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TECHNICAL MOTOBRICK WRENCHING In Remembrance of Inge K. => Project Classic Motobricks => Topic started by: koshak on February 19, 2020, 10:32:58 AM

Title: 1989 K75 reanimation
Post by: koshak on February 19, 2020, 10:32:58 AM
Hello

One day sitting in Cyprus was scrolling Latvijan online advertisements for the bikes, and saw her:
(https://i.postimg.cc/KvyDFLn1/01.jpg)

Just one photo, declared millage 43k km.
Called seller, he told the story that bike was bought in Spain somewhen 15 years ago, moved to Latvija, made local registration and.... locked in garage for these 15 years.

My friend colleague was going to Christmass holidays over there (his hometown), so he had a brief look at the bike and purchased on my behalf, moved to another storage.
Then we found who can make shipment.
So carrier picked up the bike from storage location, moved to workshop to create a box, and then loaded into container.

(https://i.postimg.cc/m2NNrDw8/02.jpg)

(https://i.postimg.cc/T3dj56NG/03.jpg)

(https://i.postimg.cc/Sx19Xzz7/07.jpg)

Since bike was abandoned for 15 years, no tests were done at purchase. The only was known that windshield is broken, one mirror fell off, scratches here and there...
(https://i.postimg.cc/nL5qWQFc/04.jpg)

(https://i.postimg.cc/8cgMpQf2/05.jpg)

(https://i.postimg.cc/d3RdDH8L/06a.jpg)

So from Riga it moved to Klaipeda, then through Rotterdam to Antwerpen, where it stuck for about a week while waiting proper taxi.

Finally, vessel with strange name SEAGO ISTANBUL loaded container onboard on 26 of January and departed to destination.
(http://www.motobrick.com/gallery/2/6834-190220101038.jpeg)

The journey has started.
(https://i.postimg.cc/vZZ9HvDZ/09.png)


The imagination painted all sorts of horror pictures of what could happen to a container ship (https://kot-3axap.livejournal.com/14531.html) in the Bay of Biscay during the icy winter season ...

(https://i.postimg.cc/7YV0kRHR/10.jpg)

(https://i.postimg.cc/vm1V5HrR/11.png)

... as a motorcycle emerges somewhere on a foreign mainland (https://www.smithsonianmag.com/travel/motorcycle-rode-tsunami-180960327/)

(https://i.postimg.cc/fb60CnCV/13.jpg)

... or even disappear in the depths (https://kot-3axap.livejournal.com/21018.html) of the sea to the joy of Poseidon (https://kot-3axap.livejournal.com/21422.html)

But the brave vessel gloriously overcame the dangers of the Atlantic Ocean, waiting for him on every wave, and prepared to enter the calmer Mediterranean Sea. Just to pass that traffic...

(https://i.postimg.cc/xCMNFxpt/14.png)

Finally port of destination appeared on the map.

(https://i.postimg.cc/hv0zKJBm/16.png)


Title: Re: 1989 K75 reanimation
Post by: billday on February 19, 2020, 11:01:36 AM
What a tale!

That crate was a thing of beauty.
Title: Re: 1989 K75 reanimation
Post by: The Mighty Gryphon on February 19, 2020, 12:25:34 PM
That crate was a thing of beauty.

I was thinking the same thing when I first saw it.
Title: Re: 1989 K75 reanimation
Post by: Rcgreaves on February 19, 2020, 12:43:42 PM
Terrific story.  How tall are you?  factory low seat. 
Title: Re: 1989 K75 reanimation
Post by: Laitch on February 19, 2020, 03:02:34 PM
 44271 icon_cheers A Homeric account, koshak—a tale certain to be told around burn barrels and in coffee houses from Istanbul to Tucumcari and beyond.
Title: Re: 1989 K75 reanimation
Post by: volador on February 20, 2020, 12:42:14 AM
He who would go to sea for pleasure would go to Hell for a pastime
Title: Re: 1989 K75 reanimation
Post by: koshak on February 20, 2020, 03:56:09 AM
Terrific story.  How tall are you?  factory low seat.
185. but irrespective of that fact would like to convert to regular seat, to eliminate that "tank cover".
but not sure how to recognize precisely suitable seat on ebay, and also they are without mountings... Did not investigate deeply yet.
Title: Re: 1989 K75 reanimation
Post by: koshak on February 20, 2020, 04:49:17 AM
So finally vessel arrived.
(https://i.postimg.cc/0jvKgYLx/17.png)

That is another story how i tried to get bike out, will skip...
After a week came to customs warehouse for "goods inspection".

