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TECHNICAL MOTOBRICK WRENCHING In Remembrance of Inge K. => Project Custom Motobricks => Topic started by: Skunky on August 25, 2017, 05:05:30 PM

Title: Not a cafe racer project K100
Post by: Skunky on August 25, 2017, 05:05:30 PM
Hi I recently stole a K100 ex police bike for a met £700. Up till now I have had newish
Bikes but this is my first build.

Thinking being ex Police for most of its 60k it would be well maintained I thought it was a great buy. The bike starts runs and drives and sounds OK if not a bit smokey ( seems to be running rich ) but plugs were nice and dry so no oil or water evidence just a little sooty. Clutch is a little stiff but it has stood for a while. I have in mind what I want to achieve and have made a mock up.






So started the strip down.......

I'm not one for giving a bike names but I have given this one many B######d F#####r piece of S##t and even the C word And at times all of them..

It would seem that although the Police mechanics maintain their fleet they do not use torque wrenches or anti seize. Bsds

The Exhaust had three stripped and crossed studs and no gaskets meaning it was corroded into place. One of the sockets snapped at the back and two studs had to be drilled out and re threaded but all done now

I have cut the frame and re- fitted and welded in the original rear section, minus any unwanted tabs etc. Ready for a seat build





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Title: Re: Not a cafe racer project K100
Post by: The Dude on August 25, 2017, 08:11:34 PM
Awsome providence,Skunky,welcome.
The smoke will be from the weed someone stuffed into the air box.Ha,the fuzz,aye!
The cuss word that works for my brick and Guzz,funnily enough,is:Honda.'Took a long time to find that out.
All the best.
Title: Re: Not a cafe racer project K100
Post by: Skunky on August 25, 2017, 11:59:28 PM
Hi Dude

If it was Skunk in the air Box I would have smoked!.  But I imagine you're right about the air box. I think the Filter has been there for a few years smelt like a badgers box. Hopefully a new one will help the mixture and reduce the blackness.
Title: Re: Not a cafe racer project K100
Post by: Martin on August 26, 2017, 01:37:47 AM
There is a plug on top of the RH front of the air box, removing this allows you to access the mixture screw, with a 5 mm allen key. To adjust you can either use a exhaust gas analyser  or use a method called the lean drop method ( look up on this site). I bought a Gunson Digital Analyser years ago for between $300.00- $400.00 a lot cheaper in the US around $200.00. If you buy one follow the instructions to the letter and be patient, it has proved to be invaluable.

A little known feature on the 2v bikes ( not on 4v engines) is that with the bike idling at 1000rpm if you press the green stater button it will tell you whether the mixture is right. When you press the button if the mixture is right the revs should either stay the same or rise slightly. If the revs drop or rise significantly the mixture will require adjusting.
Regards Martin.
Title: Re: Not a cafe racer project K100
Post by: Skunky on August 26, 2017, 05:52:34 PM
Thanks Martin useful advise that I will look at once the beemer is running again.


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Title: Re: Not a cafe racer project K100
Post by: Skunky on August 26, 2017, 06:52:59 PM
 On Monday my back had some sort of seizure reducing me to crawling around the house and not moving much. Not being good at inactivity I decided it would be the perfect time to make my seat. I have already made a seat pan using a rear from a RS as Sloping rear on the LT felt a bit clumsy.

(https://uploads.tapatalk-cdn.com/20170826/6cb6c716eebaa27508c82987c3997536.jpg)


The unit was cracked and therefore a reasonable price £15 .

So after cutting and painting I have built the new seat base.

(https://uploads.tapatalk-cdn.com/20170826/49cd6c318d7b92890d4beb0614dc332b.jpg)

(https://uploads.tapatalk-cdn.com/20170826/a6b7dfeb7c1a81ce4bf3907ae19507f1.jpg)

The lights and indicators are an led strip that will sit on the black line. (https://uploads.tapatalk-cdn.com/20170826/66dc2648de108159d802dc4cc28af548.jpg)

Anyway I had bought a used leather jacket  and turned this

(https://uploads.tapatalk-cdn.com/20170826/163dbdbe77183d6f78e4490d82ac558c.jpg)

Into this

(https://uploads.tapatalk-cdn.com/20170826/1ddee4adbfa26f86c0f22964cd9083b7.jpg)

I'm pleased with the outcome and know it will look better when stretched over the base rather than loose. Almost worth the back pain.




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Title: Re: Not a cafe racer project K100
Post by: Martin on August 26, 2017, 07:06:37 PM
Won't the jacket be a bit drafty with the back cut out? :dunno
Regards Martin.
Title: Re: Not a cafe racer project K100
Post by: Skunky on August 26, 2017, 07:09:50 PM
Matches my leather Chaps   :hehehe
Title: Re: Not a cafe racer project K100
Post by: Laitch on August 26, 2017, 11:24:30 PM
Matches my leather Chaps   :hehehe
:clap:
Title: Re: Not a cafe racer project K100
Post by: johnny on August 26, 2017, 11:40:04 PM
greetings...

matches my coddpiece... or at least the one i gotts on tonight...

j o
Title: Re: Not a cafe racer project K100
Post by: Laitch on August 26, 2017, 11:49:30 PM
matches my coddpiece... or at least the one i gotts on tonight...
https://www.youtube.com/watch?v=lN65uLXegeI
Title: Re: Not a cafe racer project K100
Post by: Skunky on August 26, 2017, 11:56:22 PM
Perhaps I'll stitch one one the front saddle. Like the CB200


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Title: Re: Not a cafe racer project K100
Post by: The Dude on August 27, 2017, 01:32:49 AM
Perhaps I'll stitch one one the front saddle. Like the CB200

Ahhh,I thought I smelt Honda,just to the left there.Awsomely reliable.
'Loved the look of the CB two hundie.
Classic use and source of leather,yet more providence.The ducktail still holds a few cans,but I guess your gunna put the brains in there or the power source or that skunk I know you've found.
I have to kayak 50 kms a week to stop my back fucking out.'Took a long time to find that out,seriously.
Title: Re: Not a cafe racer project K100
Post by: Skunky on August 27, 2017, 09:56:44 AM
No Honda there, It's a Triumph Thruxton




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Title: Re: Not a cafe racer project K100
Post by: Skunky on August 27, 2017, 09:58:07 AM
(https://uploads.tapatalk-cdn.com/20170827/ca6ccfc802a279e5c96e2d8205107bbd.jpg)


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Title: Re: Not a cafe racer project K100
Post by: The Dude on August 28, 2017, 03:34:13 AM
No Honda there, It's a Triumph Thruxton.
Nice!
Interesting codpiece surrounding the drive sprocket,must be back in fashion,Jo the trend setter?
Title: Re: Not a cafe racer project K100
Post by: Skunky on August 31, 2017, 06:18:06 AM
Greetings Beemer Lovers, Having mostly recovered from the back spasm incident I'm back on the project. The seat has been finished.


The stock front mudguards and fork brace trimmed down and repainted.




And work started on a new clock and warning light surround.





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Title: Re: Not a cafe racer project K100
Post by: MaraudeRS on September 04, 2017, 03:17:33 AM
I like your idea of using the back part of the RS cowl for the new one. As mine is a 92 RS I was considering doing the same. Keep up the good work!


