHTER
Post by: Laitch on May 10, 2017, 03:57:51 PM
Probably a dumb question but am nooblet for sure, but why the freezer exactly?
Freezing the bearings reduces their diameter slightly, making easier the installation of them within a tight tolerance. The hub is sometimes heated to expand its diameter slightly. Sometimes they are just driven into place by pounding on them with a wrench socket of appropriate diameter then life moves on.

None of this is as interesting as a cheese-producing crankcase.
Title: Re: K100 CAFE FIGHTER
Post by: thecableguy on May 10, 2017, 04:01:04 PM
None of this is as interesting as a cheese-producing crankcase.
:hehehe
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 10, 2017, 04:40:12 PM
Probably a dumb question but am nooblet for sure, but why the freezer exactly? Also awesome work man, always excited to get a notification for this thread's updates! How do you plan on wrangling those wires under the seat, bunch of zip ties or something? Another question I had was, is there any risk of oil blowing up into the air filter given the custom design of the intake manifold? I was always cautioned against similar designs on other bikes because of that for some reason, not exactly sure of how that all works though.


Laitch beat me to it.  :2thumbup:

I don't think I need to do so much about the wires under the seat except zip-tying them so they don't move. I'm going to make a fiberglass seat pan that will leave about an inch of space under it.

I can't see how oil could get in the air filter except from the crankcase breather? In the original design there is a hose leading the breather in to the plenum. I've just added a separate filter on the breather outlet now, but I'm thinking of replacing it with a hose leading to under the engine and place the filter there, to avoid mess on the top of the engine.


And thanks!
Title: K100 CAFE FIGHTER
Post by: Boxermann on May 10, 2017, 04:50:56 PM
New wheel bearings installed. Went in without a fuss after heating the hub and freezing the bearings.


Also serviced the rear caliper. New seals, pins, pads, bolts, stainless bleeding nipple and cover.
Title: Re: K100 CAFE FIGHTER
Post by: stomatomoto on May 12, 2017, 06:33:39 PM
Gooooot it, thanks, crafty! Except I don't understand the cheese-producing crank case thing either... Is this one of those things where any question x of mine results in answers that actually further raise yx additional questions? Because I'm game if you are. cool shades


Yeah that's what it was, the crank case breather thing that was mentioned to me about oil in the filter and such, but sounds like you've got it planned and sorted already, so I'll definitely be wanting some details on how you did that for if/when I try something like this with my brick!
Title: Re: K100 CAFE FIGHTER
Post by: Markus77 on May 13, 2017, 07:38:52 AM
This project is looking fantastic - looking forward to seeing more pics. Great job:)
Title: Re: K100 CAFE FIGHTER
Post by: Laitch on May 13, 2017, 08:43:15 PM
Gooooot it, thanks, crafty! Except I don't understand the cheese-producing crank case thing either... Is this one of those things where any question x of mine results in answers that actually further raise yx additional questions? !
It was a reference to a different thread where a crankcase was first producing mayonnaise then followed with cheese-product.
Title: K100 CAFE FIGHTER
Post by: Boxermann on May 16, 2017, 04:52:55 AM
Yeah that's what it was, the crank case breather thing that was mentioned to me about oil in the filter and such, but sounds like you've got it planned and sorted already, so I'll definitely be wanting some details on how you did that for if/when I try something like this with my brick!

As far as I know the reason the crankcase is vented in to the inlet manifold is solely because of emissions. The unburnt gasses that bypass the piston rings go out the breather, in to the intake manifold and back in to engine to be burnt. No performance benefit since it makes the mixture slightly less combustible. Also it messes up the inside of the manifold. Not a big deal on these engines, but on e.g. Harleys the crankcase is vented straight in to the airbox thus dirtying the filter pretty effectively.

You can route the breather to a catch tank that collects the gas, or just a filter and let it go out in to the environment. It's not that much anyway.

I own an electric car so my conscious is clean when it comes to pollution anyways  :eek: (I rarely drive it though, I mostly drive my 4.7 and 4.0 liter Jeeps...)





This project is looking fantastic - looking forward to seeing more pics. Great job:)


Thanks Markus!


I fabricated a bracket and made a coolant expansion tank out of a 500 ml oil catch tank. I'm thinking of replacing the hose connector on the outlet/vent side with a PCV-valve and I'm routing the outlet hose down the right side next to the foot pegs. I'm not sure if this will work properly since the tank is lower than the radiator, but then again the stock expansion tank isn't placed much higher. Ideally maybe the tank should be standing vertical but I couldn't make it look nice. Any input?
Title: Re: K100 CAFE FIGHTER
Post by: Filmcamera on May 16, 2017, 06:27:40 AM
Have you considered going with Evans Waterless coolant (https://www.evanscoolant.com/vehicle-types/powersports/) meaning you could get rid of the expansion tank altogether?
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 16, 2017, 06:34:27 AM
Have you considered going with Evans Waterless coolant (https://www.evanscoolant.com/vehicle-types/powersports/) meaning you could get rid of the expansion tank altogether?


Oooh.. Interesting! Did not know there was such a thing. Did some quick reading and it seems to be good stuff. Thanks!


EDIT: Just ordered 5 liters.  :clap:
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 17, 2017, 05:13:51 PM
Exhaust and muffler painted and installed. 4-1 is from cafe4racer.eu. Muffler from eBay. It had a fake carbon look originally so I removed that. Also removed the mount and the riveted strips and welded up the holes.

(https://uploads.tapatalk-cdn.com/20170517/2f3885b63d3cf02fa0ea560a9515f23f.jpg)
Title: Re: K100 CAFE FIGHTER
Post by: nods on May 17, 2017, 05:19:10 PM
Have you considered going with Evans Waterless coolant (https://www.evanscoolant.com/vehicle-types/powersports/) meaning you could get rid of the expansion tank altogether?
Top idea thanks! I've been using Evans for a couple of years in my Triumph and didn't even think about the fact that it doesn't expand 👍

Sent from my SM-G925I using Tapatalk

Title: Re: K100 CAFE FIGHTER
Post by: duckytran on May 17, 2017, 05:20:58 PM
Looking great! Is your battery located inside the seat cowl?

Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 17, 2017, 07:08:49 PM
Looking great! Is your battery located inside the seat cowl?

Thanks!

No, it is here. I have the ECU in the cowl.

(https://uploads.tapatalk-cdn.com/20170517/c17181eabfc1e63dc36505d203744710.jpg)

Title: Re: K100 CAFE FIGHTER
Post by: duckytran on May 17, 2017, 09:53:13 PM
Very cool! I have not seen it done this way.
Title: Re: K100 CAFE FIGHTER
Post by: MaraudeRS on May 17, 2017, 11:39:48 PM
Thanks!

No, it is here. I have the ECU in the cowl.

(https://uploads.tapatalk-cdn.com/20170517/c17181eabfc1e63dc36505d203744710.jpg)
Very nicely done!


