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TECHNICAL MOTOBRICK WRENCHING In Remembrance of Inge K. => Project Custom Motobricks => Topic started by: Revrdmark on July 26, 2016, 09:40:45 PM

Title: 1987 K100 cafe or something build
Post by: Revrdmark on July 26, 2016, 09:40:45 PM
    So I picked up two late 80's K100's cheap. One had a bad engine but clean title,  the second had a good engine and tranny but a salvage title. (From what I understand the salvage title comes from the bike that was originally an LT was laid down and the luggage and fairings were destroyed so insurance totaled it, but the engine and frame were untouched. So the previous owner bought  some ratty RS fairings for it and rode it a couple more years.

(http://i37.photobucket.com/albums/e66/RevrdMark/For%20Sale/A95A42C6-08CC-4B28-BEBD-8D3D60BFE98E_zpsydxcfbtn.jpg)


(http://i37.photobucket.com/albums/e66/RevrdMark/Projects/46CAA10D-20A9-41B2-A76D-5B512914B956_zps8xxloin4.jpg)


So the first job is to strip the fairings down and get to the bare frame and engine on each bike and do an engine swap.


(BTW all the fairings and luggage are for sale except the gold top case it's already claimed. If you are interested in anything let me know. )

 So the engine swap is not that difficult. Just undo 5 bolts and lift the front wheel forks and frame off the engine and shaft drive. The hardest thing was getting the cables and wires disconnected to pull the frame off the engine.

(http://i37.photobucket.com/albums/e66/RevrdMark/Projects/648AC058-7723-463B-ABA2-84E4629F617E_zpsm3loh1yr.jpg)

(http://i37.photobucket.com/albums/e66/RevrdMark/Projects/1874D537-62F5-41C6-98E3-61E8D8877E0D_zpslbnvypc8.jpg)

    So now that the engine is swapped I need to check my wiring diagram in my manual and see if I can  get rid go that big dash and replace it with a couple dials  (speedo and tach). Also need to decide if I'll do straight drag bar, clubman bars or clip on's  I'll  post more as I progress.
Title: Re: 1987 K100 cafe or something build
Post by: iiXioM on July 27, 2016, 09:50:20 AM
Hey man good luck on your project! Working on these things is fun and easier than anticipated once you get your hands in.

Question about the 'ratty fairings' on the RS. What do you mean about ratty? lol. I'm restoring an 85RT that had no plastics (check my thread) to something, and are interested in the RS fairings. Send me a message when you're free and maybe we can make a deal or something.
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on July 27, 2016, 10:35:36 AM
Hey man good luck on your project! Working on these things is fun and easier than anticipated once you get your hands in.

Question about the 'ratty fairings' on the RS. What do you mean about ratty? lol. I'm restoring an 85RT that had no plastics (check my thread) to something, and are interested in the RS fairings. Send me a message when you're free and maybe we can make a deal or something.

They are actually in very good shape minus one of the holes was split  on the right side bottom where the rubber inside piece attached. (It is a 20 Minute fiberglass repair)  By ratty I mean that they have some rick chips and they have a home made paint job with a blue/black color, no idea if its factory match or not. the windshield has a  blemish as well. It had a pair of black luggage as well, they need some fiberglass repair as well. The second picture at the top is the bike so you can get the general idea. I'll get you some pictures and send you a PM tonight.

Im finding that the systems and engine function more like a car than a motorcycle so i'm having to  just adjust my way of thinking a little to get my head around charging systems and  wiring and fuel injection etc...  I'm not looking forward to   figuring out the wiring for the  instrument cluster replacement. I'll have to do some digging to see if someone as already recorded their work in rewiring  new gauges.
Title: 1987 K100 cafe or something build
Post by: Revrdmark on July 30, 2016, 11:30:17 PM
So I have the engine swapped and all the wires hooked back up and WALLA! It runs!!!

I've been looking at all the threads about switching instrument cluster and it looks like a PITA so I think I have decided to keep the stock cluster and fab a new bracket to lower it a bit and tuck it inside a bullet fairing for a kinda Ducati GT 1000 look. We'll see I might change my mind before next spring.

I'd like to replace the handlebar controls but not sure if that would require much rewiring. I'm not a fan of the big bulky controls and really don't like the separate turn indicator switches on both sides. My concern is the clutch switch and the break reservoir pressure with an aftermarket one. Has anyone replaced them and have any advise?


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Title: Re: 1987 K100 cafe or something build
Post by: TrueAce on July 31, 2016, 12:50:12 AM
Well, the short answer for you on changing any of the stock bar controls is that it can be complicated. Just take a look at the wiring diagram for your bike, if you aren't frowning at that, remove the seat and take and look at the wiring loom...........should turn away from cosmetic control issues, and just do all the maintenance no doubt neglected.
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on August 01, 2016, 02:16:53 AM
Well the throttle controls side would also need a throttle cable since the throttle tube has that weird gear chain cable combo. But the start button, break light switch, and kill switch I could just splice in. The left side controls are a bit more complicated with the clutch engage switch, chock lever.

I'm also  exploring aftermarket exhaust the mid pipe is a bit of a challenge with the 4-1  running laterally  rather than horizontally. Would any 1000cc exhaust be an acceptable replacement. I was wondering about back pressure and fuel delivery volume in the injection system.


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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on August 08, 2016, 12:26:40 AM
So i'm going to bite the bullet and do the control swap. i got a little work done while i am waiting for parts. Since my local shop had a single cable pull throttle tube mechanism and some handle bars i liked I purchased them and started the next stage of the project.  Since the cables were so long for the "elk horn" bars that were on the bike, i trimmed about 4" off the throttle cable and  soldered a new end on it to fit the hole in the throttle tube cam. i made a little home made melting pot and melted the solder and dipped the end in it to fasten it. It worked surprisingly well!
(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/C537F952-E67C-485E-8A66-FE1E0ED0A2EE_zpsnhyyvjqb.jpg)

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/2956C177-E417-4634-B947-807DEF9FF881_zpszscdx7fs.jpg)

Bolted the tube and mechanism to the bars, it trimmed up the look quite a bit. I'm pretty happy with it.
(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/551ACE9C-64DE-4099-A189-85DE0FBE92F7_zpswbajankt.jpg)

I have the left and right controls from an '02 Kawaski ZZR 1200 coming in the mail that are considerably smaller than the BMW  controls. They should splice into the wires fairly simply (famous last words right!)

So at this point i have one running bike that i've created out of two with a clean title. The '87 frame has a '89 engine and drive in it now.

I'm waiting for the bullet fairing i bought to arrive and i'll see if i am going to keep the instrument cluster and avoid the head ache of  the wiring for a new one. I have a new brake master cylinder coming and clutch pull and lever on the way with the appropriate switches and I'll go from there once they arrive.

This is how she looks so far!
(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/8DCBC052-4D48-498A-9171-6198DFF3AD22_zpsnrdiw8ut.jpg)
(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/F40D440D-AD65-4D79-8115-78CACC8FFD8C_zps4fw7na6l.jpg)

My biggest challenge has been work space! I live in a house built in 1910 and te garage was built for a car the size of a Model T so having a project bike, a parts bike a Speed Triple and  Buell Ulysses in one garage makes for some creative positioning to get to things! I am so jealous of you guys that post pictures of big shops with big ol' work benches to work at!
Title: Re: 1987 K100 cafe or something build
Post by: TimTyler on August 08, 2016, 01:05:38 AM
My biggest challenge has been work space! I live in a house built in 1910 and te garage was built for a car the size of a Model T

Consider yourself lucky. I don't have a garage.  :yow
Title: Re: 1987 K100 cafe or something build
Post by: TrueAce on August 08, 2016, 09:39:55 AM
The new bars look good........what brand? And 22mms?
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on August 08, 2016, 10:50:50 AM
The new bars look good........what brand? And 22mms?