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Title: Re: Not a cafe racer project K100
Post by: Skunky on September 16, 2017, 09:32:16 AM
Good morning Brickers

This week has been an electrical and painting week. I was not happy with the paint on the rear tail piece so decided to reprint. I also rewired the tail lights shortened the cable and refitted the stock connector under the seat so that the seat can be removed. I then fitted a connector on the led light strip, wired in the resistors for the flasher circuit applied the decals and fitted the strip to the painted tail piece .

I also did more work on the fuel tank and the first four coats have been applied.


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Title: Re: Not a cafe racer project K100
Post by: Skunky on November 25, 2017, 03:07:53 AM
Greetings people. Build has been slow since September due to holidays work and life getting in the way. However I have spent time on the painting of the tank and I have finally finished and wired the speedo and warning light surround

(https://uploads.tapatalk-cdn.com/20171125/eab18c79bae28d67dab5816e769c20a7.jpg)



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Title: Re: Not a cafe racer project K100
Post by: Skunky on December 03, 2017, 04:27:02 PM
Operation Radiator revamp. The radiator although solid and not leaking was cosmetically in a sorry state so needed a revamp.
Title: Re: Not a cafe racer project K100
Post by: Martin on December 03, 2017, 04:40:00 PM
There are devices available to help straighten out cooling fins. Available from about $3.00 upwards, however they need to be used with care.
https://www.ebay.com.au/itm/A-C-Condenser-Radiator-Evaporator-Straightener-Fin-Comb-Rake-Cleaner-Tool/222624429526?hash=item33d57335d6:g:EG0AAOSwXf9ZoPnn I have also seen a special pair of pliers used by a radiator restorer but I'm not sure if they were custom as I have not been able to find them online.
Regards Martin.
Title: Re: Not a cafe racer project K100
Post by: Skunky on December 03, 2017, 06:24:36 PM
There are devices available to help straighten out cooling fins. Available from about $3.00 upwards, however they need to be used with care.
https://www.ebay.com.au/itm/A-C-Condenser-Radiator-Evaporator-Straightener-Fin-Comb-Rake-Cleaner-Tool/222624429526?hash=item33d57335d6:g:EG0AAOSwXf9ZoPnn (https://www.ebay.com.au/itm/A-C-Condenser-Radiator-Evaporator-Straightener-Fin-Comb-Rake-Cleaner-Tool/222624429526?hash=item33d57335d6:g:EG0AAOSwXf9ZoPnn) I have also seen a special pair of pliers used by a radiator restorer but I'm not sure if they were custom as I have not been able to find them online.
Regards Martin.


Thanks Martin


Overall there are about 5% or so that have fin damage and I decided to live with them for now and see how it shapes up in use. The fan is working well and worst case scenario is to buy another radiator .


https://www.ebay.co.uk/itm/For-Bmw-K100-Rt-Rs-Aluminum-Radiator-1985-1990-New-86-87-88-89-90/272747515077?epid=2230504805&hash=item3f8104ccc5:g:flsAAOSw74FXPcdy


The Apollo racing stainless steel look tempting.

Title: Re: Not a cafe racer project K100
Post by: Vespa no more on December 04, 2017, 03:16:11 AM
Is there something wrong here...


Laitch, your earlier history lesson bombed


Now getting back to codpieces, it is a well know fact that lined pants are very subtle.


https://www.youtube.com/watch?v=v921Sy9EaP8


Enjoy


Couple of us might have this song on vinyl


GF
Title: Re: Not a cafe racer project K100
Post by: Skunky on December 04, 2017, 04:44:25 AM
Is there something wrong here...


Laitch, your earlier history lesson bombed


Now getting back to codpieces, it is a well know fact that lined pants are very subtle.


https://www.youtube.com/watch?v=v921Sy9EaP8


Enjoy


Couple of us might have this song on vinyl


GF

Surely posting the Bee Gees is punishable offence.... :nono

https://www.youtube.com/watch?v=T-gZKRKNy4w
Title: Re: Not a cafe racer project K100
Post by: Vespa no more on December 04, 2017, 06:10:42 AM
No...


posting a clip of the Swingle Singers is a crime, or that Scot who won Slough's Got Talents,


Mine you, Kenny Everett throwing the bucket of water on Hot Gossip might pass muster.


Enough. Thought this was about K bikes
Title: Re: Not a cafe racer project K100
Post by: Skunky on December 07, 2017, 05:50:07 AM
No...


posting a clip of the Swingle Singers is a crime, or that Scot who won Slough's Got Talents,


Mine you, Kenny Everett throwing the bucket of water on Hot Gossip might pass muster.


Enough. Thought this was about K bikes
(https://uploads.tapatalk-cdn.com/20171207/ab729fabb1caf03995fba5a822db028d.jpg)

Cleaned, polished, painted ✔️



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Title: Re: Not a cafe racer project K100
Post by: DJEwen on February 18, 2018, 12:42:28 PM
(https://uploads.tapatalk-cdn.com/20171207/ab729fabb1caf03995fba5a822db028d.jpg)

Cleaned, polished, painted ✔️



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Skunky, they look excellent. What paint did you use on the covers, did you bother to bake them?
Title: Re: Not a cafe racer project K100
Post by: Skunky on February 18, 2018, 01:53:56 PM
No baking just engine paint. And polishing. I was happy with the results.
Title: Re: Not a cafe racer project K100
Post by: Skunky on May 10, 2018, 08:38:14 PM
Good Evening readers.

Due to health problems at home (not me) I have been unable to carry out any work since December. But I'm back on it in between carer duties so hopefully will make some progress. I may Put her back together and carry out further works as I go. Anyway Today I finished the re-wiring of the speedo to the BEP 3. Indicators, Lights , Speed, Warning panel all working OK except for a low fuel light which is ok as I have a fuel gauge on the speedo which is working off the fuel float. I will have to wait to check the RPM until the Engine is back together. Very pleased with the finish  :clap:.

 [ Invalid Attachment ]
Title: Re: Not a cafe racer project K100
Post by: DJEwen on May 11, 2018, 04:05:11 AM
Sorry to hear about your problems at home, Skunky.

Gauge and idiot lights are looking fantastic. Did you have any issues during wiring or can you share any lessons learned/tricks?
Title: Re: Not a cafe racer project K100
Post by: rbm on May 11, 2018, 06:42:51 AM
Hi Skunky,  check out http://www.motobrick.com/index.php/topic,10224.0.html for the fix to getting the tach working with that gauge and the BEP.
Title: Re: Not a cafe racer project K100
Post by: Skunky on May 11, 2018, 09:55:04 PM
Sorry to hear about your problems at home, Skunky.

Gauge and idiot lights are looking fantastic. Did you have any issues during wiring or can you share any lessons learned/tricks?

Thanks DJ.

No issues at all really just as long as you know what you require. The only thing I can't use is the low fuel light. There is a circuit within the lunchbox which operates the low fuel lights using a transistor so there's not an output for it on the BEP. I tried to make use of the fuel sender to do the job but to no avail. However when the fuel sender gets low the fuel display starts to flash so you know its desperate.

Anyway spent a couple of hours polishing the tank paintwork. Still not satisfied .

Hi Skunky,  check out http://www.motobrick.com/index.php/topic,10224.0.html for the fix to getting the tach working with that gauge and the BEP.

Rbm - I had already read your topic on the tacho smoothing and have studied the circuit. Marulabs claim that the BEP 3.0 unit has solved the Tacho issue from the earlier models and the 3.0 has a suppressed RPM circuit between 0 - 9V
 
A quote from their installation manual states -
 
" - RPM and SPD is output as a square wave signal, which means that the rotary pulses from the crankshaft or the rear wheel respectively, are changed in a changing frequency of low and high pulses."