Sent from my iPhone using Tapatalk
Title: Re: K100 CAFE FIGHTER
Post by: Arredondo1 on May 19, 2017, 02:15:45 AM
 Awesome build so far! Can you elaborate on how you set up the footpegs? I would like something similar to get rid of the stock brackets.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 19, 2017, 05:21:48 AM
Awesome build so far! Can you elaborate on how you set up the footpegs? I would like something similar to get rid of the stock brackets.


Thanks! There are some pictures here: http://www.motobrick.com/index.php/topic,9158.msg77783.html#msg77783 and here: http://www.motobrick.com/index.php/topic,9158.msg78053.html#msg78053


The pedals and pegs are from an universal rearset: http://www.caferacerwebshop.com/en/universal-alloy-rearset-black-type-1.html



Title: Re: K100 CAFE FIGHTER
Post by: Hank on May 21, 2017, 12:54:46 PM
It's really great to see this build come along. I want to build mine out once I can get together all the parts I need. I saw that you're using the new Motogadget bluetooth unit and the MaruLabs Magic Box 3.0.

Can you tell us how or which other relays you're using? I'm assuming one is for the radiator fan.

Thanks!
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 22, 2017, 05:23:16 AM
It's really great to see this build come along. I want to build mine out once I can get together all the parts I need. I saw that you're using the new Motogadget bluetooth unit and the MaruLabs Magic Box 3.0.

Can you tell us how or which other relays you're using? I'm assuming one is for the radiator fan.

Thanks!

Glad to hear. I hope you start a thread here when you start building.

In addition to the m.unit and BEP I'm using the original starter relay, fuel injection relay and temperature sensing switch unit.

Here is a wiring diagram (thanks to Zachary Ross at k100-forum) which may help. It's for a m.unit v2 but the wiring is mostly the same with the m.unit blue except that at the blue has a separate starter output, an extra AUX in/out and a kill switch input. Also a stand input if you want to use that. It actually has a built in starter relay, but it is only 30A and thus a little weak for a K. I think the stock relay has a 75A rating.


Title: Re: K100 CAFE FIGHTER
Post by: alex-wilson on May 22, 2017, 09:00:46 AM

Oooh.. Interesting! Did not know there was such a thing. Did some quick reading and it seems to be good stuff. Thanks!


EDIT: Just ordered 5 liters.  :clap:


Hi Boxermann


Have you spotted this on Evans site?:
"Evans waterless coolants expand 7% at operating temperature, about the same as traditional antifreeze. If there is no expansion tank on the system, the radiator will purge a small amount upon warmup. Once cooled, this is now the system’s operating level."

On one hand it still seems to expands, but on the other hand it doesnt seem to be a problem :-)

Title: Re: K100 CAFE FIGHTER
Post by: Laitch on May 22, 2017, 09:22:43 AM

Here is a wiring diagram (thanks to Zachary Ross at k100-forum) which may help.
Zach cautioned over in the K100-forum that he had not run the bike with that layout, Boxerman. Have you run yours with your modifications of that layout?
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 22, 2017, 10:07:05 AM



Hi Boxermann


Have you spotted this on Evans site?:
"Evans waterless coolants expand 7% at operating temperature, about the same as traditional antifreeze. If there is no expansion tank on the system, the radiator will purge a small amount upon warmup. Once cooled, this is now the system’s operating level."


On one hand it still seems to expands, but on the other hand it doesnt seem to be a problem :-)


Thanks! I had missed that. Just have to see to it that I don't fill it all the way up the first time then. :)




Zach cautioned over in the K100-forum that he had not run the bike with that layout, Boxerman. Have you run yours with your modifications of that layout?


I haven't started the engine yet, but I think (hope) it will work fine. I crosschecked the wiring for ignition and injection on a diagram for K100 though, since Zach's is for K75.
Title: Re: K100 CAFE FIGHTER
Post by: alex-wilson on May 22, 2017, 10:14:34 AM

Thanks! I had missed that. Just have to see to it that I don't fill it all the way up the first time then. :)



You're welcome!


Also if it helps, i have attached a wiring diagram containing only items nessesary to run the bike (no lights or switches).
I did this because i am also planning on using the m-Unit, and found it gave me an overview of what original wires not to cut :-)
Title: Re: K100 CAFE FIGHTER
Post by: Hank on May 22, 2017, 03:12:24 PM
Thanks for sharing Boxermann!

The electrical diagram is really helpful.

I will definitely start a thread once I get started. Currently have some parts on order and deciding on if I want to rebuild the shock I currently have, or just to buy a new one from RAM engineering. I live in California, and RAM is in England, so it'll take a while.

The current shock is an adjustable Koni shock that has the paint chipping from the spring and the foam bumper that's at the bottom is just about crumbled away. It seems to work fine, it's just not pretty with rust an corrosion around the shock.
Title: Re: K100 CAFE FIGHTER
Post by: MaraudeRS on May 22, 2017, 06:28:52 PM
Thanks for sharing Boxermann!

The electrical diagram is really helpful.

I will definitely start a thread once I get started. Currently have some parts on order and deciding on if I want to rebuild the shock I currently have, or just to buy a new one from RAM engineering. I live in California, and RAM is in England, so it'll take a while.

The current shock is an adjustable Koni shock that has the paint chipping from the spring and the foam bumper that's at the bottom is just about crumbled away. It seems to work fine, it's just not pretty with rust an corrosion around the shock.

I purchased a Ram shock and it didn't take that long to arrive (I'm also in CA).


Sent from my iPhone using Tapatalk
Title: Re: K100 CAFE FIGHTER
Post by: bocutter Ed on May 22, 2017, 08:55:34 PM
I live in California, and RAM is in England, so it'll take a while.
It took a week to Toronto ...
Title: Re: K100 CAFE FIGHTER
Post by: Hank on May 24, 2017, 10:46:47 AM
Great to hear about the shipping from RAM

So I want to get the MaruLabs BEP 3.0 magic box to make the stock speedo sensor work, but Cafe4Racer.eu is sold out and the MaruLabs website hasn't replied to my email request to order.

Does anyone know where else to order them?

@Boxermann, did you do the mod of flipping the fuel level sensor to get the signal right to work with the motogadget instrument cluster?

if you did, are there any recommendations or a bit of wisdom you can share in-case something goes wrong to fix it?
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 24, 2017, 02:45:08 PM

Also if it helps, i have attached a wiring diagram containing only items nessesary to run the bike (no lights or switches).
I did this because i am also planning on using the m-Unit, and found it gave me an overview of what original wires not to cut :-)

Thanks! Could come in handy if I need to re-check the wiring.


So I want to get the MaruLabs BEP 3.0 magic box to make the stock speedo sensor work, but Cafe4Racer.eu is sold out and the MaruLabs website hasn't replied to my email request to order.

Does anyone know where else to order them?

@Boxermann, did you do the mod of flipping the fuel level sensor to get the signal right to work with the motogadget instrument cluster?

if you did, are there any recommendations or a bit of wisdom you can share in-case something goes wrong to fix it?

Just keep mailing Marulabs, they'll answer eventually. I had to send a couple of emails before I got any response.

I just found out I don't really need the BEP though, since the combination m.unit and motoscope pro with a Breakoutbox takes care of everything.