They are Track Side bars. 7/8" since I was replacing all the controls there were more options in that size. I like a little rise to them but we will see how high I have to mount the fairing for clearance. Straight drag bars would give me more room to mount the fairing lower and  stream line the look more. I may switch them out yet.


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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on August 10, 2016, 09:24:15 PM
I'm looking ahead to projects down the road. I'd like to switch out the exhaust at some point. I'm interested in the 4" super trap muffler ( I had one on a 87 Honda interceptor that I learned to ride on when I was 20 years old. ) Anyway, anyone have experience with them? Also wondering if anyone has a link to a 4-1 piece that would get me to the 2" opening on the super trapp or am I going to have to see if my muffler shop can fab one ?


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Title: Re: 1987 K100 cafe or something build
Post by: Laitch on August 10, 2016, 09:49:03 PM
Also wondering if anyone has a link to a 4-1 piece that would get me to the 2" opening on the super trapp or am I going to have to see if my muffler shop can fab one ?
Like this (http://cafe4racer.eu/en/bmw-k75-100-1100/21-collector-4to1-bmw-k100.html)? It might need a reducer. Some heating and ventilating outfits can fabricate that stuff, too.
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on August 12, 2016, 01:15:43 AM
For the record let me just say ... I hate wiring motorcycles!


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Title: 1987 K100 cafe or something build
Post by: Revrdmark on August 13, 2016, 01:02:23 AM
Hooray!!! I got the left controls  from an '02 ZZR 1200 wired in after a lot of trial and error. To be honest I'm not sure  how I did it just going through one function button and circuit at a time till they all worked. Tomorrow I'll tackle the right side start and kill switch

(http://uploads.tapatalk-cdn.com/20160813/8c3b71e6e75266780df9fdb9ba3a8cdc.jpg)




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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on August 13, 2016, 11:54:45 PM
Ok the ZX10 starter button and kill switch are installed and working. Only one problem ... When I flip the kill switch from dead to run the brake light comes on. I have no idea why.  The original lever and switch are still connected. I'm wondering if they might share a ground or something with the ignition button or something. If I can't track down why I may just  run the break light separate from the original loom.


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Title: Re: 1987 K100 cafe or something build
Post by: Shiny on August 14, 2016, 09:00:51 PM
Great work! The bmw turn signals are idiosyncratic to say the least. It'd be great if you could try to take a pic of the wiring for documentation.
Title: Re: 1987 K100 cafe or something build
Post by: NickHeijman on August 15, 2016, 08:39:47 AM
Woow good job on the controls.

Could you drop some pictures and some documentery, if possible. It would be helpfull for all other.
Changing the controls will be one of the steps ill be taking on my CF.

Cheers,
Nick
Title: 1987 K100 cafe or something build
Post by: Revrdmark on August 15, 2016, 10:26:24 AM
I'll get a write up and some pics up soon. It's VBS week so Work is busy this week so I'll try and get something up in one of the evenings.


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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on August 15, 2016, 07:31:07 PM
So here is a little write up for replacing the handle bar controls on a 1987 BMW K100,

I initially removed the handlebars because the K100 was originally an LT model with very high rise bars and I wanted something sleeker. 7/8” bars were the most easily accessible but that would mean replacing the throttle tube, clutch and break levers and the buttons and controls on the bars. Secondly I did not like the big box of buttons on the stock controls.  Finally I wanted to move the turn indicator switch to a toggle switch on the left hand, rather than one on each side with the turn off on the right.

Originally, I had planned on using some Chinese controls that I have used on some other cafι racer projects I have built, but the left control also has a cable that the choke works off of and none of the aftermarket controls had a lever to engage the choke. So I just began looking for left hand handlebar controls on eBay. Nothing after-market filled the bill of a high/low beam headlight switch, toggle switch for left and right turn signals, horn and a built in lever for the choke. I came across a used 2002 Kawasaki ZZR 1200 left hand control that has a choke lever built in, the high/low beam switch and the turn signal toggle switch. The same seller had a 2010 ZX10 right side control with kill and starter switch, so I combined shipping and ordered them both. They matched up well, were smaller than the stock ones, and look in great shape .(If you are wanting to do a similar switch I don’t have the original Kawasaki Part #’s but a simple OEM part search at a place like Bike Bandit will get you the information. Or look on eBay like me. I got the units for each under $15)

The Left controls (From the ZZR1200) were a little challenging to figure out until i figured out that the  turn signal  and the horn button shared a ground on the stock switch.  Plus I had to bring the wire for the right side turn signal over from the  right side stock controls and ground the signal stop switch on the right as well. The nice thing about buying two bikes to make one complete  running bike is that you have spare parts, so I was willing to  basically cut the wires, open up the  stock controls and  take it apart to see what  wire connected to what switch along with my Hayes repair manual wire diagram. If I screwed it up too bad I could always grab the switches from the donor bike and put everything back by reconnecting the  wires.

So here is  the way I wired up the turn signal toggle, High/Low beam toggle and horn button on left hand control.

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/EA96F4D2-0F8E-425B-AB74-7D86923C6D4F_zpsmlclsuyv.jpg)

Turn switch toggle & Horn:
             From ZZR control --------------- to ---------------Stock K100 wire harness
                1. Orange + Blk/Grey (from Horn button).... Brown
                2. Blk/Yellow………………………………………..…. Brown/Yellow
                3. Green…………………………………………………… Blue/Red
                4. Grey …………………….………………………….…. Blue/Yellow (from the turn signal
                                                                                              button on right control)

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/2EAA2996-7D96-4A34-951C-4400C6761CFD_zpsfsgsqdqv.jpg)

Hi/Low Beam switch:
            From ZZR control --------------- to ---------------Stock K100 wire harness
                  1. Red/Yellow …………………………………………. Yellow
                  2. Blue/Yellow ………………………………………… Yellow/White
                  3. Red ……………………………………………………… White
                                                                               Unused Blue/Green - Extra wire for parking light.

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/946FE8E8-81DF-4880-9F2E-693AC02393CA_zpsbjy0hsrz.jpg)

Here is how I wired the kill switch and starter button on the right side control. (The ZX10 control has an extra switch that is unused at this point so there will be two extra wires that are not connected when you are done.  Also when I wired the ZX10 control up and turned the kill switch to run the break light turns on.  I am still tracking that issue down. If I can not figure out the cause I will just runt the break light switch as a separate system from the rest of the wiring harness and snip the original break light wire. At this point I still have the original brake lever connected so it may be an issue with the stock brake switch and not my wiring of controls but we will see once its all buttoned up.)