(https://i.postimg.cc/jdZw9Jv0/18.jpg)

Had to open box for customs officer to verify frame and engine numbers and mileage. There were hundreds of screws, had to declare to customs officer that actually it is not a bike import but golden screws.

And here she is, a first look at a new girlfriend, the first timid touch, a gentle wipe of the number on the frame ...
(https://i.postimg.cc/qvFtBV91/19.jpg)

Inspection completed, numbers verified. Was lucky enough to find the truck to take her home immediately. Closing crate back, waiting driver, loading.
(https://i.postimg.cc/LXthVqhW/21.jpg)

Crate safely arrived home and i ran back to work
(https://i.postimg.cc/2yCy9zZS/22.jpg)

Opened crate next day evening. And did not find keys. Although keys were discussed with transport company specifically, not to loose them. Next day was spend for searching keys overseas, they were located in Vilnius warehouse. DHL - and now i have them.

But even if keys were delivered, bike was dead for 15 years. Would not try before some checks.
So inspection was started.


Title: Re: 1989 K75 reanimation
Post by: koshak on February 20, 2020, 07:26:39 AM
(https://i.postimg.cc/tRcvS6z3/DSC08262.jpg)

(https://i.postimg.cc/bJNVMHMT/20200214-075518.jpg)

Need such windshield. Do not see in any catalogue.
Although here were numerous remarks that it is mix and custom, i do not see "custom" traces, and also do not understand the reasons of such customization.
This fairing is quite ugly, i am thinking to remove it, to replace with just radiator cover.

(https://i.postimg.cc/Gt4733bT/20200214-075527.jpg)

(https://i.postimg.cc/Y0TXvcSn/20200214-075538.jpg)


The mesh in front of radiator is absent.
(https://i.postimg.cc/yYSQwNfw/DSC08265.jpg)

At both sides installed same temperature gauges. But - connected to nowhere, both.
(https://i.postimg.cc/mgfXRGJh/DSC08268.jpg)

Just visual check is enough to assess battery condition.
(https://i.postimg.cc/bvqmD9zh/DSC08276.jpg)

Too dusty... Washing is needed.
(https://i.postimg.cc/mrV8Q1DF/DSC08281.jpg)

Some leakages in front.
(https://i.postimg.cc/t43r4MGk/DSC08284.jpg)

(https://i.postimg.cc/633zz62b/DSC08286.jpg)

(https://i.postimg.cc/DZM6NV1v/DSC08293.jpg)

Fuel tank is almost full of fuel. Suppose 15 years old fuel. Is anybody interested in antique liquid?
So to remove tank closed the hose. Will need to install quick coupling, for easier handling. Did such on my R1200C.
(https://i.postimg.cc/90wb5xBG/DSC08294.jpg)
Title: Re: 1989 K75 reanimation
Post by: Bon Jon Bovi on February 20, 2020, 11:19:34 AM
If I remember the pic of the bike washed up on a beach occurred off the coast of England during a winter storm around 2012, 2013. Several crates of motorcycles washed overboard and floated ashore, where enterprising Bretoners whisked them away before authorities could round them up.

I would be interested in your low seat and hardware if at some future date you decide to get rid of them. This is a great story, probably all due to the storyteller!
 :k75x:
Title: Re: 1989 K75 reanimation
Post by: Skunky on February 20, 2020, 04:18:41 PM
Looks like a good project bike. What are your'e plans for her. Customization or restoration
Title: Re: 1989 K75 reanimation
Post by: koshak on February 21, 2020, 02:35:51 AM
Seat - as i wrote, would be interesting in conversion to regular. Not sure yet how to get correct one with accessories.