For the fuel I just had to connect the yellow wire from the tank to the fuel input on the Breakoutbox then go the settings in the motoscope and set where the floater is when it's full and where it is when it's empty. Worked perfectly.

I thought I needed the BEP for the neutral indicator, but I could not make it work with the motoscope. At first I thought maybe I had done something wrong, but then five minutes ago I tried connecting the blue/yellow wire from the gear position switch straight to the neutral input on the Breakoutbox and, hey presto, it worked.
Title: Re: K100 CAFE FIGHTER
Post by: Hank on May 26, 2017, 03:34:29 PM
 :clap:


That's great you got the fuel gauge to work without taking the sensor unit out!


What about the speedometer? are you able to use the stock sensor on the rear drive with the motoscope pro?
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 29, 2017, 05:50:35 AM


What about the speedometer? are you able to use the stock sensor on the rear drive with the motoscope pro?


I haven't driven the bike yet so I don't know, but I have no doubt it'll work just fine. Motogadget knows their stuff.


Finally got to painting. Jet black with satin gloss clear coat. Will wet sand and buff the clear coat later this week.

I did not like the gap where the tank meets the seat so as you might see I have modified the shape slightly with fiberglass filler.
Title: K100 CAFE FIGHTER
Post by: Boxermann on June 03, 2017, 05:23:42 AM
Getting there... I'm not satisfied with the finish on the tank and cowl though, so I'm going to paint it again. Wasn't going to do it until some time later at first, but then the bike fell of the lift.. nothing badly damaged, but the tank got some ugly scratches.

(https://uploads.tapatalk-cdn.com/20170603/50e09f5da9cadeaf8b365f36fcf52efe.jpg)

New custom brake lines from Hel. Also installed a hydraulic brake switch banjo bolt in the rear. Just need to fix the wiring.

(https://uploads.tapatalk-cdn.com/20170603/33b5b1901c192f523c9f8c5af8334928.jpg)(https://uploads.tapatalk-cdn.com/20170603/7a99a1f854a4f2eaf7758ee3e1bfd847.jpg)
Title: Re: K100 CAFE FIGHTER
Post by: Hank on June 05, 2017, 06:41:17 PM
Did you powdercoat your crank case and valve cover?


Would anyone or should anyone powder coat be put on the gas tank to make the paint more durable?




Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on June 09, 2017, 01:18:51 PM
Did you powdercoat your crank case and valve cover?

Would anyone or should anyone powder coat be put on the gas tank to make the paint more durable?


I painted them with Hammerite at first. Then added a layer of Colormatic 2K clear coat recently. I wish I had clear coated the entire engine though, since Hammerite sucks. It chips if you look at it angrily while holding a something sharp... And can't handle gasoline. I spilled some gasoline today and now I have to repaint the entire upper part of the engine with a brush (since I don't want to disassemble everything again). Crap.

Powder coating the tank.. I don't know?


Started the bike today and it ran great. Checked the ignition timing and it seems like I got more or less right straight away. I need to sync the TBs though.

It sounded awesome too I think. I'll post a video soon. If the weather permits I'm going to take it for a test ride during the weekend.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on June 09, 2017, 01:22:22 PM
(https://uploads.tapatalk-cdn.com/20170609/80f381b7789ccc56871399192ae698d9.jpg)(https://uploads.tapatalk-cdn.com/20170609/087aac601dbb8c940be99ccabfaac671.jpg)(https://uploads.tapatalk-cdn.com/20170609/fab7a1a1d673b193884e5a97a5722970.jpg)(https://uploads.tapatalk-cdn.com/20170609/311ecd97da2bea450bcd7b9b2a26736e.jpg)(https://uploads.tapatalk-cdn.com/20170609/c28f4c71f1137e297117f562a45ffad2.jpg)
Title: Re: K100 CAFE FIGHTER
Post by: Hank on June 09, 2017, 04:26:54 PM
Great to see an update, sorry to hear about the paint. Maybe you can try airbrushing the paint where it's damaged for a smooth finish?


Do you mind sharing the model of the ignition key unit that you fit into the frame? Having it small and hidden is great!I'm thinking it's a universal 2-position switch?


Looking forward to seeing all the progress

Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on June 14, 2017, 08:16:08 AM
Great to see an update, sorry to hear about the paint. Maybe you can try airbrushing the paint where it's damaged for a smooth finish?

Do you mind sharing the model of the ignition key unit that you fit into the frame? Having it small and hidden is great!I'm thinking it's a universal 2-position switch?

Looking forward to seeing all the progress


It's just under the throttle bodies, so I'm just going to cover things up, spray it with etching primer, then brush on caliper paint and finish of with 2k clear coat.

This key switch: http://www.ebay.com/itm/282406644853 (http://www.ebay.com/itm/282406644853)

Not great quality, but it's ok for me since I'm just using it as a backup.


Finally got to take it for a test ride the other day and it was way over my expectations. Engine and gearbox was smooth as silk and handling and brakes were great.

To do before I can call it "finished" (for now):
Also I'm planning to use a solenoid connected to a thermostat switch to pull the choke (or rather 'idle control') lever under a set engine temperature. I'm using a universal trunk release solenoid that pulls 15mm, which should be enough to pull it halfway. I don't see the need to be able to pull it all the way, since I'm not planning to use this bike in cold weather.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on June 14, 2017, 08:18:48 AM
double post...
Title: Re: K100 CAFE FIGHTER
Post by: Laitch on June 14, 2017, 01:55:53 PM
Also I'm planning to use a solenoid connected to a thermostat switch to pull the choke (or rather 'idle control') lever under a set engine temperature. I'm using a universal trunk release solenoid that pulls 15mm, which should be enough to pull it halfway. I don't see the need to be able to pull it all the way . . .
Consider riding the bike for a while before you expend time and energy in that direction. The temperature was 8ºC at my place today. I placed the choke (idle control) at first position then shut it off after I shifted into third. I rode in third for one kilometer and the bike was ready to go. I only use it on cool morning first startups and don't need to use it again the rest of the day.  I might use the control at full setting when the temperature is ≤30ºF but I'll shut it off using the same routine.

Your design might eliminate memory problems effecting performance, i.e., leaving the choke on for miles, but so far, my memory works for the ten seconds or so that this process takes, if I recall correctly. :giggles
Title: Re: K100 CAFE FIGHTER
Post by: jonas_105 on June 16, 2017, 04:47:01 AM
Was it easy to fit the 3spoke wheels?
arent they wider than the originals?


Great build btw!!  :2thumbup:
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on June 17, 2017, 03:34:38 AM
Consider riding the bike for a while before you expend time and energy in that direction. The temperature was 8ºC at my place today. I placed the choke (idle control) at first position then shut it off after I shifted into third. I rode in third for one kilometer and the bike was ready to go. I only use it on cool morning first startups and don't need to use it again the rest of the day.  I might use the control at full setting when the temperature is ≤30ºF but I'll shut it off using the same routine.