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/E2684664-5C13-4E86-A156-1F33445E3270_zps2ogodgqa.jpg)

                 ZX10 Control ---------------------- To ------------------ Stock BMW K100 Wire harness
                         1. From 1 side of Ignition button Blk/Red ………… Blk/Yellow
                         2. From 1 side of Ignition button Blk/Red ………… Blk/Green
                         3. From Kill Switch , Yellow/Red ………………………. Green
                         4. From Kill Switch, Red ……………………………………. Green/Yellow
                         5.                                          Brown to Ground (-)
                         6.                                     Brown White to Ground (-)

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/0BA39A4D-6D36-41DD-AC3F-4C051E7CF53D_zps2hiub6sm.jpg)
Title: 1987 K100 cafe or something build
Post by: Revrdmark on August 20, 2016, 08:05:45 PM
So a little more work today. I got a little bullet fairing a few weeks ago and was trying to figure out how to mount it. I originally thought I'd modify the faring stay and mount it to that. But when I mocked it up it had to be so far forward and so high to clear the new bars the lines looked terrible. So I thought I would mount it on some left over screw holes on the triple tree and fabricate a bracket of some kind.  So I used some flat steel and a vice  to bend up a little mount and welded it with my arch welder. I'm still learning welding and I kinda suck at it but black paint covers a multitude of sins :-)

(http://uploads.tapatalk-cdn.com/20160820/a6850c01be0206537c67479059e29e90.jpg)

I used some left over angle iron to make the top bracket. Originally I used a torch to heat up some old rebar and try and get them bent at correct angles and lengths on each side and then weld them to the angle iron. With my little torch, grinder, hammer and bench vise as my only metal working tools I couldn't get the angles and length correct and my welds sucked so I went with plan "B"

I took some threaded rod and ran it through one of the windshield bolt holes, put a fender washer on the inside and a nut on the outside. I used u-bolt to lock it down to the angle iron and it was pretty sturdy and looks much cleaner than my booger welds. Plus I can turn the bolts and get the lengths as exactly centered as I like.

(http://uploads.tapatalk-cdn.com/20160821/84cba52044423c1ea146fd2f7fdb193f.jpg)

It's starting to look like a motorcycle again rather than a bunch of pipes bolted to an engine.
(http://uploads.tapatalk-cdn.com/20160821/0b9ddf60a377165e6510a2ce298d2d1e.jpg)

Next will be fitting light in that fairing and a seat pan and chopping the rear frame and reinforcing to fit.



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Title: Re: 1987 K100 cafe or something build
Post by: TrueAce on August 20, 2016, 08:08:06 PM
Clever! Keep going.....good post!
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on August 22, 2016, 11:03:24 PM
So had the day off today  so i finished up connecting wires and tucking them away. 

I'm not sure the story but the the bike that donated the engine and drive train started life as a LT model with ABS, but no brain t make it work. I took the conventional brakes off the donor bike and installed them on the keeper bike and removed the calipers with the  sensors on them and the two solenoids from the keeper bike. (If you are interested in them they are for sale.) I took the  wiring harness for the ABS out and cleaned things up in general.

I'll be installing a new koso speedometer when it comes in a big brown truck. Am I correct in  the fact that the speedo drive on the rear wheel is not a typical reed sensor and wont directly connect to the new speedo w/o  modification?

I'll be relocating the ECU under the seat and moving the battery to the tail section but  I'm running out of room on the handlebars and might  look for a new place to mount my key ignition switch. Anyone moved their  key to a new location and have any suggestions or advise?
Title: Re: 1987 K100 cafe or something build
Post by: pablooo on August 23, 2016, 12:04:04 AM
As for the ignition relocation, I've seen them in the airbox such as what a fellow motobricker did here http://www.motobrick.com/index.php?topic=3605.0 (http://www.motobrick.com/index.php?topic=3605.0) or what I did, as i've seen some others on here do as well was use two wormgear clamps (one to the ignition and one on the frame intertwined with each other) to the frame on the side or wherever you'd like.
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on August 23, 2016, 01:54:30 AM
That air box mount looks very cool. I was thinking of maybe mounting the key cylinder on top of the coil covers where there is a power port at the moment with either a plastic or sheet metal bracket


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Title: Re: 1987 K100 cafe or something build
Post by: TrueAce on August 23, 2016, 11:36:16 AM
One switch is ignition, the other for lights so no drain during starting, the brass started button gets it going. You put the bike in neutral before and after using the left-side starter switch.
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on August 23, 2016, 03:55:19 PM
One switch is ignition, the other for lights so no drain during starting,

In my younger "more testosterone than brains" days. We had a light kill switch so if someone was looking for you or chasing you could kill the lights and duck down a side street... I mean acquaintances of mine installed them ... ::: avoiding direct eye contact:::  :-)


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Title: Re: 1987 K100 cafe or something build
Post by: TrueAce on August 23, 2016, 10:35:19 PM
Somehow, I figured you would know why I wired it that way........not just to eliminate the load shed relay. Do you have NV Google's ,too?
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on August 24, 2016, 12:10:17 PM
No NV goggles just questions of how I lived to be 48 and glad I'm not young and stupid still. :-)


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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on August 24, 2016, 01:47:00 PM
Ordered the Ducati gt1000 tail section today. It's two weeks out. Have to wait  to relocate the battery and ECU till it comes. I can do a few odds and ends till it comes.


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Title: Re: 1987 K100 cafe or something build
Post by: TrueAce on August 24, 2016, 03:23:52 PM
I find the NV Google's distort my night vision depth perception at anything over 90.
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on August 24, 2016, 03:28:47 PM
I found that driving at night w/o lights at anything over 90 distorts my bones when i hit the pavement :-)

(http://i37.photobucket.com/albums/e66/RevrdMark/302437_2557724108539_1417083396_33022128_918063588_n.jpg)
Title: 1987 K100 cafe or something build
Post by: Revrdmark on August 26, 2016, 12:32:49 AM
Ok back on topic from my mis-spent youth... So the speedometer/bike computer arrived today. It's just an odometer speedometer and tach. I'll use the reed sensor for speedo and connect the tach to the #1 plug. I'm going to try and fabricate a simple bracket with three LED lights for the turn signals and oil light. I'll see if I can fit the key on it too but I'm not too hopeful, there is not much room for it. I think I'll look at some of the great suggestions you guys gave me for relocating the key. I'd love to have the neutral light but I'm not sure I'm up for the work involved to make it work. The clutch switch seems to be working fine I've started it several times so far.

I have a question about lubing  the shaft splines...I understand that the hallow shift will pull the lube up and away from the end that needs lube would thicker grease like bearing grease I've  used on automotive bearings keep that at bay? I've also heard that making a "plug" out of exterior silicon caulk works. Any thoughts?


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Title: Re: 1987 K100 cafe or something build
Post by: duckytran on August 30, 2016, 11:39:56 AM
Here's where I relocated my starter key:
Title: Re: 1987 K100 cafe or something build
Post by: duckytran on August 30, 2016, 12:24:30 PM
Here's a pic of the Acewell 3962 setup:
Title: 1987 K100 cafe or something build
Post by: Revrdmark on September 08, 2016, 12:51:21 AM
So latest up date. I've actually done what feels like a lot of work but it's been wiring and bolt turning so after all that work the bike still looks pretty much the same as it did before! I swapped the front forks from the dead bike to the keeper and increased the HP by at least 25 by putting gaters on the forks :-)

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/8BDBAF8E-F045-44F5-B990-620A30FE0617_zpsao8zrc9q.jpg)

I also swapped the wheels cause one bike had literally brand new tires on it. (And I'm cheap) The previous owner took a nail in the front tire on the last trip he took on it and put them on so he could get home. They are cheap Shinkos but I'm not worried about high performance on this bike. I had some spare clubman bars that I put on but without putting risers on the triple tree I had tank clearance issues so I took them off again. I have a fairing that I'm going to put on that the lines lined up perfect with the clubman bars... But oh well. It sits too high with the bars I had on it so ordered a straight drag bar but now I'll need to fabricate a new lower bracket for it when the bars get here. Any job worth doing is worth doing twice right?! I'm kind of tired of making brackets to hold stuff so I think I will mount the key in the air box. I need to go to a hardware store and get some pipe that will fit the key cylinder. Shortened up the choke and clutch cables and soldered new ends on them as well

A big brown truck delivered the GT100 tail today! So I'll fight the urge to start mounting that till after I get the mechanical stuff done :-(.  And finally cleaned up all the wiring I've done and cut out from removing the non-working ABS stuff.