I'm hoping that they are right but if not you'll be hearing from me  :yes



 
Title: Re: Not a cafe racer project K100
Post by: rbm on May 13, 2018, 07:32:59 AM
Rbm - I had already read your topic on the tacho smoothing and have studied the circuit. Marulabs claim that the BEP 3.0 unit has solved the Tacho issue from the earlier models and the 3.0 has a suppressed RPM circuit between 0 - 9V
You're right, but the problem is not with the BEP, it's with the gauge.  Read this thread to understand the fix I am suggesting:

http://www.motobrick.com/index.php/topic,11148.msg96987.html#msg96987
Title: Re: Not a cafe racer project K100
Post by: Skunky on May 15, 2018, 02:24:07 AM
You're right, but the problem is not with the BEP, it's with the gauge.  Read this thread to understand the fix I am suggesting:

http://www.motobrick.com/index.php/topic,11148.msg96987.html#msg96987

Thanks Robert. Very easy and very useful.  :clap:
Title: Re: Not a cafe racer project K100
Post by: Skunky on May 16, 2018, 03:40:32 PM
Hi Beemerphiles, I managed to get some time on my project last weekend.


Saturday I spent time trying to get a shine on the petrol Tank and fitted the petrol cap which I have stripped and polished the aluminium.


Title: Re: Not a cafe racer project K100
Post by: Skunky on May 16, 2018, 03:51:55 PM
Sunday


It was gearbox out day.


Checked Splines, not too bad.


Freed up and greased clutch arm


Checked clutch condition. Also not too bad, looks dry no sign of oil or grease and plenty of ware left.


Title: Re: Not a cafe racer project K100
Post by: DJEwen on May 16, 2018, 04:18:52 PM
Nice work, Skunky! Digging the polishing. Are those the black emblems? They look cool!
Title: Re: Not a cafe racer project K100
Post by: Martin on May 16, 2018, 04:20:26 PM
While you are there you need to fit a grease nipple to the arm. An occasional squirt will push out all the crap and make life easier for the cable and your arm'
Regards Martin.
 [ Invalid Attachment ]
Title: Re: Not a cafe racer project K100
Post by: Skunky on May 17, 2018, 07:58:11 PM
Evening campers


A little more progress today. Engine side casings and hoses back on. Swingman and drive back together and lived. Getting very close to a restart. Need to put in oil and rbm's Chinese speedo mod tomorrow.













Title: Re: Not a cafe racer project K100
Post by: Skunky on May 22, 2018, 05:42:44 PM
Morning brickers


Wheel and brake discís are being transformed


Title: Re: Not a cafe racer project K100
Post by: Martin on May 22, 2018, 06:44:08 PM
There's a cheat for masking wheels. Deflate the tyre and push in playing cards around the rim, fanning them out as you move around the rim. Mask up the remainder and paint,
Regards Martin.
Title: Re: Not a cafe racer project K100
Post by: Skunky on May 23, 2018, 04:38:00 PM
There's a cheat for masking wheels. Deflate the tyre and push in playing cards around the rim, fanning them out as you move around the rim. Mask up the remainder and paint,
Regards Martin.


Thanks Martin, I actually used a similar method. I used small overlapping strips of masking tape tucked under the rim like cards and then taped newspaper to the first layer.
Title: Re: Not a cafe racer project K100
Post by: DJEwen on May 23, 2018, 05:15:49 PM
Cracking work, Skunky!
Title: Re: Not a cafe racer project K100
Post by: Skunky on May 25, 2018, 06:38:34 AM
EXHAUSTION!!

On my very first post I wrote....



So started the strip down.......

I'm not one for giving a bike names but I have given this one many B######d F#####r piece of S##t and even the C word And at times all of them..

It would seem that although the Police mechanics maintain their fleet they do not use torque wrenches or anti seize. Bsds

The Exhaust had three stripped and crossed studs and no gaskets meaning it was corroded into place. One of the sockets snapped at the back and two studs had to be drilled out and re threaded but all done now



What I never added was that one of the headers (number 2) was stuck in the engine block and during removal came of off the pipe, with the help of a little corrosion and the brutal efforts of an overzealous amateur mechanic. Anyway because I wanted to use the original round exhaust and the header pipes would not come out of the silencer I decided to try a high temperature chemical weld called JB weld High Heat and was able to carry out a repair losing about 14" off the pipe length.
I then shortened the silencer and painted the header pipes etc etc.

It seemed like a good idea at the time, until the refit anyway. Could I get the BSTRD to fit?  No!. I found that I had an alignment problem and no amount of prising heating of pipes etc could shift them. In the end I decided to get the heavy rubber hammer into use with the intention of knocking the F**K out of it until the header came free of the back box. Still wouldn't shift, but after an hour of ugly brute force and a vocabulary that made Goodfella's look like a kids movie, I noticed that I had managed to shift the offending header forward enough to force a fit.  :clap:

However, JB high heat weld is Tough as duck and has been smashed survived heat from a blowtorch and did not crack or break. Pretty impressive. We will see how it deals with Britains pot hole infested roads. Photo's to follow.

 





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Title: Re: Not a cafe racer project K100
Post by: Skunky on May 27, 2018, 08:24:34 AM
What I never added was that one of the headers (number 2) was stuck in the engine block and during removal came of off the pipe, with the help of a little corrosion and the brutal efforts of an overzealous amateur mechanic. Anyway because I wanted to use the original round exhaust and the header pipes would not come out of the silencer I decided to try a high temperature chemical weld called JB weld High Heat and was able to carry out a repair losing about 14" off the pipe length.
I then shortened the silencer and painted the header pipes etc etc.

It seemed like a good idea at the time, until the refit anyway. Could I get the BSTRD to fit?  No!. I found that I had an alignment problem and no amount of prising heating of pipes etc could shift them. In the end I decided to get the heavy rubber hammer into use with the intention of knocking the F**K out of it until the header came free of the back box. Still wouldn't shift, but after an hour of ugly brute force and a vocabulary that made Goodfella's look like a kids movie, I noticed that I had managed to shift the offending header forward enough to force a fit.  :clap:

However, JB high heat weld is Tough as duck and has been smashed survived heat from a blowtorch and did not crack or break. Pretty impressive. We will see how it deals with Britains pot hole infested roads. Photo's to follow.
Title: Re: Not a cafe racer project K100
Post by: DJEwen on May 30, 2018, 04:06:07 PM
a vocabulary that made Goodfella's look like a kids movie

:hehehe

Great effort! Keep at it, Skunky!
Title: Re: Not a cafe racer project K100
Post by: Skunky on May 30, 2018, 07:11:59 PM
:hehehe

Great effort! Keep at it, Skunky!