Your design might eliminate memory problems effecting performance, i.e., leaving the choke on for miles, but so far, my memory works for the ten seconds or so that this process takes, if I recall correctly. :giggles


Yeah, you might be right. Thanks for the advice. :2thumbup:




Was it easy to fit the 3spoke wheels?
arent they wider than the originals?


Great build btw!!  :2thumbup:


Thanks!


Yeah, the 3-spoke (K1100) are wider. I don't have a center stand and had to adjust the side stand a little so it doesn't touch the tire when it's up. Of course it also puts the center line a couple of centimeters to the left.
Title: Re: K100 CAFE FIGHTER
Post by: stomatomoto on June 17, 2017, 12:42:23 PM
MOAR PICS!
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on June 19, 2017, 09:01:30 AM
Painting done. Quite happy with the result. Black (RAL 9005, Jet black) and three coats of matte clear coat. The belly ban was already black so I just wet sanded the clear coat with 1200 grit and laid on two coats of matte clear.


Also made a bracket for the MT headlight.



Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on June 19, 2017, 09:25:25 AM
Rear view with a 160 tire.


After the test ride I quickly saw the need for a rear fender to prevent the engine filling up with gravel and dirt, so I cut and reshaped the old one.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on June 20, 2017, 03:52:38 AM
My first attempt at making a seat. I'm not 100% satisfied but it'll do for now after I've fixed some details.


I used soundproofing foam as a base, and glued 12mm foam to the back of the skai / faux leather.
Title: K100 CAFE FIGHTER
Post by: Boxermann on June 20, 2017, 05:35:01 PM
Almost there now...

(https://uploads.tapatalk-cdn.com/20170621/7a7c8ce4d3fdc70f545b5b198ba47cfa.jpg)

(https://uploads.tapatalk-cdn.com/20170621/521c0ee11d4708c6af93aa1eb32a8eae.jpg)

(https://uploads.tapatalk-cdn.com/20170621/4317825b8f51a96d4aa5d37288f366f2.jpg)
Title: Re: K100 CAFE FIGHTER
Post by: duckytran on June 20, 2017, 05:43:11 PM
Nicely done! I like the murdered out look.  :2thumbup:
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on June 22, 2017, 03:56:23 AM
Nicely done! I like the murdered out look.  :2thumbup:


Thanks!


Title: Re: K100 CAFE FIGHTER
Post by: nods on June 22, 2017, 04:31:45 AM
Yeah that's very cool mate 👍

Sent from my SM-G925I using Tapatalk

Title: Re: K100 CAFE FIGHTER
Post by: Laitch on June 22, 2017, 06:03:55 AM
How are the manifold tubes attached to the throttle bodies? If it is by screw clamps, the screws seem well-hidden. How is the manifold/air sensor/air cleaner assembly anchored? The durability of the manifold's epoxied tube joints will interest others here.

It's a good-looking machine. The paint job and your design have merged the intersecting angles nicely. Mounting the tragkorb on it containing your picnic lunch will be a challenge. :giggles
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on June 22, 2017, 06:26:52 AM
How are the manifold tubes attached to the throttle bodies? If it is by screw clamps, the screws seem well-hidden. How is the manifold/air sensor/air cleaner assembly anchored? The durability of the manifold's epoxied tube joints will interest others here.

It's a good-looking machine. The paint job and your design have merged the intersecting angles nicely. Mounting the tragkorb on it containing your picnic lunch will be a challenge. :giggles


Thanks! I'm using OEM one-time clamps. I couldn't find any screw clamps thin enough. MAF is attached to the frame - I think I've posted a picture of the bracket here in the thread somewhere. I couldn't find a hose with the right angle to connect the MAF and the manifold, so I made one out of tape... Multiple small pieces and then covered in glue.

Time will tell about the epoxy.. So far so good at least.

Regarding the picnic lunch.. I'm thinking of making a bag that fits in the hole under the seat for that purpose.  :lets-eat:


Yeah that's very cool mate 👍


Thanks!
Title: Re: K100 CAFE FIGHTER
Post by: duckytran on June 22, 2017, 10:36:30 AM
I'd love to hear how mean she sounds! :mbird
Title: Re: K100 CAFE FIGHTER
Post by: cafek1 on July 25, 2017, 10:37:28 PM
You are a legend for getting all this to work!



Now, I'm interested - you said you didn't need the BEP to get the speed sensor output "right" for the motoscope - but instead you went direct from the OEM sensor to the scope. How did that work out?
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on July 26, 2017, 03:47:16 AM
You are a legend for getting all this to work!



Now, I'm interested - you said you didn't need the BEP to get the speed sensor output "right" for the motoscope - but instead you went direct from the OEM sensor to the scope. How did that work out?


Thanks!


I couldn't make it work. Apparently the OEM signal is to weak for the motoscope. I could not make it work properly with the BEP either as the signal was too uneven, so I ended up using the magnet sensor that came with the motoscope pro. I hid it under the rear brake caliper and glued the magnet on the rotor.
Title: Re: K100 CAFE FIGHTER
Post by: cafek1 on July 26, 2017, 04:27:52 AM
Oh that's a shame. So did you end up using the BEP at all? (Hall sensor --> tacho?)
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on July 26, 2017, 04:56:49 AM
Oh that's a shame. So did you end up using the BEP at all? (Hall sensor --> tacho?)


Nope, no use for it at all.

I got the tacho-signal from the ignition coil if I remember correctly.
Title: Re: K100 CAFE FIGHTER
Post by: gast on July 26, 2017, 05:13:15 AM
Very good looking! Where are you planning to place the number plate?
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on July 26, 2017, 05:48:55 AM
Very good looking! Where are you planning to place the number plate?

Thanks!

I put it here:
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on August 01, 2017, 06:42:01 AM
The durability of the manifold's epoxied tube joints will interest others here.


1000 km now and holding up just fine.
Title: Re: K100 CAFE FIGHTER
Post by: Laitch on August 01, 2017, 09:46:54 AM
1000 km now and holding up just fine.
Thanks for the update.
Title: Re: K100 CAFE FIGHTER
Post by: Bluesmoke69 on August 13, 2017, 12:12:09 AM
Looks great!
Title: Re: K100 CAFE FIGHTER
Post by: jc55 on August 19, 2017, 01:32:02 PM
Looks awesome!!!
Title: Re: K100 CAFE FIGHTER
Post by: Markus77 on August 21, 2017, 11:35:45 AM
Congratulations! The bike looks amazing:)
Title: Re: K100 CAFE FIGHTER
Post by: uhoh7 on August 26, 2017, 01:41:32 AM
What an inspiration!


Here is what I want to know: wet weight?
Title: Re: K100 CAFE FIGHTER
Post by: KRider on August 26, 2017, 06:15:08 AM
Bike looks really nice!! Done a great job.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on September 21, 2017, 04:49:35 AM
Thanks for the update.

2500 now and still fine.


Looks great!

Looks awesome!!!

Congratulations! The bike looks amazing:)

What an inspiration!

Bike looks really nice!! Done a great job.

Thanks guys!




Here is what I want to know: wet weight?