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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on September 09, 2016, 08:22:55 PM
I've set a goal of spending an hour or so on the bike each night so I don't make my wife a bike widow or my kids bike orphans :-) so tonight my project was to fab up yet another bracket. This was for the acewell bike computer. So had some left over sheet metal that I cut up, bent it up drilled a few holes and bolted it on. Need to trim up a few sharp edges and shape it a little then add a few coats of paint. I'm waiting on some LED light I'll drill holes and mount on it for turn signal lights and a red oil light. But this is it so far.

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/0160BAF5-E1E2-4EE3-8187-6B72A2E5CA0E_zpsk0bcmrpw.jpg)


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Title: 1987 K100 cafe or something build
Post by: Revrdmark on September 15, 2016, 09:24:18 PM
Part truck came today YAY!  Got the straight drag bars and fabricated my third fairing bracket ( Well 2.5 I modified the last one I built) so I just need to install the LED lights on the speedo bracket and reinstall the radiator. Then I can tackle the next big project - cutting the tail shortening it re-welding the stock loop back and angling  it  up slightly to line up with the tail section. Here is a quickie mock up of it so far. Sorry for the bad picture. That's as far away and best angle I could get in my tiny shop. (http://uploads.tapatalk-cdn.com/20160916/c37272cbb5c44bf923173cd21f9ce3cf.jpg)

(http://uploads.tapatalk-cdn.com/20160916/3331676ce5d4d2a76b48b0808be5873b.jpg)


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Title: Re: 1987 K100 cafe or something build
Post by: duckytran on September 15, 2016, 09:45:02 PM
Mark,

Check out this K100RS from this blog site. It has a similar look to yours.

https://rocket-garage.blogspot.com/2016/09/kappa-cafe-tracker.html

Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on September 17, 2016, 12:58:35 AM
So I'd really like to have a neutral light  and i've read the  thread and seen the diagram for the three relay switch method or making the light function. I pretty much understand how the wiring works. I think i have located the three GPI wires coming out of the transmission under the battery tray, and understand the wiring that links the relays together, what i don't understand is the power supply from the switch. Are there two power wires coming from the key switch that go to 30 and 86?  What does the "yes" under the switch mean?  Any help  figuring out those wires would  be appreciated.

(http://i39.servimg.com/u/f39/16/61/73/02/sjema12.jpg)
Title: Re: 1987 K100 cafe or something build
Post by: rbm on September 17, 2016, 08:55:58 AM
You need a single source of switched +12V for this circuit (it's recommended to use the Green/Black wire from Pin 6 on the OEM cluster for this purpose).  You short Pin 86 and 30 together on Relay #1 and join up the Green/Black.  No need for two wires.  One can only guess as to what the "Yes" means in the diagram.
Title: Re: 1987 K100 cafe or something build
Post by: psykologik on September 26, 2016, 08:27:56 AM
This is coming along beautifully. Very close to the vibe I'd like to capture in the build I'm planning to do once I find the right donor(s). Using the Ducati tail section is sheer brilliance!


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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on September 27, 2016, 01:30:08 AM
 Thanks psykologik it was a coin flip whether to knock the 80's off the brick and go more retro or go more street fighter modern.  So far I'm happy with how it's turning out.

So latest victories include: 1) got a neutral light via the three switch diagram above. Just need to solder the wires and and find a place to tuck the switches away. 2) built a little bracket to hold the speedometer  reed sensor and got it mounted up.  3) mounted up the tachometer reading wire buy wrapping it around spark plug wire. 4) and got the oil pressure light wired up.

Next project is to mount the ignition key in the air box. Went to the hardware store and found a couple PVC pipe pieces that will serve as a chamber for the cylinder.

I'm looking for a good spot to mount my turn signals. On my speed triple they are mounted on a little trim piece that attaches to the end of the radiator. I'm toying with the idea of making a simple flat trim piece to bolt onto  the end of the radiator to mount the signals. Just an idea  at this point unless I find something cleaner and simpler. I'll post up some pictures of progress soon


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Title: 1987 K100 cafe or something build
Post by: Revrdmark on September 27, 2016, 11:21:57 AM
So I'm using a very basic Acewell ace-1500 speedo/tach it has a fuel gauge that I originally wasn't planning on using since I use my trip gauge mostly as a fuel gauge. But when the dash is energized the little fuel icon and bar graph are turned on. I was hoping that if the blue wire was not connected it would just not show anything :-/.  I've seen the posts about reversing the swing arms on the sender in the tank which now that I have been elbow deep in wiring harness for a couple months I'm feeling a little more confident (thanks to you all  here) I feel like I might tackle, so my question is, is the blue wire from the dash a negative like the oil light? I haven't taken the sender out of the tank yet but was just thinking I might get a clue as to what wire it connects to from the tank. There are 4 wires that come from the tank. 2 I assume energize the fuel pump and the other two I assume are the gauge. So do I connect the blue to negative or positive? Any help would be appreciated. Thanks yoose guys!


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Title: Re: 1987 K100 cafe or something build
Post by: Martin on September 27, 2016, 03:26:46 PM
Bar end indicators, or mirrors with built in indicators. Both available on Ebay.
Regards Martin
Title: 1987 K100 cafe or something build
Post by: Revrdmark on October 01, 2016, 10:32:29 AM
I was hoping to get the wiring all buttoned up today and close that chapter of my life. No such luck. Got my 3 switch Frankenstein contraption for the neutral light ready to install and one switch was not working after it worked last weekend. Scratched my head then switched the wires with one or the two working ones and "click" One of my wires coming from the Gear Position Indicator Switch is dead. So I'll be laying on my back trying to pull that off and get it live again today then plug everything back together.


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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on October 02, 2016, 12:00:48 AM
So that was a PITA!!!  Took the rear wheel off the drive shaft and housing off just to get to the GPI. Took it off pulled off the cap and sure enough one of springs behind the pins had broken. So lucky for me I have a donor bike  so took the wheel and shaft housing off a second time. Pulled the other GPI  off and it works fine installed it on the project bike. Reinstalled shaft and housing (after a trip to auto part store for moly lube) soldered up the switches hooked up battery turned the key put it in neutral and SHAZAAM!!! little green light on my home made dash lit! That was a hell of a lot of work for a little green LED to tell me I'm not in gear.!


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Title: Re: 1987 K100 cafe or something build
Post by: Martin on October 02, 2016, 12:16:10 AM
Probably a bit late but the switch is subject to a lot of road crap. I coated mine in Plasti Dip and has worked fine for about 16 years.
Regards Martin.
Title: Re: 1987 K100 cafe or something build
Post by: Laitch on October 02, 2016, 12:21:32 AM
I coated mine in Plasti Dip and has worked fine for about 16 years.
I've coated mine in road crap, Martin. It's the homeopathic treatment.
Title: 1987 K100 cafe or something build
Post by: Revrdmark on October 03, 2016, 12:14:18 AM
Yay! I'm finally seeing the light of the endless rewire a BMW tunnel! Got the speedo/tach wired up, got the oil light wired, got the neutral light working and got turn signals working. Headlight is a simple plug in affair ( but I'm sure I just jinxed it by saying that out loud)   Fabricating little brackets to hold turn signals and wiring up tail light and electronics are done woooooo hooooo! Here is a pic of the Acewell computer and LED lights I've hooked up.
(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/E394B550-656D-4456-B99C-970B8420E60A_zpst90qn3jl.jpg)


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Title: Re: 1987 K100 cafe or something build
Post by: Laitch on October 03, 2016, 08:49:22 AM
Nice going, Revrdmark! Thanks, too, for providing another example of a well-illustrated and documented project.
Title: 1987 K100 cafe or something build
Post by: Revrdmark on October 11, 2016, 11:25:57 AM
Well I relocated the key yesterday. I originally was planning on putting it in the air box but the examples I saw of that project must have been a different model cause when I opened the air box there was way too much stuff in there or not enough room to fit the length of the key switch mechanism. Plus the "hump" that goes over the transmission limits the space. So I went to my old standby: goodwill thrift store $1.99 plastic cutting board! I cut out a piece with a hole, glued in a piece of PVC pipe and painted it and attached it to the top of the ignition coil covers with a little piece of angle iron. I'm not crazy about it and may rethink it at a later time. But it works and will get me down the road. I'll post some pics tonight.