Can't find the f'in exhaust bracket. Note to self. Try to work tidier.  :dunno2:




Anyway much like you. I put new oil, water, gearbox and final drive oil. Connected the speedo sensor ans span the wheel. And 8 mph on the speedo. Also wired in Rbms easy conditioning circuit before reporting the fuel tank. Might be ready for its first Start tomorrow. If I can just find where I put that petrol can.. :hehehe
Title: Re: Not a cafe racer project K100
Post by: DJEwen on May 31, 2018, 06:48:23 AM
In for first start video  :popcorm
Title: Re: Not a cafe racer project K100
Post by: Skunky on May 31, 2018, 04:59:08 PM
In for first start video  :popcorm
.
Don't hold your breath. Turns over OK. But would not start  :falldown:


So I need to go through everything and find out why. Checked the plugs and I'm getting a spark. seems to be a little fuel on the plugs but nor sure if there is enough or not. It could also be that there is not a full charge on the battery, I understand that they can be a little temperamental. So Overnight charge and give it another try in the morning. Failing that I will leave it until Wednesday and look at the fuelling.
Title: Re: Not a cafe racer project K100
Post by: Laitch on May 31, 2018, 05:59:41 PM
 :popcorm
Title: Re: Not a cafe racer project K100
Post by: Martin on May 31, 2018, 07:04:30 PM
Four pin plug under the right hand side of the petrol tank.
Regards Martin.
Title: Re: Not a cafe racer project K100
Post by: Skunky on June 03, 2018, 02:29:38 AM
Four pin plug under the right hand side of the petrol tank.
Regards Martin.
[/quotde]


Thanks Martin. I assume your talking about the fuel tank plug. I have already checked that. And cleaned all contacts. I didn't have time to delve too deeply as I was going away for a few days to celebrate my Dad's 84th birthday and visit my little Grand Monkey. Anyway fuel pump was working and I have fuel at the rail but not spitting out of the injectors. A quick check shows I have no voltages showing on the controller pins so that's where I will be going next. Probably due to the after market speedo installation. All the fuses are intact. I shall work through the wiring with Mr Haynes and sort it out tomorrow.

Title: Re: Not a cafe racer project K100
Post by: Skunky on June 03, 2018, 02:59:45 PM
Evening campers - Spent some time on the Bitch today. Started with Basics, remade all ground connections, opened cleaned and sealed all connectors under the tank. Then started working though Crazy Frog troubleshooting guide and the wiring diagrams. Anyway I found that the Fuel injection relay wasn't activating when the ignition was on and the Start button was pressed which I discovered was caused by a poor connection on the Ignition control unit. Great I thought and put her together for another try. Still would not start.
Back to the drawing board .


I have a couple of questions


Does the fuel pump only run when you press the Start button or should it run when the ignition is on?


And the same question with regard to the FI relay?



Title: Re: Not a cafe racer project K100
Post by: Laitch on June 03, 2018, 04:29:18 PM
Does the fuel pump only run when you press the Start button or should it run when the ignition is on? And the same question with regard to the FI relay?
The short answer is Yes, the FI relay closes and the pump runs only when you press the starter button, on your K100LT. An explanation of what happens is found in Vogel's troubleshooting document (http://hrsbstaff.ednet.ns.ca/bvogel/K100/download/bike-wont-start1.htm) if you scroll down through it about half way,
Title: Re: Not a cafe racer project K100
Post by: Skunky on June 04, 2018, 06:54:11 PM
The short answer is Yes, the FI relay closes and the pump runs only when you press the starter button, on your K100LT. An explanation of what happens is found in Vogel's troubleshooting document (http://hrsbstaff.ednet.ns.ca/bvogel/K100/download/bike-wont-start1.htm) if you scroll down through it about half way,

Thanks Laitch

I read Vogels step by step and have started working though it. Which is how I came by the FI relay not activating. I am at work for a couple of nights so won't be looking again until Wednesday or Thursday. I will be checking that the injectors are getting both positive and pulsing negative connections. And if not why not. I'm not sure how much of a fuel squirt I should see. I definitely have fuel pressure at the rail but there seems to be very little fuel on the plugs after trying to start. I would expect to see fuel escaping if I turn it over with a spark plug out. But I do not.
Title: Re: Not a cafe racer project K100
Post by: Skunky on June 06, 2018, 05:29:10 PM
Hi Brickers


I Decided to get the wheels back on and get the bike off of the blocks and then tomorrow I will deal with the starting issue.


Title: Re: Not a cafe racer project K100
Post by: Skunky on June 10, 2018, 06:13:57 AM
.
Don't hold your breath. Turns over OK. But would not start  :falldown:


So I need to go through everything and find out why. Checked the plugs and I'm getting a spark. seems to be a little fuel on the plugs but nor sure if there is enough or not. It could also be that there is not a full charge on the battery, I understand that they can be a little temperamental. So Overnight charge and give it another try in the morning. Failing that I will leave it until Wednesday and look at the fuelling.

Morning All

Yesterday was get the F##ker running day.

I armed myself with everything I needed to solve the starting issue. Multimeter, Electrical diagrams, De-oxit, Vogels non starting guide on my Laptop, Oil, Syringe, Patience and of course Cider.

Stage 1 - I opened cleaned and resealed all electrical sensors under the tank. Again!  :dunno

Stage 2 - Remove spark plugs, cleaned and checked the gaps. Then put a small squirt of oil in each cylinder to improve compression and smoke out the street  :nono. Put on the petrol tank and start..........................Still nothing  :dunno

Stage 3 - Start running through the Electrical system and Vogels check list. Injector and Temp sensor resistances were OK. Checked the FI relay had +12v and that +12v was reaching pin 9 on the ECU plug (and therefore the injectors) all good.
I then started on the negative pulsing from the by putting a 12v led between pin 9+ and pin 12 with the ecu plugged in and had no light up. I started to check the feed to the hall sensors and Airflow meter and when I was turning over the check to voltage I had a single pop ignition and a flash on the led. Bearing in mind the fuel tank was off at this time.
I refitted the tank and she started :clap: :clap: Smoke billowing down the street and very lumpy.
I let it run to burn off most of the oil and then removed and cleaned the plugs again. This time it started smooth as you like. :clap: :clap: :clap: :clap: :clap:
I would like to have found a definite fault but it appears the bike was just being reluctant.
 
Title: Re: Not a cafe racer project K100
Post by: rbm on June 10, 2018, 07:10:50 AM
Congrats on getting the F##ker running.  Seems yesterday was the worldwide "get the F##ker running" day because I helped a friend get his non-running K running.  It had been non-running since last year.  New plugs, fuel filter, and temp sensor cured the problems.
Title: Re: Not a cafe racer project K100
Post by: Skunky on June 10, 2018, 07:49:24 AM
Thanks rbm, The information available on this forum and from the Guys that in habit it make the Job easy really. I come from an age where as kids we were always stripping and rebuilding our bikes and cars. Albeit they were a lot simpler. I despair at my children who would never change a tyre let alone a spark plug! :dunno.

Your conditioning circuit worked a treat by the way  :2thumbup:

I will post a video when I can find a way to make one small enough for the forum.
Title: Re: Not a cafe racer project K100
Post by: Laitch on June 10, 2018, 08:01:04 AM
I will post a video when I can find a way to make one small enough for the forum.
Make a YouTube video and post a link to it. Wear a mask and use an assumed name if your actual surname is Skunky. :giggles Nobody will ever know.
Title: Re: Not a cafe racer project K100
Post by: Skunky on June 10, 2018, 08:26:54 AM
There is one on my Instagram gary skunk
Title: Re: Not a cafe racer project K100
Post by: Skunky on June 10, 2018, 11:38:21 AM
i refitted the tank and she started...

4 pin...


* free bizzaro.gif (2.17 kB . 93x85 - viewed 24 times)

Did the 4 pin about a dozen times. She actually fired first time with the tank off :dunno. That's how I knew she would start.  :neener:
Title: Re: Not a cafe racer project K100
Post by: johnny on June 10, 2018, 11:40:25 AM
demonstrates sometimes a dozen aints enough...

does the steering go to full lock before those mirrors hit the tank...
Title: Re: Not a cafe racer project K100
Post by: DJEwen on June 10, 2018, 02:20:14 PM
Well done, Gary! Got a finished photo shoot?
Title: Re: Not a cafe racer project K100
Post by: Skunky on June 11, 2018, 06:29:08 PM
demonstrates sometimes a dozen aints enough...

does the steering go to full lock before those mirrors hit the tank...

