K100 CAFE FIGHTER

[Filmcamera]

Have you considered going with Evans Waterless coolant meaning you could get rid of the expansion tank altogether?

[Boxermann]

Have you considered going with Evans Waterless coolant 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:

[Boxermann]

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.

[nods]

Have you considered going with Evans Waterless coolant 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 👍

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[duckytran]

Looking great! Is your battery located inside the seat cowl?

[Boxermann]

Looking great! Is your battery located inside the seat cowl?

Thanks!

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

[duckytran]

Very cool! I have not seen it done this way.

[MaraudeRS]

Thanks!

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

Very nicely done!


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[Arredondo1]

 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.

[Boxermann]

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

[Hank]

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!

[Boxermann]

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.

[alex-wilson]

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 :-)

[Laitch]

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?

[Boxermann]

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.

[alex-wilson]

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 :-)

[Hank]

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.

[MaraudeRS]

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).


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[bocutter Ed]

I live in California, and RAM is in England, so it'll take a while.

It took a week to Toronto ...

[Hank]

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?

[Boxermann]

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.

[Hank]

 :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?

[Boxermann]

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.

[Boxermann]

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.



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

[Hank]

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?