A friend turned me on to the cutting board as build material. It's waterproof can be painted and screwed into and is relatively strong. I've used it as an "electronics board" on previous builds to attach switches etc under the seat.


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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on October 11, 2016, 08:17:33 PM
So here are a couple pictures of the parts I've had to manufacture for the build.

New key placement:
(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/FE27C838-AFD8-4493-BE4C-887FE9B6135F_zpsfrtissmr.jpg)

Speedometer sensor bracket:
(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/3B1900D2-63DB-41E7-9DEF-C4943EA6A928_zpsoqiengxm.jpg)


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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on October 27, 2016, 01:13:11 AM
So i was  planning the next electrical project: the fuel gauge and sender. I took the sender out of the tank and was  planning on modifying it to work with the Acewell gauge. Upon removing the unit i looked at it and it was looking pretty corroded and brittle. The prospects of taking it apart without  damaging it in a terminal way seemed unlikely. I went on Ebay and  bought a  Kawasaki EX250  sender and float for $15. Its a simple 2 wire sender so just ground one wire and connect other to the blue wire on the gauge.  So i plan on just splicing the in tank fuel pump wires past the sender and making a new plate to bolt onto the bottom of the  tank to hold the new sender. I'll have to take the float and beam off the original and attach it to the new sender, but it seems pretty doable.  I'll try and get it put together this weekend and get some pictures up.
Title: 1987 K100 cafe or something build
Post by: Revrdmark on October 30, 2016, 11:50:23 PM
Here are some pictures of the work done on the fuel tank. This is the sender I picked up off eBay that works with my Acewell gauge. I'll need to do some creative bending of the float and arm to make it register correctly, or snip of the old wand and solder or weld it to the new sender.

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/108FEA56-893B-4007-8260-CAA2D4F306A1_zpsnr9qly7n.jpg)

This is a piece of metal I cut out of a 4x4 post hanger I had in the garage drilled some holes made a new cap out of it.
(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/419C46C2-5BFB-4F86-A88D-33AC22BC93B2_zpskzqsdw3k.jpg)

I had to trim the corners of the sender to make it fit in the screw holes and also used a couple thick rubber fender washers to seal up the hole and the  new plate

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/E50A03B3-61C5-4654-87EF-1DDE241F384A_zpsqvzkd4ig.jpg)

I've soldered and sealed some wire extensions on the fuel pump wires. I'll drill a hole in the bottom of the tank and run the wires through it and splice them into the old 4 post plug. I'll either use some steel epoxy fuel tank repair paste or some fuel resistant sealant around the wires to seal the hole. Everything seems to work on a dry run.
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on November 03, 2016, 01:45:01 AM
Drilled the hole ran the wires through and hopefully sealed it all up water tight with a good glop of fuel resistant sealant. I still need to bend the float arm. After that hopefully this project is done and can start on the next. Most likely welding and angling up the tail section and installing the fiberglass tail.

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/45237401-FD37-41AC-B211-FA56291C6457_zpsyt5skabo.jpg)


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Title: Re: 1987 K100 cafe or something build
Post by: duckytran on November 03, 2016, 08:48:43 AM
I'd like to know how accurate the fuel level reading will be. Mine isn't accurate with the Acewell, so I'll need to dig into it when time permits. Looking forward to seeing your tail section come together.
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on November 03, 2016, 10:19:04 AM
I've only moved the arm back and forth manually but the gauge worked as it should on the "dash". I will need to make sure I get the float arm bent correctly around all that rigging inside the tank.


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Title: 1987 K100 cafe or something build
Post by: Revrdmark on December 03, 2016, 11:01:51 PM
So I finally got a little work done on the bike this week. I welded the original loop back on the shortened frame and cut out about a 30 degree "V" out of the tube to bend the tail up at a good angle to make the Ducati tail piece look right ( in my opinion). I welded the seam closed so it welded strong at a tilted up angle. I cut out a piece of the thrift store plastic cutting board and screwed it on with a couple pipe clamps as a surface to mount the ECU too

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/721600D1-82BB-4E44-A743-020726B24B44_zpsn3w1fcdt.jpg)

I thought I'd share some of the trial and error process as well. The last two posts were about putting a new fuel level sender in the tank since the one I had was in pretty poor shape and I was planing on selling the other tank from my parts bike if I could put a new sender in the original tank cheaply. So I did all that work of fitting the Kawasaki mechanism into the opening, drilling a hole for and soldering up the fuel pump wires and sealing it and installing it. I could never get the float arm bent in such a way to get the float to the bottom of the tank or the top  so it either read 3/4 full or 1/4 full never F or E. I was messing around with the original float and reading the threads about taking the  sender apart and turning the wire windings around so it read opposite to work for an Acewell  gauge. It dawned on me "why not just cut the wires at the plug, reverse them  and solder them back together rather than damage the sender by taking it apart?" I said a prayer took the sender out of my parts bike, snipped the wires, reversed them, connected them to my Acewell gauge and  moved the arm up and down. Eureka! It works perfectly.

So I have a fully functional fuel gauge, a neutral light, oil light, and speedo and tach. So far so good.  Next  project is fabricating a bracket for the tail section to mount to securely.


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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on December 13, 2016, 12:40:53 AM
Worked some more on the  brick today. I fabricated a  brace to mount the seat pan to out of square tubing. My welding skills with my little arch welder are lacking especially with the different thicknesses of metal, so no nasty comments about my booger welds!! The brace isn't structural mostly just a  platform to  bolt the seat to. it will look a little better with a  bit of grinding primer and black paint

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/2F717C2B-C6F0-44A7-B9CD-599A16AF6CA7_zpsu5xx5cbu.jpg)

so starting to see the light at the end of the mechanical and fabricating  part of the build. I'm trying to decide what i will do for the tail/brake light. I like the look of the LED strips but i  think i might go with a simple  round flush mount tail light and  mount  some  flush mount turn indicators.
Title: Re: 1987 K100 cafe or something build
Post by: duckytran on December 13, 2016, 09:36:48 AM
So I finally got a little work done on the bike this week. I welded the original loop back on the shortened frame and cut out about a 30 degree "V" out of the tube to bend the tail up at a good angle to make the Ducati tail piece look right ( in my opinion). I welded the seam closed so it welded strong at a tilted up angle. I cut out a piece of the thrift store plastic cutting board and screwed it on with a couple pipe clamps as a surface to mount the ECU too

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/721600D1-82BB-4E44-A743-020726B24B44_zpsn3w1fcdt.jpg)

I thought I'd share some of the trial and error process as well. The last two posts were about putting a new fuel level sender in the tank since the one I had was in pretty poor shape and I was planing on selling the other tank from my parts bike if I could put a new sender in the original tank cheaply. So I did all that work of fitting the Kawasaki mechanism into the opening, drilling a hole for and soldering up the fuel pump wires and sealing it and installing it. I could never get the float arm bent in such a way to get the float to the bottom of the tank or the top  so it either read 3/4 full or 1/4 full never F or E. I was messing around with the original float and reading the threads about taking the  sender apart and turning the wire windings around so it read opposite to work for an Acewell  gauge. It dawned on me "why not just cut the wires at the plug, reverse them  and solder them back together rather than damage the sender by taking it apart?" I said a prayer took the sender out of my parts bike, snipped the wires, reversed them, connected them to my Acewell gauge and  moved the arm up and down. Eureka! It works perfectly.