Haven't weighed it, but I would guess around 230 kg?
Title: K100 CAFE FIGHTER
Post by: Boxermann on October 17, 2017, 04:51:19 AM
Hoping for one or two more K rides before winter storage.

(https://uploads.tapatalk-cdn.com/20171017/fd76bd8cc72a1d45a08c5e6eef055821.jpg)
(https://uploads.tapatalk-cdn.com/20171017/82905ac05a03ba06d852ac6940510305.jpg)(https://uploads.tapatalk-cdn.com/20171017/30d99c4fe549827b9bd2ae8f6a247f93.jpg)(https://uploads.tapatalk-cdn.com/20171017/044f3fefc6f6832c972750a27b137c33.jpg)
Title: Re: K100 CAFE FIGHTER
Post by: Laitch on October 17, 2017, 06:11:07 AM
How did you resolve the starting speed control (choke) placement. Did you fabricate an automatic device, relocate the original control, or do you simply manipulate the throttle during warmup?
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on October 17, 2017, 06:24:28 AM
How did you resolve the starting speed control (choke) placement. Did you fabricate an automatic device, relocate the original control, or do you simply manipulate the throttle during warmup?


I didn't bother with it haven't felt the need to do something about it either. I have a slightly elevated idle though - around 1050 rpm - because of some adjustment issue with the custom throttle that I haven't bothered to address.
Title: Re: K100 CAFE FIGHTER
Post by: Laitch on October 17, 2017, 07:27:48 AM

I didn't bother with it haven't felt the need to do something about it either. I have a slightly elevated idle though - around 1050 rpm - because of some adjustment issue with the custom throttle that I haven't bothered to address.
Good attitude! Ride on!
Title: Re: K100 CAFE FIGHTER
Post by: boostd4 on October 17, 2017, 10:59:11 AM
Do your mirrors clear the gas tank at full lock?  I couldn't get mine to not hit the tank when mounted under the grips and had to go over, but my clip ons aren't as low as yours.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on October 17, 2017, 11:04:35 AM
Do your mirrors clear the gas tank at full lock?  I couldn't get mine to not hit the tank when mounted under the grips and had to go over, but my clip ons aren't as low as yours.

No problem.

(https://uploads.tapatalk-cdn.com/20171017/c8d5accfe3315011503625c8b0a63a86.jpg)(https://uploads.tapatalk-cdn.com/20171017/abadcce1ac19cbabab463de30d7ef2f2.jpg)

Title: Re: K100 CAFE FIGHTER
Post by: boostd4 on October 17, 2017, 11:33:45 AM
I have the same headlight.. love it and found this:

https://www.retrofitlab.com/en/motor-1/yamaha-mt03-mh1.html

Not too bad for a full bolt-in Xenon projector/HID upgrade!  Will be next season for me... I have a white/black themed bike and this eliminates a bunch of the chrome in the back housing of the headlamp - might fit your build too.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on October 17, 2017, 01:30:48 PM
I have the same headlight.. love it and found this:

https://www.retrofitlab.com/en/motor-1/yamaha-mt03-mh1.html (https://www.retrofitlab.com/en/motor-1/yamaha-mt03-mh1.html)

Not too bad for a full bolt-in Xenon projector/HID upgrade!  Will be next season for me... I have a white/black themed bike and this eliminates a bunch of the chrome in the back housing of the headlamp - might fit your build too.


Oooh. That's awesome. I will definitively consider this for next season.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on January 23, 2018, 04:04:10 AM
Spring can't come soon enough.
Title: Re: K100 CAFE FIGHTER
Post by: stomatomoto on March 01, 2018, 07:19:13 PM
Damn that thing is amazing... This is my benchmark build for this bike. Have you considered doing the paralever conversion to ditch the spline issue? That's big on my list too, but hella costly...
Title: Re: K100 CAFE FIGHTER
Post by: boostd4 on March 01, 2018, 07:32:43 PM
What did you do with the expansion tank?  Waterless coolant?  Was curious how that's converted.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on March 02, 2018, 01:39:25 AM

Damn that thing is amazing... This is my benchmark build for this bike. Have you considered doing the paralever conversion to ditch the spline issue? That's big on my list too, but hella costly...

Thanks! No, I don’t have any plans on rebuilding this one. I’d rather build another. Right now I’m busy with a Harley, but I’m considering building some kind of scrambler out of a K75 next winter.



What did you do with the expansion tank?  Waterless coolant?  Was curious how that's converted.

I plugged the hole at the filling cap, ditched the tank and filled with Evans waterless coolant. Simple as that. Works great.
Title: Re: K100 CAFE FIGHTER
Post by: stomatomoto on March 02, 2018, 05:26:50 AM
Thanks! No, I don’t have any plans on rebuilding this one. I’d rather build another. Right now I’m busy with a Harley, but I’m considering building some kind of scrambler out of a K75 next winter.



I plugged the hole at the filling cap, ditched the tank and filled with Evans waterless coolant. Simple as that. Works great.


Awesome. Just so you know, if you put all of your project materials and steps and such into a detailed guide, I would so pay for an ebook of that if it was comprehensive and all that!
Title: Re: K100 CAFE FIGHTER
Post by: DJEwen on March 02, 2018, 06:25:01 AM
I plugged the hole at the filling cap, ditched the tank and filled with Evans waterless coolant. Simple as that. Works great.

Genius! Glad I saw this post, this is exactly why I  DONATE TO THE UP-KEEP OF THE MOTOBRICK.COM FORUM (http://www.motobrick.com/index.php/topic,10818.0.html) to keep this shared knowledge alive.

I've been researching this topic myself the last few evenings trying to decide on the right bottle size, how/where to mount it and whether to install a spigot or run the hose in the filler with a slotted gromit to the bottom etc etc.

I've just checked out the Evans Waterless coolant, It's a little pricey but I reckon in the long run its the cheaper alternative, shame I've already got my distilled water and coolant on the garage shelf waiting. Did you bother to run the Prep Fluid first or just go straight in with the waterless, Boxerman?

What did you use to plug the hole, just a NPT plug?

Cheers
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on March 02, 2018, 08:27:33 AM
I've been researching this topic myself the last few evenings trying to decide on the right bottle size, how/where to mount it and whether to install a spigot or run the hose in the filler with a slotted gromit to the bottom etc etc.



Yeah, I did that too before finding out about waterless coolants. Bought several canisters, coolant, made a bracket, etc...




Did you bother to run the Prep Fluid first or just go straight in with the waterless, Boxerman?


No, I didn't bother with Prep Pluid. Just flushed it thoroughly and let it dry.



What did you use to plug the hole, just a NPT plug?
A rubber cap held in place with a hose clamp.
Title: Re: K100 CAFE FIGHTER
Post by: boostd4 on March 02, 2018, 08:34:21 AM
Have you been through a hot summer this way?  Stuck in traffic, etc?
Title: Re: K100 CAFE FIGHTER
Post by: DJEwen on March 02, 2018, 09:23:48 AM

Yeah, I did that too before finding out about waterless coolants. Bought several canisters, coolant, made a bracket, etc...