Yes it does Johnny , Otherwise they would be up
Title: Re: Not a cafe racer project K100
Post by: Skunky on June 11, 2018, 06:31:17 PM
Well done, Gary! Got a finished photo shoot?

Still not quite finished Dave, Have to make side panels and number plate holder lights.  etc. Then MOT etc. but she sounds good.

Title: Re: Not a cafe racer project K100
Post by: Skunky on June 11, 2018, 06:36:44 PM
So especially for Laitch but for anyone else a quick video.

https://www.youtube.com/watch?v=1vXL6DoMNeY




Title: Re: Not a cafe racer project K100
Post by: Filmcamera on June 11, 2018, 08:13:37 PM
Very nice looking bike! Congratulations and enjoy riding, it actually looks comfortable...
Title: Re: Not a cafe racer project K100
Post by: Laitch on June 12, 2018, 01:20:41 AM
Looking refined and elegant, Skunky! Thanks for the vid. Good luck with the MOT. It must be wonderful to be so well-protected from yourself. :giggles
Title: Re: Not a cafe racer project K100
Post by: Skunky on June 12, 2018, 06:54:15 AM
Looking refined and elegant, Skunky! Thanks for the vid. Good luck with the MOT. It must be wonderful to be so well-protected from yourself. :giggles

Laitch, Not entirely sure what you mean :dunno. But if I was well protected I wouldn't have so many toys,

 or genital warts. :hehehe
Title: Re: Not a cafe racer project K100
Post by: Laitch on June 12, 2018, 08:57:02 AM
Laitch, Not entirely sure what you mean :dunno . But if I was well protected I wouldn't have so many toys,

 or genital warts. :hehehe
I mean your government loves you, wants what's best for you and expresses that through the MOT. As far the warts, try an old scouring pad. :giggles
Title: Re: Not a cafe racer project K100
Post by: Skunky on June 12, 2018, 05:55:30 PM
I mean your government loves you, wants what's best for you and expresses that through the MOT. As far the warts, try an old scouring pad. :giggles

That's how I got em!!. Remember Kids, NEVER share needles or genital scouring pads.   :hehehe
Title: Re: Not a cafe racer project K100
Post by: Skunky on June 20, 2018, 10:32:04 PM
Morning. 

Recycle/design/rehash/paint/wrap = Rear number plate holder  :clap:

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Title: Re: Not a cafe racer project K100
Post by: DJEwen on June 21, 2018, 12:33:06 PM
Nice bit of up-cycling, Skunky.
Title: Re: Not a cafe racer project K100
Post by: Skunky on June 28, 2018, 06:24:45 PM
Morning Brickers

Lots of thought of where I will put the ignition switch. Played with lots of ideas and then decided on the following using another piece of the recycled sign.

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Title: Re: Not a cafe racer project K100
Post by: The Mighty Gryphon on June 28, 2018, 07:17:12 PM
Here is some serious sign recycling at the Meadville, PA highway department:
Title: Re: Not a cafe racer project K100
Post by: Skunky on July 04, 2018, 03:46:02 AM
Good Morning World.

Spent the last few days finishing off the Machine and then took it for its MOT. The garage where I go are very accommodating and looked her over before the test and advised me of the following.
Under new legislation the indicators on a motorcycle over 50cc need to be more than 240mm apart at the rear and more than 300mm apart at the front. When you consider that a 7 inch headlight is only 177mm wide that means that unless your Bike has long stalks it could fail an MOT. The tester told me that most bikes already fail this requirement!
Anyway I need to add extra indicators to the rear, he will let the front go through. New indicators ordered.

Also the rear brakes were binding. I had bought new pads and the inside pad seems to be dragging. When I looked closely it seems that the rear calliper does not sit centrally over the disc. There was not any shim fitted when I took the disc off for cleaning and I could not see any on my Haynes manual. I ended up sanding down the inside disc and it's moving freely now.

I need to play with the bike a bit. Its running a little lumpy and I'm getting popping and the occasional backfire. Wakes up the pedestrians  :hehehe. The bike starts on the button and idles ok. Does not need the choke either. I think I may need to look at the air mixture or possibly ignition timing. If I get no joy I will post a video.
Title: Re: Not a cafe racer project K100
Post by: Laitch on July 04, 2018, 10:11:39 AM
Under new legislation the indicators on a motorcycle over 50cc need to be more than 240mm apart at the rear and more than 300mm apart at the front.
:laughing-on-ground:
Title: Re: Not a cafe racer project K100
Post by: Skunky on July 04, 2018, 12:08:27 PM
Looking refined and elegant, Skunky! Thanks for the vid. Good luck with the MOT. It must be wonderful to be so well-protected from yourself. :giggles

I think OVERprotected is more apt Laitch  :clap:
Title: Re: Not a cafe racer project K100
Post by: The Mighty Gryphon on July 04, 2018, 02:19:17 PM
Popping is most likely an exhaust leak, either at the head or the header to silencer connection.  Also, you need to completely close the throttle when decelerating.

Lumpy running may be varnished injectors.  A couple tanks of fuel with fuel system cleaner run through at high rpms can help this a lot.  Possibly one of the most enjoyable service procedures you can do to your bike.
Title: Re: Not a cafe racer project K100
Post by: Skunky on July 04, 2018, 04:04:05 PM
Popping is most likely an exhaust leak, either at the head or the header to silencer connection.  Also, you need to completely close the throttle when decelerating.

Lumpy running may be varnished injectors.  A couple tanks of fuel with fuel system cleaner run through at high rpms can help this a lot.  Possibly one of the most enjoyable service procedures you can do to your bike.

Hi Gryph, I agree whole heartedly, I need to get some miles in and get the injectors cleaned out. I've added fuel/injector cleaner into the tank and will continue to do so for at least 200 miles. As for the popping and backfiring, i'm suspecting either air mix or temp sensor as it was running rich before work commenced. Again though as the bike hasn't run for 6 years I need to get everything settled down first. Every time I ride it gets a little better.

I should get the MOT done on Monday/Tuesday next week then I'm burning up miles.
Title: Re: Not a cafe racer project K100
Post by: The Mighty Gryphon on July 04, 2018, 04:13:37 PM
My 16V K100RS had sticky injectors when I got it.  They weren't bad enough to justify the hassle and cost of removing and sending them out for cleaning so I ran cleaner in the tank for a thousand or so miles.  I still remember when they finally broke completely free, what a sweet feeling!  Like a supercharger kicking in.
Title: Re: Not a cafe racer project K100
Post by: DJEwen on July 05, 2018, 02:39:57 AM
I should get the MOT done on Monday/Tuesday next week then I'm burning up miles.

Good luck, Skunky!

Neither my front (either side of a 6.5" ShinYo headlight) or rear indicators (bolted to either side of the frame hoop) are 300mm apart, Triple S went through with no advisory's, MOT Testers discretion I believe.

Title: Re: Not a cafe racer project K100
Post by: Skunky on July 05, 2018, 03:27:11 AM
Good luck, Skunky!

Neither my front (either side of a 6.5" ShinYo headlight) or rear indicators (bolted to either side of the frame hoop) are 300mm apart, Triple S went through with no advisory's, MOT Testers discretion I believe.