So I have a fully functional fuel gauge, a neutral light, oil light, and speedo and tach. So far so good.  Next  project is fabricating a bracket for the tail section to mount to securely.


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This is great Mark. I also need to do the same wire reverse scheme since my Acewell fuel gauge never read accurately either.
Thanks.
Title: Re: 1987 K100 cafe or something build
Post by: MaraudeRS on December 13, 2016, 08:44:49 PM
Cool


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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on March 25, 2017, 11:15:12 PM
So the snow is finally melted and the temperatures are above 40 degrees so i started  some projects. I started stripping the paint off the fuel tank. OMG  what a  pain! So as best i can see, the tank has been painted no less than 4 times! There are four layers of paint to try and get off this  tank. I have used Citi-orange stripper on paint projects in the past with a lot of success, but with this much paint on the  tank it is taking forever. I have basically stripped the tank three times to get the layers off and am just now getting to  bare metal.

Here is  one layer of  paint and clear coat  bubbling up  with citrus stripper:
(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/EE89F609-D6EA-4AA2-8DC0-15A477D5AF5B_zpsa2qe4ohd.jpg)

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/27A735B2-322E-4504-8EFC-75B661CD77A1_zps4zjfmlne.jpg)


 I bought a little 2.5 Inch flush mount tail/brake light and will be mounting it in the tail section. I cut the hole for the rubber grommet that the light fits into. I'll wait to actually put the rubber in till after the  paint is done so that i don't have to  try and pry it out to get it painted.

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/5199EA39-E01B-44F2-AD32-88208B2663D8_zpsacsohbxm.jpg)

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/60B3D20F-2952-4431-A918-DEC99A04510E_zpscq1wjzum.jpg)

 More pictures as i get back into the swing of things!
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on March 27, 2017, 05:04:34 PM
Since I don't have any trunk or storage area on the bike anymore I was thinking of making two little "saddle bags" that would fit in the triangle where the old side covers used to be. And I hit a milestone today! All the wiring is finished (I'm sure I jinxed it now) but got head light, tail/brake light, turn signals, neutral, oil light, ignition and kill button, and instrument cluster all wired and functioning!!! So I'm to the point of working on paint plans and prep and then reassembly and hopefully... test ride in the next few weeks when weather permits! Wish me luck!


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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on March 27, 2017, 05:30:20 PM
greetings...

john ralston is in your home town... he is one of the best holster makers on earth...

i betts he would be tickled to stitch up a set of triangle tragkorbs for you...

http://www.5shotleather.com

j o
Thanks! I'll look him up always happy to support local craftsman!!


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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on April 03, 2017, 12:24:35 AM
So I wired up turn signals and put the super trapp exhaust on ( just finger tight) and all the parts I have all over my garage and look there's a motorcycle in there!
(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/87EF16BA-A0EF-41CD-995C-1928F36410B1_zpspikuri77.jpg)


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Title: Re: 1987 K100 cafe or something build
Post by: duckytran on April 03, 2017, 09:22:45 AM
Looking good Mark! I see you have the tank prepped for paint. Looking forward to seeing the color scheme on it.
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on April 03, 2017, 06:26:03 PM
Looking forward to seeing the color scheme on it.

I think I'm going to go with a white/ cream color and do a "M Stripe"  with silver white and black stripes rather than red purple blue. I think I'll do the seat in dark tan or brown and still think I'll do saddle bags where side covers were in the same color


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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on April 04, 2017, 05:15:47 PM
So  next problem to solve:  I have had the bike up on the center stand all winter during the process of the build. I  finally  took it down to roll it  to another spot in the garage and the  4 into 1  piece and the exhaust are  right where the foot of the center stand goes when it is in the up position. Have any of you had a similar clearance issue? Not sure if shortening the  pipes would give me the clearance or  if  extending them would help???  I'd love to see any solutions you all have done to solve any similar problems.

Title: Re: 1987 K100 cafe or something build
Post by: duckytran on April 04, 2017, 05:24:06 PM
I've removed my center stand  :bmwsmile . Makes the bike lighter too!
Title: Re: 1987 K100 cafe or something build
Post by: Laitch on April 04, 2017, 05:25:57 PM
I'd love to see any solutions you all have done to solve any similar problems.
I think a few photos of the challenge would help stimulate thinking—not that there are any flaws in your description.
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on April 04, 2017, 05:26:36 PM
I might end up removing it too. And what is with the crazy angle of the kick stand! ?  That thing is so far over when it's on the stand!


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Title: Re: 1987 K100 cafe or something build
Post by: duckytran on April 04, 2017, 05:29:26 PM
I might end up removing it too. And what is with the crazy angle of the kick stand! ?  That thing is so far over when it's on the stand!


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I've added a 1/2 heel to my stick stand so the bike doesn't lean over as extreme.



I've added a 1/2 heel to my stick stand so the bike doesn't lean over as extreme.
Title: Re: 1987 K100 cafe or something build
Post by: Laitch on April 04, 2017, 05:46:37 PM
And what is with the crazy angle of the kick stand! ?  That thing is so far over when it's on the stand!
Have you ever tried to tip it over at that angle? That won't be happening easily and consequently it isn't easy to tip it in the opposite direction either. It's an exciting-looking angle though.
Title: 1987 K100 cafe or something build
Post by: Revrdmark on April 06, 2017, 01:45:08 PM
So I'm hopefully going to start some paint in the next week or so. I am fairly solid on the black/grey/white "M stripe" on the fuel tank. I went down to a local vinyl wrap place and they sold me scrap vinyl in three colors for $10.  So looking for opinions ( of which I will most likely ignore ... ha!) on what pattern looks best. I'm thinking a dark grey/silver color with either the strip going totally across the side of the tank like this:

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/A139256D-9BE9-4BE9-9839-EFD2CE4BA896_zpszioll7wn.jpg)

OR... a smaller stripe coming out of the BMW logo like this:(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/8042E9F6-E070-4E9C-8F8B-EF46F3180F21_zpsamrif4rl.jpg)

Any thoughts?


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Title: Re: 1987 K100 cafe or something build
Post by: duckytran on April 06, 2017, 01:58:18 PM
I like the first one. Makes more of a statement! You have a big tail piece. Perhaps incorporate the smaller stripes there.
Title: 1987 K100 cafe or something build
Post by: Revrdmark on April 08, 2017, 11:50:27 AM
So started the base color coat. Just using a dupli-cote ford grey color from the local paint shop so I can easily get color match for touch ups. Here is one coat of primer and color on the tail section.
(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/D6783BF2-9E7D-4205-8D9C-70EC9DC0FE79_zpsn09tgsz6.jpg)

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/994F0DCF-2A75-4AC5-92BC-5317D4D04D37_zpsizlfybwp.jpg)

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/78426502-ABDC-422F-B9CA-A631282B3F51_zpstfzapfjh.jpg)


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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on April 09, 2017, 06:32:08 PM
First coat of metallic gray on the fuel tank

(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/5F700B91-75F9-4EFA-ABBF-78030C1F6CD4_zpsvswsitsl.jpg)

There was a little blemish on the top of the tank I couldn't see except in bright light but I think I'll just leave it


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Title: Re: 1987 K100 cafe or something build
Post by: Martin on April 09, 2017, 10:11:37 PM