[/size]
No, I didn't bother with Prep Pluid. Just flushed it thoroughly and let it dry.
[/size]
[/size]

[/size]A rubber cap held in place with a hose clamp.

How do you check/are sure of your level now? Did you do many checks and top-ups during the first road tests post build?
It's obviously quite a task to gain access to the fill cap unless you have fuel line quick disconnects for the tank removal.
Title: K100 CAFE FIGHTER
Post by: Boxermann on March 02, 2018, 10:52:05 AM
How do you check/are sure of your level now? Did you do many checks and top-ups during the first road tests post build?
It's obviously quite a task to gain access to the fill cap unless you have fuel line quick disconnects for the tank removal.

I filled about 2.6 liters (2.8 minus ca 7% as it expands when warm). I haven’t checked since and don’t see any reason for it to diminish. It’s a closed system, and I’ve replaced all hoses and gaskets with new ones. And temp is displayed on the speedo, so if I’m losing capacity I would notice it fast.

Waterless coolants isn’t as effective as regular coolants when it comes to cooling, but for a Cafe Racer kind of bike that’s just driven occasionally it won’t make much difference I think. The fan just runs a little more often.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on March 03, 2018, 08:47:21 AM
Have you been through a hot summer this way?  Stuck in traffic, etc?



Yup. Well.. A Scandinavian summer at least.  :eek:
Title: Re: K100 CAFE FIGHTER
Post by: Sebavidaurre on March 08, 2018, 03:01:13 PM
well that beemer looks spiffy. Way to hit the apex in your design... Congrats
Title: Re: K100 cafe fighter
Post by: woodgeek on March 08, 2018, 03:21:51 PM
Bike has apparently been well maintained. I'm replacing clutch plate, voltage regulator, alternator rubbers and a couple of the bearings.
Did you replace the voltage regulator because of its age or did it measure bad?
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on March 08, 2018, 04:37:10 PM
well that beemer looks spiffy. Way to hit the apex in your design... Congrats

Thanks!


Did you replace the voltage regulator because of its age or did it measure bad?

Brushes was worn out and a new regulator cost about the same as replacing the brushes on the old one.

Title: Re: K100 CAFE FIGHTER
Post by: woodgeek on March 08, 2018, 04:40:38 PM
Brushes was worn out and a new regulator cost about the same as replacing the brushes on the old one.
Got it. Thanks! :2thumbup:
Title: Re: K100 CAFE FIGHTER
Post by: oneplustwo on May 03, 2018, 01:07:30 AM
Great build Boxermann!  Really inspirational for a build I'm planning.  A few questions if you don't mind.  I read through the thread a few times so apologies if I missed it somewhere.

1.  How did you make the groove for the rear LED?  I saw your frame weld photos but didn't see how you got the groove in the tubing.
2.  Which bar end indicators did you use?
3.  Where did the MAF bracket mount to?  The frame tube running down the center of the tank?
4.  Did you connect your external relays to the relays of the m.unit?  Or were they triggered separately?
5.  How did you mount your seat to the frame?  Is it just bolted on or were you able to fab a release similar to the stock seat?

Thanks in advance for the insight!  And congrats again on an amazing build!
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 03, 2018, 04:36:19 AM
Great build Boxermann!  Really inspirational for a build I'm planning.  A few questions if you don't mind.  I read through the thread a few times so apologies if I missed it somewhere.

1.  How did you make the groove for the rear LED?  I saw your frame weld photos but didn't see how you got the groove in the tubing.
2.  Which bar end indicators did you use?
3.  Where did the MAF bracket mount to?  The frame tube running down the center of the tank?
4.  Did you connect your external relays to the relays of the m.unit?  Or were they triggered separately?
5.  How did you mount your seat to the frame?  Is it just bolted on or were you able to fab a release similar to the stock seat?

Thanks in advance for the insight!  And congrats again on an amazing build!


Thanks!


1. I used metal filling.
2. Motogadget m.blaze disc.
3. The plate on the frame on the right side. It has two holes in it.
4. Ignition relay and start relay are connected to the m.unit. See attached wiring scheme. It's for a m.unit v1, but it's mostly the same.
5. Velcro.  :2thumbup:



Good luck with your build! Just ask if you have any more questions.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 03, 2018, 04:47:23 AM
.
Title: Re: K100 CAFE FIGHTER
Post by: oneplustwo on May 03, 2018, 08:37:43 PM
Awesome, thanks!  The motogadget stuff is cool, but pricey.  A few pieces from there and I will have already matched how much I paid for the whole bike!


Love to velcro idea, keep it simple.


Where did you relocate your horn?
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 04, 2018, 04:10:06 AM
Awesome, thanks!  The motogadget stuff is cool, but pricey.  A few pieces from there and I will have already matched how much I paid for the whole bike!


Love to velcro idea, keep it simple.


Where did you relocate your horn?


Check out www.elektronikbox.de (http://www.elektronikbox.de) for a cheaper alternative for the m.unit.

The velcro works great. I have a little compartment for tools and papers there. The velcro makes it easy to access.

The horn is behind the MAF. I replaced it with a smaller one.
Title: Re: K100 CAFE FIGHTER
Post by: oneplustwo on May 04, 2018, 06:13:35 PM
Is it the version G box?  http://www.elektronikbox.de/ebox_g_uk.html


Looks like it integrates the m.unit button functionality as well.  No bluetooth though.  Definitely cheaper, but with the bluetooth, I might splurge for the m.unit to get rid of needing the key.  Super trick!


Speaking of controls, is there a rhyme or reason to choosing a different set?  Mine definitely could use replacing.  I'm likely to eliminate the "choke" so no need for that control.  I'd be looking for something simple that would fit with minimal modification.
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 05, 2018, 04:59:42 AM
Is it the version G box?  http://www.elektronikbox.de/ebox_g_uk.html (http://www.elektronikbox.de/ebox_g_uk.html)


Looks like it integrates the m.unit button functionality as well.  No bluetooth though.  Definitely cheaper, but with the bluetooth, I might splurge for the m.unit to get rid of needing the key.  Super trick!


Speaking of controls, is there a rhyme or reason to choosing a different set?  Mine definitely could use replacing.  I'm likely to eliminate the "choke" so no need for that control.  I'd be looking for something simple that would fit with minimal modification.


I haven't looked into the elektronikbox products that much, but probably that one yeah.


One very annoying thing with the m.unit blue is that the bluetooth keyless-go function doesn't work with 4-button configuration I have. You need to have a separate start button. Mine is configured to light+left turn signal for start and it doesn't work. Hopefully they get this sorted out.


I replaced my controls with motogadget m.switches because the I think the OEM ones are ugly and didn't match the rest of my bike. There are knockoffs on eBay if you think the motogadget ones are to pricey.

I'm doing fine without the choke (idle increaser).
Title: Re: K100 CAFE FIGHTER
Post by: oneplustwo on May 05, 2018, 12:04:21 PM
What if you used a three button version on one side?  I assume the extra button could be used as the start button?