He's letting the front go through which are 240mm. But he wasn't happy with the rear LED strip indicators when the brake lights were on as the yellow doesn't show clearly, so I'm putting a couple of additional ones on. TBH I had to agree with him. He also pointed out that the new headlight beam isn't the right shape. But as it's an e-marked light he's letting that through too. It just goes to show that even if you buy e-marked gear made for British roads they still might not be good enough. 
Title: Re: Not a cafe racer project K100
Post by: Skunky on July 11, 2018, 04:44:28 PM
Enough Said. Time to get some miles in.

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Title: Re: Not a cafe racer project K100
Post by: DJEwen on July 11, 2018, 05:16:17 PM
Congratulations, Skunky!!

Any advisoryís?
Title: Re: Not a cafe racer project K100
Post by: Skunky on July 12, 2018, 01:45:42 AM
No Advisory's. I need to give her a good run now.
Title: Re: Not a cafe racer project K100
Post by: Laitch on July 12, 2018, 07:27:04 AM
A Skunk brand forkónice!

How about post a 360ļ photo array of this specimen, Skunky?
Title: Re: Not a cafe racer project K100
Post by: Skunky on July 12, 2018, 12:14:20 PM
A Skunk brand forkónice!

How about post a 360ļ photo array of this specimen, Skunky?

I need to do one of those video shoots cool place, funky music. before and after... Where will I find the time to ride the BSTD  :hehehe  etc etc.
Title: Re: Not a cafe racer project K100
Post by: Skunky on July 14, 2018, 10:35:22 AM
Brotherhood of the Beemer hear my confession. Insanity! Distraction! or Just Early Stage dementia I am not sure......

Last Sunday I took off the rear tail piece,(which I had so lovingly created using a broken tail from an RS instead of the slightly clumsier tail from the LT), In order to fit some additional Indicators to satisfy the MOT gods. Fitted the indicators and later that evening went for a short run down a fast dual carriageway for a "check everything was OK" joy ride. Got back home minus the tail!!!!

Went back out and recovered it.

And this.......


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Became this.........


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To say that I was pissed off would be an understatement. But it was me that put the tailpiece back on, and me that didn't put the screws back in. Oh and me that has to bear the bits falling off criticism and the "what else haven't you done up" Jibes from her in doors. 
I quickly knocked up an alternative tail from the LT one that I hag in the Garage (As you Do). But it doesn't fit the seat properly. I managed to get another rs tail unit from DJ Ewen which I will start work on this week. 



Apart from that the bike is finished and on the road and getting better every time I ride it. I will take the time to take some more photos etc and paste them up when I get time.


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Title: Re: Not a cafe racer project K100
Post by: Skunky on July 20, 2018, 11:11:34 AM
Hi Beemerphiles

My BMW gets better and better I can see why you love them so much. I have created a hooligan with a sofa comfortable ride

Anyway Thanks to DJewen who sold me the tail from his bike so that I could replace the one that I smashed, I decided to change the design slightly to sink the light strip in flush.

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Then the reshaping

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Filling and rubbing down

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Undercoat

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Topcoat and Decals

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Looks OK to me


Title: Re: Not a cafe racer project K100
Post by: beemuker on July 20, 2018, 04:13:09 PM
Wow thanks Skunky this whole thread has been very entertaining
Title: Re: Not a cafe racer project K100
Post by: Skunky on July 20, 2018, 04:39:00 PM
A photo of my hareem

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Title: Re: Not a cafe racer project K100
Post by: beemuker on July 20, 2018, 04:41:44 PM
A photo of my hareem


too much glare in the windows, but the bikes look great. well done
Title: Re: Not a cafe racer project K100
Post by: Skunky on July 20, 2018, 04:53:04 PM
too much glare in the windows, but the bikes look great. well done

Caught me out there. The window cleaner had been. Normally filthy. :eek:
Title: Re: Not a cafe racer project K100
Post by: beemuker on July 20, 2018, 04:56:19 PM
Caught me out there. The window cleaner had been. Normally filthy. :eek:
I mean, too much glare to see the harum :neener:
Title: Re: Not a cafe racer project K100
Post by: Skunky on July 20, 2018, 05:35:16 PM
There you go

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Title: Re: Not a cafe racer project K100
Post by: beemuker on July 20, 2018, 06:30:12 PM
 Nice I think the black and white works really well really shows off the awesome looking Engine and mine is a yellow case 75 s and I feel like the lighter colors with the black engine and really show  show it off
Title: Re: Not a cafe racer project K100
Post by: Skunky on July 24, 2018, 03:43:14 PM
Side Stand Mk3

When I first got the bike the side stand was snapped so I sourced and and purchased a replacement from fleabay. Cleaned and painted it looked ok. About the second or third use it snapped in the same place as the original!!!!!. After gnashing my teeth and cursing purfusily. I threw my hands in the air and said f##k it, Iíll use the main stand. Anyway come the real world of daily use, I soon realised what a pain it is on my slightly sloping driveway. Stop the bike pull it on the stand, open the garage, lift it off the stand drive in, lift in back. So the answer is get another side stand.
I searched for and acquired another stand this time from a K1100 as popular opinion and rumour say they are stronger.

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The stand has been stripped back to bare metal and painted with engine enamel. The last picture is me filling the tube with the paint to stop internal corrosion.
Title: Re: Not a cafe racer project K100
Post by: DJEwen on July 24, 2018, 03:55:51 PM
Fantastic job on the new tail, Skunky. Well done.
Title: Re: Not a cafe racer project K100
Post by: Skunky on July 28, 2018, 08:09:42 AM
Finished the last bits and pieces.

Made new brackets and fitted the new Tailpiece MK3 with the light strip sunk into the tail. Looks much better I think. I also used rubber well nuts and allen bolts for a better looking and stronger fit. 


* file-26.jpeg (69.36 kB . 768x576 - viewed 545 times)
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Fitted the replacement Side Stand. Or as DJewen called it the Suicide stand. What a mad idea a stand that springs back up and is impossible to put down while sitting on the bike. I find if you get off, put it down with your boot you can lower the bike onto it. Never seen one like this before though  :dunno.   

Finally Calibrated the speedo. I took the bike out with a GPS program on my mobile phone and it was within 2 MPH. GPS show 40 Speedo said 38 No changes required.  The cheapo Chinese speedo works great. The indicator lights are clear and bright and its accurate. I can say first impressions are that it was a bargain at £21.00 Sterling. I will update on its long term reliability.


Title: Re: Not a cafe racer project K100
Post by: Skunky on July 28, 2018, 10:46:38 AM
(http://www.motobrick.com/gallery/1/5132-280718073736-16071117.jpeg)
Title: Re: Not a cafe racer project K100
Post by: Skunky on August 02, 2018, 05:33:24 PM
It seems I canít park without taking a photo


(http://www.motobrick.com/gallery/1/5132-020818113218-1610360.jpeg)


(http://www.motobrick.com/gallery/1/5132-020818113219-1610260.jpeg)










 
Title: Re: Not a cafe racer project K100
Post by: Skunky on August 30, 2018, 08:16:58 AM
A few more photos. Since I finished I painted the exhaust and the Radiator grill black and fitted new tyres. I split the use between the BMW and my Triumph and I am loving it. She continues to run like a dream with no Issues. Itís a great bike 😀.