Customization or restoration - present plans -> restoration with conversion:
- replacement of front fairing
- seat conversion

Would like to have such configuration, with or without windshield:
(http://www.motobrick.com/gallery/2/6834-210220023211.jpeg)

Will appreciate if somebody can recommend suitable correct parts, preferably from Europe/UK.
Title: Re: 1989 K75 reanimation
Post by: Laitch on February 21, 2020, 09:52:56 AM
Seat - as i wrote, would be interesting in conversion to regular. Not sure yet how to get correct one with accessories.
I use Max BMW's parts fiche (https://shop.maxbmw.com/fiche/DiagramsMain.aspx?vid=51739&rnd=07242017) to search for parts and verify their suitability. It uses an efficient search format. In the UK, the main sources for new and used parts by members here are Motobins (https://www.motobins.co.uk/) and Motorworks (http://www.motorworks.co.uk/vlive/Home/index.php). James Sherlock, a salvage company, is also a source for used parts.

What you need for seat conversion is in this diagram from Max.
(http://www.motobrick.com/gallery/2/1601-210220083844.png)

The Brick in your example photo has an original equipment standard height Comfort seat. These are relatively uncommon over here but get positive reviews from their users who travel long distances. The photo arrow shows a battery cover which accompanies models with standard height seats—one on each side. These usually must be found as used parts.
(http://www.motobrick.com/gallery/2/1601-210220084248.jpeg)


This photo shows the standard height bench seat. These are the most common standard height seats. Some riders find these seats uncomfortable on rides longer than a few hours. I have one that was remodeled using more resilient and comfortable padding. I like this seat's profile because it allows me to shift position on it easily.
(http://www.motobrick.com/gallery/2/1601-210220084849.png)


If you complete the conversion, you should consider searching for and installing the combination  toolbox and control unit holder that accompanies the standard height seat on a stock Brick.
(http://www.motobrick.com/gallery/2/1601-210220094957.png)
Title: Re: 1989 K75 reanimation
Post by: koshak on February 21, 2020, 12:01:15 PM
Thank you, Laitch. That is great summary and good starting point.

James Sherlock through ebay i used for my conversion of k1200GT to k1200R. Got many parts from them but unfortunately their shipping costs are incredible.
Battery covers look same for both seat, that is correct?
And I saw some information, that parts from RT model are not suitable, is my understanding correct?
Title: Re: 1989 K75 reanimation
Post by: Laitch on February 21, 2020, 12:59:11 PM
Battery covers look same for both seat, that is correct?
And I saw some information, that parts from RT model are not suitable, is my understanding correct?
Both styles of standard height seats have the same battery covers. I was describing these covers based on your K75 and the K75 in your example photo, not any other model including the K75RT. Your understaning is correct. It's best to verify all understandings, suppositions, theories and hypotheses with hard data and multiple experiential descriptions. In fact, skip all the supposition, etc. and head straight to the parts fiche then to verification of what you find.  :laughing4-giggles:

This is where the Max parts fiche helps. If you look for K75 RT battery covers in the K75RT Frame and Fairing section, you might note that it has a different part number than the cover for a K75. That verifies that part won't work on your model unless there is a note that states it will. BMW line diagrams are not always accurate regarding the parts' shapes; they just indicate part positions and utility. I haven't had trouble just buying the part if its in the section for my Brick's model and is listed for its model year.

It's useful to obtain inside and outside photos of the part before buying it from private sources because claims for its fitment can be inaccurate. You can post the photos here for verification if you are in doubt.
Title: Re: 1989 K75 reanimation
Post by: Rcgreaves on February 23, 2020, 01:01:57 PM
185. but irrespective of that fact would like to convert to regular seat, to eliminate that "tank cover".
but not sure how to recognize precisely suitable seat on ebay, and also they are without mountings... Did not investigate deeply yet.