What are the buttons for otherwise?  I was thinking something like this...
Left top - horn
Left bottom - signal

Right top - start
Right bottom - signal
Right rear (assuming three button unit) - kill/stop

Also, which throttle/brake/clutch assemblies did you go with?

Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 06, 2018, 02:58:29 PM
What if you used a three button version on one side?  I assume the extra button could be used as the start button?


What are the buttons for otherwise?  I was thinking something like this...
Left top - horn
Left bottom - signal

Right top - start
Right bottom - signal
Right rear (assuming three button unit) - kill/stop

Also, which throttle/brake/clutch assemblies did you go with?


Yeah, but I would rather not spend more money on a 3 button version. I've mailed them and hopefully they'll look into it.


The button setup sounds ok. throttle/brake/clutch assemblies are cheap China eBay finds. For the brake, just make sure the bore size is correct. If my memory serves me right I think it is 13mm for non-ABS and 12mm with ABS for the K's.
Title: Re: K100 CAFE FIGHTER
Post by: oneplustwo on May 07, 2018, 12:48:35 PM
Got it, thanks.

Related to wiring:
1. Did you redo a lot of the wiring harness with the m.unit wiring kit?  Or were you able to disassemble and tap into the existing pretty easily?  I know you used the m.button so that was all fresh.  More curious about the other bits rearward of the handlebars.
2. In retrospect, without needing the BEP 3.0, do you think you could have fit the ECU under the tank as well?

Related to your intake:
1. Was the boxed section you folded from aluminum done for ease of fabrication or to create enough volume to match the stock air box for intake tuning reasons?
2. How did you affix the 38mm tubes to the throttle bodies?  Looks like maybe you used the short stock bits as an interface, but I couldn't see clamps or anything.
3. Are those 38mm elbows off the shelf pieces you can buy?
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on May 08, 2018, 05:29:02 AM
Related to wiring:
1. Did you redo a lot of the wiring harness with the m.unit wiring kit?  Or were you able to disassemble and tap into the existing pretty easily?  I know you used the m.button so that was all fresh.  More curious about the other bits rearward of the handlebars.
2. In retrospect, without needing the BEP 3.0, do you think you could have fit the ECU under the tank as well?


1. I redid all the wiring. Not that hard if you follow the schematics and take your time.
2. No, its too big to fit there.

[/size]

[/size]Related to your intake:
[/size]1. Was the boxed section you folded from aluminum done for ease of fabrication or to create enough volume to match the stock air box for intake tuning reasons?
[/size]2. How did you affix the 38mm tubes to the throttle bodies?  Looks like maybe you used the short stock bits as an interface, but I couldn't see clamps or anything.
[/size]3. Are those 38mm elbows off the shelf pieces you can buy?


1. Both.
2. I cut the bottom of some 40mm rubber table leg caps to use as an interface between the alu tubes and the OEM bushings.
3. eBay. Search for 38mm aluminium elbow.
Title: Re: K100 CAFE FIGHTER
Post by: oneplustwo on May 09, 2018, 08:31:02 PM
Were you able to reuse all the connectors?  Or did you have to buy those?  Or were you able to reuse the connectors and associated wiring as needed?
Title: Re: K100 CAFE FIGHTER
Post by: oneplustwo on June 26, 2018, 12:43:44 AM
Which air filter did you use?  The 3" ones I'm finding are humongous!
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on June 26, 2018, 03:48:21 AM
Were you able to reuse all the connectors?  Or did you have to buy those?  Or were you able to reuse the connectors and associated wiring as needed?

I replaced most of them.


Which air filter did you use?  The 3" ones I'm finding are humongous!

https://www.ebay.com/itm/JR-Race-Car-371-6216-Air-Filter-3-1-2-OD-with-10-Degree-Angle-/312145731830
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on October 26, 2018, 03:40:08 AM
@ Oslo Motor Show 2018
Title: Re: K100 CAFE FIGHTER
Post by: almostordinary on November 10, 2018, 09:17:10 PM
Great thread! Definitely will be coming back here while I undergo my k75 build.

Amazing work!
Title: Re: K100 CAFE FIGHTER
Post by: holmesy on November 11, 2018, 04:25:59 AM
Great work mate. Love seeing the bricks stripped down!
Title: Re: K100 CAFE FIGHTER
Post by: almostordinary on November 18, 2018, 03:58:01 PM
Quick question, what is  that you're using for the Twist Throttle Assembly and what cable did you use to re-run the throttle cable from the stock setup?

Thanks!
Title: Re: K100 CAFE FIGHTER
Post by: Boxermann on November 18, 2018, 04:04:28 PM
Great thread! Definitely will be coming back here while I undergo my k75 build.

Amazing work!
Great work mate. Love seeing the bricks stripped down!

Thanks!


Quick question, what is  that you're using for the Twist Throttle Assembly and what cable did you use to re-run the throttle cable from the stock setup?


It's a universal throttle assembly (eBay) and I modified stock cables to fit the throttle assembly.
Title: K100 CAFE FIGHTER / M-unit Blue & M-Lock / Starter problem
Post by: Jean-Charles31 on January 08, 2019, 03:22:30 PM
Hello everyone,

I just installed the M-unit Blue with the M-lock on my K75.

Everything works fine but I have a problem !  :johnny

My problem has to come from the AUX2 wiring terminal that contains the fan relay or my connections with the injection relay (I removed the relay relay relay) ... My problem is that when I start the bike, the starting relay with the starter engages, but the power is very low ... while the battery is 13.8 Volts. As if the starter did not have full power ...

I have 2 wiring schemes, including that of "Boxermann" for M-unit (the old model) and that of the ignition scheme that I have bad to read because of poor quality ... (See Attachment)

I do not know where the mistake is ... Can you help me?
Do you have a better quality scheme? or an updated schema?

PS : Sorry for the translation, I'm french

Looking forward to reading you soon ...
Title: Re: K100 CAFE FIGHTER / M-unit Blue & M-Lock / Starter problem
Post by: Laitch on January 08, 2019, 05:25:19 PM
but the power is very low ... while the battery is 13.8 Volts. As if the starter did not have full power ...
How many volts are at the starter, Jean-Charles?

The drawings you have supplied are blurred. Do you have drawings with higher resolution?
Title: Re: K100 CAFE FIGHTER / M-unit Blue & M-Lock / Starter problem
Post by: alex-wilson on January 09, 2019, 01:38:11 AM

I have 2 wiring schemes, including that of "Boxermann" for M-unit (the old model) and that of the ignition scheme that I have bad to read because of poor quality ... (See Attachment)

I do not know where the mistake is ... Can you help me?
Do you have a better quality scheme? or an updated schema?


Hi Jean
The first scheme can be found here: https://www.dropbox.com/s/j5ebwkz9jh974g2/Electrical%20-%20K75%20Wiring%20M-unit.jpg?dl=0
​ (https://www.dropbox.com/s/j5ebwkz9jh974g2/Electrical%20-%20K75%20Wiring%20M-unit.jpg?dl=0
​)

The second scheme is one i made, i have yet to test out if it all works, this will be done during the next couple of months.
Here is a link to that scheme: https://www.dropbox.com/s/nc106xipquqosy1/1K100_Early_Wiring_Diagram_only_ignition2.png?dl=0
​ (https://www.dropbox.com/s/nc106xipquqosy1/1K100_Early_Wiring_Diagram_only_ignition2.png?dl=0
​)

As far as i understand, you need to keep the Fuel Injection Relay (this can be replaced with a solid state relay from motogadget) for all the original functions (high temp cut-out and so on) to function correctly.