I'd fix it now otherwise you will probably regret not doing it. It is easier now than later.
Regards Martin.
Title: Re: 1987 K100 cafe or something build
Post by: Laitch on April 10, 2017, 12:16:01 AM
There was a little blemish on the top of the tank I couldn't see except in bright light but I think I'll just leave it
I'd fix it now otherwise you will probably regret not doing it. It is easier now than later.
Regards Martin.
It looks like a nozzle ding. Cherish it as a lingering artifact from your bike's past and symbolic of indifference to the futile pursuit of perfection. 
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on April 12, 2017, 01:40:36 AM
Color is on the tank so I cut some 2" strips of vinyl to get ready to stick on before clear coat. I think I'm going to leave the paint a matte finish rather than sand it to a gloss. I kinda like the look better. I got home from work late (imagine that, the pastor working late during Holy Week!) so I just taped up the stripes to get a general idea of the look and I'll probably stick them on tomorrow
(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/E007379B-4356-4FF2-986F-96D50432B55A_zps65da1yzs.jpg)


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Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on April 12, 2017, 10:24:22 PM
Came home after work and was probably too anxious to get the stripes put on the tank. I'm 80% happy with how they turned out. I didn't get them exactly in the same place on both sides. Unless you are looking for it you probably won't notice unless you look at one side then run around and look at the other. Also the vinyl slipped out of my hand and stuck to the tank and took a piece of paint off GRRRRR. I'm going to try and touch it up with a paint brush but I hate accidents like that!!! There was smoke coming out my ears for a while.

*Note - Now that i've gotten away from the project for a bit and taken a second look at the chip i think i can mask the stripes and  get a good blend with spray 

So here it is so far
( notice the paint chip right above the white stripe!!)
(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/0B60979F-54D7-4F29-A95B-F8D6F7F1E0D0_zpsmr0a4uuk.jpg)

Other side
(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/57B870BE-1514-40C2-BF48-B7D4060CCD30_zpsgzeqjci0.jpg)

It looks ok from 5 feet lol. I just can't stop and let people look at it up close. :-)
(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/62AD1B38-7796-4A70-8B63-C930014CC133_zpsg3mfqcow.jpg)

I have tons of the vinyl so I may redo it at a later date but at this point I'll let it go


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Title: 1987 K100 cafe or something build
Post by: Revrdmark on April 13, 2017, 12:12:36 PM
BTW I added up the costs of the bike purchase and parts minus the income from selling off unused and extra parts and so far I am in the black $345 on the project Woo hooo!


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Title: 1987 K100 cafe or something build
Post by: Revrdmark on May 08, 2017, 10:12:25 PM
Took the bike around the block today for first test ride. I've got a few things to button up but it's about 80% done. Need to paint the fairing and front wheel fender, zip tie some wires to the frame and the fan is not coming on so need to trouble shoot that. Finally, get some grips and bar end mirrors and and make a bracket to hold the supertrapp exhaust then call it good.
(http://i37.photobucket.com/albums/e66/RevrdMark/1987%20BMW%20K100%20Build/7C0F9A61-467A-4288-BD62-F738BFBD7D42_zpsnzjbw5ie.jpg)


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Title: Re: 1987 K100 cafe or something build
Post by: MaraudeRS on May 09, 2017, 01:39:01 AM
It looks fantastic. I love the seat and cowl.


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Title: Re: 1987 K100 cafe or something build
Post by: Boxermann on May 10, 2017, 03:27:13 AM
Looks great!
Title: Re: 1987 K100 cafe or something build
Post by: Laitch on May 10, 2017, 11:29:40 AM
BTW I added up the costs of the bike purchase and parts minus the income from selling off unused and extra parts and so far I am in the black $345 on the project Woo hooo!
You made more money selling the parts than the bike and its modification parts cost you in the first place?
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on May 11, 2017, 12:09:03 AM
You made more money selling the parts than the bike and its modification parts cost you in the first place?
So far yes. Although I'm about $215 in the black now had to buy a few parts since I posted up that total


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Title: Re: 1987 K100 cafe or something build
Post by: Laitch on May 11, 2017, 12:21:58 AM
So far yes.
That's pretty good, alright! :clap:
Title: Re: 1987 K100 cafe or something build
Post by: technostructural on May 11, 2017, 05:40:59 AM
Need to paint the fairing and front wheel fender, zip tie some wires to the frame and the fan is not coming on so need to trouble shoot that.
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There is a lot written about this. The fans rarely come on, and it seems to vary between bikes without rhyme or reason. There is a way to jump a couple of connections in your fuse/relay box to do a test. If you search "radiator fan test", you should be able to find it.


Great work so far. Looks cool and tasteful.
Title: Re: 1987 K100 cafe or something build
Post by: Laitch on May 11, 2017, 09:26:43 AM
The fans rarely come on, and it seems to vary between bikes without rhyme or reason. T
The concept is simple and differs among bikes for logical, prosaic reasons. On a bike with an appropriate level of high-quality coolant in its system, the fan's activation depends upon the weather, traffic, coolant:distilled water ratio, and how hard the bike is being ridden. At approximately <217ΊF coolant temperature, the fan doesn't run. At approximately ≥217ΊF, it does run.
Title: Re: 1987 K100 cafe or something build
Post by: The Mighty Gryphon on May 11, 2017, 10:17:21 AM
Nekid bricks don't be holdin' no heat in like dem faired ones.
Title: 1987 K100 cafe or something build
Post by: Revrdmark on May 11, 2017, 11:33:18 AM
I was letting it idle in the driveway to double check connections and charging etc an it got HOT and boiled the water wetter in the cooling system ( I didn't have the expansion tank on at the time) and it was spitting boiling water out the overflow tube and the fan never kicked on. When it's moving and air is going over the engine it's ok.  I'll by pass the wires and make sure the fan actually functions and may just  put a switch on it depending on what I find out.

Also the charging system is a little suspect. I'm a little new to bricks ( this is my first one and learning curve is huge for me) at idle the voltage was about 12.5 at 2000 rpm its steady at 14. I assume that's normal??


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Title: Re: 1987 K100 cafe or something build
Post by: Filmcamera on May 11, 2017, 11:46:35 AM
The voltage seems fine, I just had my alternator fixed and that is exactly what it gives me now.


My fan also had issues coming on automatically so I installed a manual switch - living where I do I use it a lot!  There are very clear and easy to follow instructions on the site and even for someone as electrophobic as me it was quick and simple to do. I will probably get round to fixing the sensor so it works automatically as well one day but it is not a priority.


The bike looks great btw  :2thumbup:
Title: Re: 1987 K100 cafe or something build
Post by: Boxermann on May 11, 2017, 01:19:50 PM

An alternative solution for the fan could be to buy a 2$ thermostat switch on eBay, set it to 103° Celsius and connect it to the fan (and ground..), then drill a hole for the temp sensor in the blanking plug on the water/oil pump and glue it in place with epoxy.

http://www.ebay.com/itm/50-110-C-W1209-Digital-thermostat-Temperature-Control-Switch-12V-sensor-/252062159071 (http://www.ebay.com/itm/50-110-C-W1209-Digital-thermostat-Temperature-Control-Switch-12V-sensor-/252062159071)
Title: Re: 1987 K100 cafe or something build
Post by: Laitch on May 11, 2017, 01:34:19 PM

I was letting it idle in the driveway to double check connections and charging etc an it got HOT and boiled the water wetter in the cooling system ( I didn't have the expansion tank on at the time) and it was spitting boiling water out the overflow tube and the fan never kicked on.
Also the charging system is a little suspect. I'm a little new to bricks ( this is my first one and learning curve is huge for me) at idle the voltage was about 12.5 at 2000 rpm its steady at 14. I assume that's normal??
It looks like a new Spal fan might drop your in-the-black figure a little more, Rev. It'll be a good investment though.