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Title: Re: Not a cafe racer project K100
Post by: Skunky on September 18, 2018, 08:36:07 PM
Hey People. Just thought I would share the cost of my Build. Being Anal I kept a spread sheet.

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I think it was a bargain. Still going great and still turning heads   :clap:
Title: Re: Not a cafe racer project K100
Post by: johnny on September 18, 2018, 09:07:13 PM
greetings...

needs skunk tail handlebar tassels... and a skunk head on the front side of that cluster...

j o
Title: Re: Not a cafe racer project K100
Post by: Skunky on September 18, 2018, 09:38:56 PM
greetings...

needs skunk tail handlebar tassels... and a skunk head on the front side of that cluster...

j o

That's a skunk face cluster and theres already a Skunk head inside the helmet. Or is that a helmet inside the skunk head.
Title: Re: Not a cafe racer project K100
Post by: Skunky on May 22, 2019, 06:47:37 AM
Morning folks

Been a long time since I posted here. Bikes still going well but I have a list of things I need to attend to.

1)  Sort out the air balance. Still runs rich. The plugs need regular cleaning.

2)  The Fan is not coming on. Possibly its not getting hot enough but I suspect either the relay or sensor.

3)  Bloody Starter motor. Had to jump start it a few times. Just found out about the reverse sprag thing. But its working again at the moment.

4)  Fuel light, Not really important as I have a working gauge.

Still looks good though

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Title: Re: Not a cafe racer project K100
Post by: Skunky on June 01, 2019, 05:24:49 AM
Morning folks

Been a long time since I posted here. Bikes still going well but I have a list of things I need to attend to.

1)  Sort out the air balance. Still runs rich. The plugs need regular cleaning.

2)  The Fan is not coming on. Possibly its not getting hot enough but I suspect either the relay or sensor.

3)  Bloody Starter motor. Had to jump start it a few times. Just found out about the reverse sprag thing. But its working again at the moment.

4)  Fuel light, Not really important as I have a working gauge.

Still looks good though


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Had some time yesterday.

1)  Sort out the air balance. Still runs rich. The plugs need regular cleaning.

Carried out a throttle body Balance using a set of vacuum gauges. And then tried the lean drop method to try to clean the CO2 mix. Seems to be running much smoother and cleaner. The adjusted is a fiddly little sucker to get to with my oversized mitts. It was really out a long way so I expect it to be better. I will run it for a while and chack for further soot.   

3)  Bloody Starter motor. Had to jump start it a few times. Just found out about the reverse sprag thing. But its working again at the moment.

Tried the reverse sprag cleaning thing a few times and it starts fine. I'm not actually sure if it isn't battery/alternator related as when it stopped working I lost the indicators lights and horn. I always leave my bikes on trickle chargers so it's always OK when I first start and leave but tends to fail later. Further investigation to follow.

4)  Fuel light, Not really important as I have a working gauge.

Title: Re: Not a cafe racer project K100
Post by: Skunky on July 25, 2019, 01:29:22 PM
Had a good day. The Beemer and my Thruxton passed their NOT tests today. The tester failed my K on throttle return sticky until I showed him the adjuster screw.

Still I in love💘

Title: Re: Not a cafe racer project K100
Post by: billday on July 25, 2019, 03:05:56 PM

3)  Bloody Starter motor. Had to jump start it a few times. Just found out about the reverse sprag thing. But its working again at the moment.

Tried the reverse sprag cleaning thing a few times and it starts fine. I'm not actually sure if it isn't battery/alternator related as when it stopped working I lost the indicators lights and horn. I always leave my bikes on trickle chargers so it's always OK when I first start and leave but tends to fail later. Further investigation to follow.

Euromotoelectrics sells a starter service kit that includes replacement brushes. Not much money and not a difficult job once you master pulling the starter motor. Worn starter motor brushes can lead to oddball electric issues, so this is totally worth doing.

As far as the sprag clutch, run the proper motor oil and that shouldn't be a problem.

Keep enjoying your K!
Title: Re: Not a cafe racer project K100
Post by: Skunky on July 26, 2019, 02:22:53 AM
Euromotoelectrics sells a starter service kit that includes replacement brushes. Not much money and not a difficult job once you master pulling the starter motor. Worn starter motor brushes can lead to oddball electric issues, so this is totally worth doing.

As far as the sprag clutch, run the proper motor oil and that shouldn't be a problem.

Keep enjoying your K!

I. Already stripped the starter and found the brushes to be ok. However the copper contacts were really cruddy and scortched. 20 minutes with a wire brush did the job. I've had no starter trouble since 😁
Title: Re: Not a cafe racer project K100
Post by: Skunky on October 24, 2019, 07:41:12 AM
Had a seal go on the front forks so stripped the wheel off and fitted new ones. Used a variation on Jonnyís plastic bag trick.

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Title: Re: Not a cafe racer project K100
Post by: DJEwen on October 24, 2019, 07:50:45 AM
Looks clean, Gary.

How are you getting on with the Honda?
Title: Re: Not a cafe racer project K100
Post by: Skunky on October 26, 2019, 05:59:25 PM
Looks clean, Gary.

How are you getting on with the Honda?


Taking too long. I bought an old school Audi TT that needed work and had a few jobs todo on the K. Frame is done and some of the chrome but still a long way to go
Title: Re: Not a cafe racer project K100
Post by: Skunky on January 29, 2020, 05:45:20 PM
Iíve taken my K bike off the road to revisit areas that I want to improve. Iím going to upgrade the handlebar controls and switches but without losing any functionality. I will also take the opportunity to change the brake lines and change some of the dodgy connectors. (Starting with the 4 way to the fuel tank) replacing them with new waterproof connectors. Just about have everything I need so here goes.  [ Invalid Attachment ]
Title: Re: Not a cafe racer project K100
Post by: Skunky on February 01, 2020, 06:28:22 AM
Completed some work over the last few days . Stripped down the controls brake and clutch levers and removed brake lines and fluid. I bought a slim choke control from a motoguzzi which will sit next to the new buttons and shortened the choke cable outer and make a new end to fit to the motoguzzi lever. I think it looks ok.
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Title: Re: Not a cafe racer project K100
Post by: Skunky on February 01, 2020, 07:05:49 AM
Sorry second image didnít attach

Title: Re: Not a cafe racer project K100
Post by: Skunky on February 12, 2020, 04:58:36 AM
Hi Kids. 

As part of the ongoing handlebar upgrade I decided to fit bar end indicators. Mainly because I park my bikes in a garage next to the wall I decided to go for a cheaper unit and see how they work so I purchased the following units for what can only be described as peanuts.

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The Indicators came and to my astonishment don't look too shabby. They have both white and yellow LED's in and are pretty bright. The only downfall is that when the white light is on the yellow indicator does not show up very well when the indicators are running. Other than turning the lights off when I indicate (which I will no longer be able to do when the handlebar switches are finished), the only other option is to have a circuit that turns the white light off when the turn signal is received, as seen on new cars with LED day running lights.
I decided to fall back on my very basic electonics training and build a circuit to do the job.
So using a 12v relay a capacitor and a diode I came up with a very basic circuit that as Boris say's "Gets it Done!"

I made a video of the result just follow the link. 

https://www.youtube.com/watch?v=o7yz0aH_EFI
Title: Re: Not a cafe racer project K100
Post by: billday on February 12, 2020, 06:47:33 AM
Those do look decent, and congratulations on figuring out the wiring.