Regarding the low power, what size cables are you using both positive and negative?

Title: Re: K100 CAFE FIGHTER
Post by: Jean-Charles31 on January 09, 2019, 05:38:41 AM
Thank you Alex for your answer, and thank you for the second scheme in good quality!

Regarding the size (section) of cable and the one provided by motogadget large diameter, for the rest I used the motogadget cable kit. I will test your second plan this weekend, but I do not see where my mistake is ...

To answer "Laitch", I did not look at the multimeter the input value of the start relay. For the drawings, those are the same as "Alex" just loaded on the forum.

It does not explain the low starting power...
Title: Re: K100 CAFE FIGHTER
Post by: alex-wilson on January 09, 2019, 05:49:10 AM
Thank you Alex for your answer, and thank you for the second scheme in good quality!

Regarding the size (section) of cable and the one provided by motogadget large diameter, for the rest I used the motogadget cable kit. I will test your second plan this weekend, but I do not see where my mistake is ...

You are welcome! :)

I would like to hear how you progress this weekend!

Are your lights (headlight and so on) when the starter motor is running?
As far as i remember the original harness turns off the lights and "Load Shed Relay" when the starter is running to give it maximum power.
Title: Re: K100 CAFE FIGHTER
Post by: Jean-Charles31 on January 09, 2019, 06:15:33 AM
Yes the box off the headlights, the speedometer, when I turn on the starter (like the loadshell relay of origin) that's why I do not understand ...

Here is another diagram that I followed too, especially for the "ignition" terminal on the m-unit blue.
Title: Re: K100 CAFE FIGHTER
Post by: alex-wilson on January 09, 2019, 06:46:11 AM
Yes the box off the headlights, the speedometer, when I turn on the starter (like the loadshell relay of origin) that's why I do not understand ...

Here is another diagram that I followed too, especially for the "ignition" terminal on the m-unit blue.

That is also a great diagram!

What battery are you using?
I put a very small lithium battery on mine last season, and I had to leave the headlight on for 1-2min before pressing the start button to let the battery “heat up”, otherwise it was very slow at cranking the engine.
I got so annoyed about this, that I put two identical small lithium batteries on, to double the cranking amps.
Title: Re: K100 CAFE FIGHTER
Post by: Jean-Charles31 on January 09, 2019, 07:04:03 AM
My project K75 was already rolling (see photos), I just wanted to make him last modifications (fork GSXR, M-unit, M-lock, etc.) for the winter.

I have a large capacity lithium battery that starts the bike normally, it is perfect for the K75.
Title: Re: K100 CAFE FIGHTER
Post by: alex-wilson on January 09, 2019, 07:22:35 AM
My project K75 was already rolling (see photos), I just wanted to make him last modifications (fork GSXR, M-unit, M-lock, etc.) for the winter.

I have a large capacity lithium battery that starts the bike normally, it is perfect for the K75.

That's a great looking bike! :D

I can't figure out what the problem could be :/
Are you sure the battery is fully charged?
Are you still using the original starter relay?
 
Title: Re: K100 CAFE FIGHTER
Post by: Jean-Charles31 on January 09, 2019, 07:56:26 AM
Thank you !

Yes Alex, 13.8 Volt lithium battery, boch brand starter relay (stock).

At the time of the wiring I found an error on the diagram, at the relay of the fan between the terminal "Green-Brow & Violet-Purple" I had to reverse the connection to my bike because the plan did not match but that does not come from there.

I wonder if it does not come from the m-lock, because I did not take the original neiman connection, I came directly to connect to the injection relay ... the original Neiman socket remains empty. It's weird!

Is there a need to disconnect elements of the original beams on the Ignition control unit? to connect differently? normally everything stays as originally, it's just to resume existing connections?
Title: Re: K100 CAFE FIGHTER
Post by: Laitch on January 09, 2019, 09:28:49 AM
13.8 Volt lithium battery, boch brand starter relay (stock).
What is the battery output as the starter is engaged?
Title: Re: K100 CAFE FIGHTER
Post by: Jean-Charles31 on January 09, 2019, 09:31:59 AM
I have not looked yet, I will be at the garage by this weekend, I will communicate the values of the multimeter
Title: Re: K100 CAFE FIGHTER
Post by: Soggz on January 10, 2019, 02:08:47 AM
Nice work. Shame you don’t live closer. I would have had that front fairing!
Title: Re: K100 CAFE FIGHTER
Post by: Jean-Charles31 on January 12, 2019, 06:54:30 AM
Hello guys, I finally went to my garage to check ...

When I wanted to take the two connection terminals to the start relay with the multimeter .... White smoke appeared in voualn start! and it allowed me to find my mistake!

Big error of inattention, I had taken again the terminal N ° of the load shedding relay to connect it in GND, which made that the current leaked during the engagement of the motor starter! Holy fear!  yawl

Now the bike starts very well !!!  bmp

Little information, I put the positive meter and power supply of the injector relay on the terminal "Ignition" of the box m-unit. Others in Aux 1 and 2 (relay fan, power supply and green / yellow wire box) front and rear position headlight, etc ...

Thanks to you guys for taking your time to answer me, I will put pictures soon!
Title: Re: K100 CAFE FIGHTER
Post by: Jean-Charles31 on January 12, 2019, 06:58:34 AM
Hello guys, I finally went to my garage to check ...

When I wanted to take the two connection terminals to the start relay with the multimeter .... White smoke appeared trying to start! and it allowed me to find my mistake!  :johnny

Big mistake of inattention, I took the terminal (black wire) of the load shed relay to connect it in GND, which caused that the current leaked when the engagement of the motor starter! and it could not start ... The thread to completely burnt! Holy fear!

So I have to remove the conexion and remake the entire cable that goes from the start to relay start.
Now the bike starts very well !!!  bmp

Little information, I put the positive meter and power supply of the injector relay on the terminal "Ignition" of the box m-unit. Others in Aux 1 and 2 (relay fan, power supply and green / yellow wire box) front and rear position headlight, etc ...

Thanks to you guys for taking your time to answer me, I will put pictures soon!
Title: Re: K100 CAFE FIGHTER
Post by: alex-wilson on January 14, 2019, 02:10:26 AM
Great to hear you found the mistake! :D
Just to be sure - does that mean that there are no mistakes on the scheme i made, or do i have to make some changes? :)
Title: Re: K100 CAFE FIGHTER
Post by: oneplustwo on February 07, 2019, 12:48:34 PM
Boxermann - quick question on the throttle assembly. I have the same one... did you do anything to lube the assembly or otherwise improve upon just screwing the thing together?  I was considering teflon tape between the tube and the bar and somehow greasing where the cable end goes into the housing.