Concerning the coolant spitting:
Was the overheat light on during the spitting?
Could the blades of the fan be rotated with little effort the engine was when off?
Was the coolant fresh? An expansion tank is necessary with this system.

Concerning assumption of the battery's condition:
14V is good output, but why assume anything? There is plenty of is plenty of substantiated data available on appropriate voltage. Here is some. (http://blog.jpcycles.com/how-to-test-motorcycle-charging-system/)
Title: 1987 K100 cafe or something build
Post by: Revrdmark on May 27, 2017, 11:44:49 PM
Took the brick on a real maiden voyage today ( about 30 min ride) while moving it ran like a champ!  But again after the ride and letting it idle at about 1K rpm for 5-7 minutes it got hot and popped the rubber top off of the stock expansion tank and the fan never turned on. Also the battery was drained. I stopped while on the ride to get fuel and battery had plenty of umph after riding it at speed for 15-20 minutes. I replaced the stock gauges with a little Acewell computer so I don't have a temp light. The expansion tank did have some sludge in it so I'll do a good garden hose flush and hook the fan up to a battery directly just to make sure it functions at all. After I get that data depending on what I find I may just replace the thermostat with an after market auto parts one and wire up a the fan outside the wiring harness. Or maybe put it on a switch. The battery is a little troublesome. I'm thinking I may have an open circuit somewhere pulling power that I don't know about. BTW have I mentioned I HATE MOTORCYCLE WIRING!! Other than that I am very happy with how it has turned out thus far!


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Title: Re: 1987 K100 cafe or something build
Post by: duckytran on July 11, 2017, 10:20:12 AM
Any update Mark? I'd love to see some pics of the finished bike.
Title: 1987 K100 cafe or something build
Post by: Revrdmark on July 11, 2017, 01:06:33 PM
Any update Mark? I'd love to see some pics of the finished bike.

I finally got around to trouble shooting the fan. Good news bad news good news.  Since I was going to pull the radiator I hooked up the garden hose and did a good radiator flush. I pulled the radiator  and alligator clipped the wires from the fan to the battery and Shazam it turned on. Good news. I then looked at my wiring manual and sure enough I was right. When I removed the instrument cluster I removed the circuit that regulates the fan. Bad news. BUT I had a little handle bar mounted switch that was in a box of old parts and wired it up to the fan to manually turn it on.  Started it up opened the "choke" to let it rev high and it didn't over heat or spray boiling coolant everywhere. My battery is still suspect I think it might just be  I need a new one. I depleted  it several times while doing wiring projects checking this and that and I think it might just be done. I'll put it on battery tender and get a green light after 10 mins or so but I get about two tries at cranking it before it's too low.  But it runs ok and seems to charge when it's out and about. Just one more thing ... 

I just moved into a new house this month and the only thing I hate more than German wiring is packing and moving!  My garage is full of boxes so work is a little slow these last few yards to the goal line. AND I was going to put my Speed Triple up for sale and the Sprag Clutch went out on it (pretty common on speed triples it should have been a recall ... but don't get me going!) literally the day I put it up.  So waiting on parts time and garage space to fix it. Other than that life is good!


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Title: Re: 1987 K100 cafe or something build
Post by: duckytran on July 11, 2017, 04:41:18 PM
Hardly used and less than 1 yr old. Make an offer!
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on July 21, 2017, 11:31:59 PM
So took the brick out on a real maiden voyage tonight about a 30 mile ride.  Ran like a champ. Still a few fine tuning to do. Need to clean up the exhaust a little think I will do a high mount.  Need to put a resistor in the turn signal wires.  But other than that the brick ran like a champ. I stopped on the way to a little town South of Spokane called Rockford at a little chapel out in the Palouse to take a few pics (https://uploads.tapatalk-cdn.com/20170722/944fa51533a6182be371be680b8551cc.jpg)
(https://uploads.tapatalk-cdn.com/20170722/6c4ba5b22153117333ca67692d0595ea.jpg)
(https://uploads.tapatalk-cdn.com/20170722/c0f0a5a28f90a40636fb6272d6b46ed6.jpg)


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Title: Re: 1987 K100 cafe or something build
Post by: prakash on July 22, 2017, 10:29:05 AM
Beautifully done. Love the tank and tail section.
Title: Re: 1987 K100 cafe or something build
Post by: Jared on August 25, 2017, 08:35:56 PM
Hey mate, i feel like we are going through the same problems right now except my bike is far from finished. Iv just moved so everything thrown into boxes and my dog chewed up my wiring loom after i pulled it out of the bike so I'm just re-using the plugs and starting from scratch. Just drawn up a rough wiring diagram but hopefully i don't forget anything. How do you like the supertrapp? Im looking at buying one but from what iv heard not everyone likes them.
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on December 28, 2017, 02:32:41 PM
I moved into a new house with a real garage this summer. I hit that “ I want to ride this bike not work on it” stage so I just kinda clamped on the super trap quick painted the tank left the engine and wheels unpainted and ugly and rode it. So now I’m going to try and finish up the loose ends while there is 6” snow on the ground.  I would like to enter the brick in a local show in April. Finally I’m so sorry photo bucket in linked all my images on this thread. I’m not paying their huge fees. Anyone have a new pic hosting solution?


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Title: 1987 K100 cafe or something build
Post by: Revrdmark on December 28, 2017, 02:42:22 PM
Jared, I kind of have no opinion on my supertrapp. I like the look of it I haven’t really messed with the plates and the brick is not really a speed machine. It looks good it does what it’s supposed to so I’ll keep it. How’s your wiring harness going? I have a mostly complete one ( missing a few plugs) let me know if you need photos or would like it. I’m going to be collecting all the old parts for sale soon


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Title: Re: 1987 K100 cafe or something build
Post by: Filmcamera on December 28, 2017, 02:43:19 PM
Hi,

You can post pics directly into Motobrick

http://www.motobrick.com/index.php/topic,10306.0.html (http://www.motobrick.com/index.php/topic,10306.0.html)

Works pretty well, especially the bulk add

Good luck
Title: Re: 1987 K100 cafe or something build
Post by: rbm on December 28, 2017, 05:56:43 PM
+1 on the Motobrick gallery.  I also use Tinypic.com as I link to the same pictures on other sites and don't want to abuse Motobrick bandwidth.
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on April 20, 2018, 12:51:16 AM
So first sunny day of the season. Stopped for some glamour shots :-)
(https://uploads.tapatalk-cdn.com/20180420/3bf8600cfae2abaff82836263a4f3f0e.jpg)(https://uploads.tapatalk-cdn.com/20180420/a09937fe16d4f6a8ca0cf9d672e5d0fc.jpg)(https://uploads.tapatalk-cdn.com/20180420/6fa4500b2943fd5908ad68075ca7fb6e.jpg)


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Title: Re: 1987 K100 cafe or something build
Post by: Laitch on April 20, 2018, 07:24:43 AM
Still looking good. Congratulations on the big 5-0!
Title: Re: 1987 K100 cafe or something build
Post by: Revrdmark on April 20, 2018, 11:04:10 PM
Still looking good. Congratulations on the big 5-0!
My goal was to finish it before my 50th B-day hence the # decal. Took it out today with an R1, zx10, CBR, busa and a Ducati street fighter and quickly learned the limits of a 25 year old highway mile muncher and a modern sport bike. But guess which bike everyone stood around taking pictures of and asking questions about?! THE BRICK!

Ero-bikes stick together even if they are 25 years apart (and about 80 mph) lol
(https://uploads.tapatalk-cdn.com/20180421/43238e957b100a5eb3d313300dd6ed14.jpg)


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