I wonder about the safety of white running lights on the handlebar ends, though. Mightn't that confuse the already dim-witted motorist? Will it pass inspection?
Title: Re: Not a cafe racer project K100
Post by: Skunky on February 12, 2020, 07:44:44 AM
Those do look decent, and congratulations on figuring out the wiring.

I wonder about the safety of white running lights on the handlebar ends, though. Mightn't that confuse the already dim-witted motorist? Will it pass inspection?

Technically on the British MOT you should not have a white light facing toward the rear so an over enthusiastic Tester could see it as a problem in which case I'll disconnect it. As for the dim-witted motorist anything that makes us more visible has to help.   
Title: Re: Not a cafe racer project K100
Post by: Skunky on March 01, 2020, 02:45:35 PM
Been busy with life for a few weeks but a stinking cold means I managed to spend time on the handle bar project over the weekend. Sitting down in the warm with a soldering iron and a pile of components is the best  cold treatment Ever.
I have wired the handle bar switches and connectors and the indicator wires are in position for the bar end units. Ready to start the refit.

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Title: Re: Not a cafe racer project K100
Post by: billday on March 01, 2020, 04:58:57 PM
Elegant.
Title: Re: Not a cafe racer project K100
Post by: Skunky on March 01, 2020, 06:02:36 PM
Elegant.
Thanks Billday. I'm pleased with how its shaping up. More time on it tomorrow.
Title: Re: Not a cafe racer project K100
Post by: Skunky on March 29, 2020, 04:12:14 AM
Small side project. Replace the annoying and letís face it, notoriously unreliable 4 way connector to the fuel tank and put it in a more accessible location so that I donít have to remove the sides to get the tank off


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Title: Re: Not a cafe racer project K100
Post by: volador on March 29, 2020, 07:09:14 AM
Nice work. Just an observation looks like green and yellow are reversed
Title: Re: Not a cafe racer project K100
Post by: Skunky on March 29, 2020, 07:25:42 AM
Nice work. Just an observation looks like green and yellow are reversed

No they are the right way round. Bike starts runs and roars  112350
Title: Re: Not a cafe racer project K100
Post by: Skunky on April 01, 2020, 04:25:48 PM
Finished the handlebar upgrade all the switches are wired and working, with the wires running through the bars. Iíve also fitted new levers, master cylinder and brake hoses. The brake switch has been replaced with a pressure switch at the calliper. I have managed to retain all of the original functionality including the self cancelling feature.

A few pictures and a video below.

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https://youtu.be/5ZJyriTVh7o


Title: Re: Not a cafe racer project K100
Post by: AtLarge on April 01, 2020, 06:55:28 PM
Very clean install  112350
Title: Re: Not a cafe racer project K100
Post by: Texer on April 04, 2020, 05:29:54 AM
Nice work and result - thanks for posting the great video.
Title: Re: Not a cafe racer project K100
Post by: milq on April 04, 2020, 11:26:16 PM
Those switches look nice and clean. Are they made by MotoGadget?
Title: Re: Not a cafe racer project K100
Post by: Skunky on April 05, 2020, 02:52:06 PM
Those switches look nice and clean. Are they made by MotoGadget?

In Answer to Milq and another question asked by sr20clubbie

The switches are not Motogadget just ones from ebay. I wanted to reduce the size of the cables as I was running it through the handlebars. I also decided to only have switched negative reducing the chances of shorts in the switches and lowering the voltages so I used a 4 way relay board and switch the starter, high/low beam and cutout switch through that. I also fitted a changeover relay for the cutout as the cutout switch is momentary. I wanted to keep the BMW flasher unit as I like the auto cutout function as I'm lazy and have been known to leave my indicators on.

The Choke lever is from a Motoguzzi V11. i used all the existing BMW cables but had to make new cable end on the choke. It all works great.
Title: Re: Not a cafe racer project K100
Post by: billday on April 05, 2020, 06:07:55 PM
Well done!
Title: Re: Not a cafe racer project K100
Post by: sr20clubbie on April 11, 2020, 04:19:29 AM
Hi Skunky, what brake and clutch levers did you use?
Title: Re: Not a cafe racer project K100
Post by: Skunky on April 11, 2020, 05:11:42 AM
Hi Skunky, what brake and clutch levers did you use?

sr20clubbie I used a set which are common on e-bay. However I had to make alterations to make them fit to the switches. I cut off the mirror fixings and repainted. I also did away with the brake light switch and replaced it with a pressure switch on the front callipers.

I was also not sure whether the brake master cylinder would be man enough but itís better than the oem unit
Title: Re: Not a cafe racer project K100
Post by: sr20clubbie on April 11, 2020, 05:19:02 AM
Hey Skunky, thanks for that,Iíll have a look around is there a particular size reservoir thatís needed.
Also where did you buy the choke lever from.

Thanks mate.
 
Title: Re: Not a cafe racer project K100
Post by: sr20clubbie on April 11, 2020, 05:21:18 AM
I just seen the 7/8th size there. 
Title: Re: Not a cafe racer project K100
Post by: Skunky on April 11, 2020, 12:31:33 PM
7/8ths is 22mm which is the right size
Title: Re: Not a cafe racer project K100
Post by: sr20clubbie on April 11, 2020, 08:50:48 PM
Hey Skunky, I actually meant what bore size. Most of the aftermarket ones I have seen are 14mm, I think I need a 19-20mm bore size (correct me if Iím wrong) did you get rid of the abs system?

Cheers Paul
Title: Re: Not a cafe racer project K100
Post by: Skunky on April 12, 2020, 02:58:19 AM
Hey Skunky, I actually meant what bore size. Most of the aftermarket ones I have seen are 14mm, I think I need a 19-20mm bore size (correct me if Iím wrong) did you get rid of the abs system?

Cheers Paul

I have rental bars on mine which have the smaller bore and I changed the rubber on the bar ends to make them fit. You can get indicators for 22mm bars. My bike did not have ABS fitted. But plenty of guys have removed theirs.

Quote from: sr20clubbie link=topic=10301.msg120670#msg120670
date=1586596742

Also where did you buy the choke lever from.
 

E bay Motoguzzi V11
Title: Re: Not a cafe racer project K100
Post by: Skunky on April 19, 2020, 07:52:13 AM
Due to the Pandemic I seem to have a lot more time on my hands lately, So after completing the Handlebar Switches I started looking at what else I can improve.

When I finished the bike in 2017 the mechanic at the MOT centre did not like the rear strip light because when the brake lights are on the integral indicators do not show up. So to make him happy (and keep me safer because he was right) I fitted a pair of mini indicators either side of the rear tail unit. Problem solved.

So why does it still piss me off!. Even after recently fitting bar end indicators I scoured flea bay until I found a light strip where the supplier claims the indicator sections are still visible when the brake light is on and ordered it.

Although slightly thicker meaning I had to make a subtle adjustment to the rear tail piece it actually works. I have taken photos of the old and new lights strips but because of the glare it doesn't look that different in the photos. So heres two pictures that look almost the same  :laughing4-giggles:

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Title: Re: Not a cafe racer project K100
Post by: Skunky on May 13, 2020, 04:45:28 PM
As an extension to the handlebar project. I decided to make switch ikon but the print sheet is so big I thought I would make my own tank badges to suit the Skunk theme.


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Title: Re: Not a cafe racer project K100
Post by: sj2000 on July 05, 2020, 12:58:07 AM
Wondering if you can draw the diagram of how you connect the switches, could you please take a picture how you connect the brake switches, thanks. The bike looks nice with all modern accessories. 112350