So for us non- metric types 185 is
185 cm = 6'0.83
185 cm is taller than about 87.5% of men and 100% of women in the USA. ... One inch is 2.54 centimeters so Inches = centimeters / 2.54. Some countries use feet and inches to measure height and others use centimeters or meters.

PS - how cool you shared the tracking of the container ship with us. 

I was amazed how shiney clean I was able to make my fuel tank with simple cleaning methods and materials. 

Title: Re: 1989 K75 reanimation
Post by: The Mighty Gryphon on February 23, 2020, 01:10:37 PM
would like to convert to regular seat, to eliminate that "tank cover".

Recently(in the past two weeks) i saw a photo of a K bike with a low seat that didn't have that awful tank cover.  The owner had cut off the battery covers where they met the seat.  The bike looked pretty good in the photos.

Wish I could remember where I saw it.  I don't think it was on any of the K bike forums, maybe it was ebay or Craig's List.
Title: Re: 1989 K75 reanimation
Post by: Rcgreaves on February 23, 2020, 01:21:09 PM
At 5'7" I would scratch up the fuel tank plenty without that surround. 

Also, I find myself gripping it with my knee or knees in the corner adding to my sense of connectedness to the moto. 

Indeed, it took me several months to get around to installing my low seat system last summer, but with it installed I found myself craving more time on my cycle. The surround is functional for me.

That said, yes, it changes the lines significantly- more of a  Shadow, Magna, Virago look.   
Title: Re: 1989 K75 reanimation
Post by: koshak on February 24, 2020, 04:44:21 AM
stripping continued
(https://i.postimg.cc/mZcWgBXS/DSC08296.jpg)

such funny relays used
(https://i.postimg.cc/XNTSZmt6/DSC08302.jpg)

alternator and starter are asking for a polish
(https://i.postimg.cc/gr9DYvM1/DSC08334.jpg)

traces of leakages in front of engine
(https://i.postimg.cc/pXzNKkth/DSC08355.jpg)

thick layer of petrified grease
(https://i.postimg.cc/pLHwC820/DSC08360.jpg)

condition of alternator terminals, do not think there would be any circuit
(https://i.postimg.cc/7ZnpW6hq/DSC08380.jpg)

some empty connector. What is that?
(https://i.postimg.cc/Jh79VLHZ/DSC08386.jpg)

could not take out rail with injectors, so removed them individually
(https://i.postimg.cc/TPkBT4nS/DSC08393.jpg)

getting ready fro frame lift
(https://i.postimg.cc/63ygqf0Q/DSC08394.jpg)

why BMW did such dirt collector, which is not accessible at all when assembled?
(https://i.postimg.cc/k4zZbR1v/DSC08411.jpg)

When released clutch cable, oil started to flow off this hole... understood there is no any seal by design.
(https://i.postimg.cc/qqKFXBWV/DSC08415.jpg)

Washing time
(https://i.postimg.cc/XNBt0xqH/DSC08418.jpg)

Rear master cylinder is dead
(https://i.postimg.cc/vHRk896Q/DSC08419.jpg)

The first serious issue discovered. Understand that it is time to search for a driveshaft replacement...
(https://i.postimg.cc/GhkN42kv/DSC08424.jpg)

Other side is better
(https://i.postimg.cc/Bn4zH0gk/DSC08427.jpg)

Such a strange and confusing construction.
(https://i.postimg.cc/bwgBRBVJ/DSC08437.jpg)
Title: Re: 1989 K75 reanimation
Post by: billday on February 24, 2020, 05:57:24 AM
Sorry about your splines  . . .
Title: Re: 1989 K75 reanimation
Post by: The Mighty Gryphon on February 24, 2020, 07:52:13 AM
Looks like you need to put a couple cans of Deoxit on the shopping list.  If you can find it, S100 motorcycle cleaner is my favorite way to clean parts as I take them off the bike.  Does an incredible job of removing the accumulated road dirt and grease, and makes all the rest of the restoration work much more pleasant.

Good news on the rear master cylinder is that some of us here have found a very inexpensive replacement.
Title: Re: 1989 K75 reanimation
Post by: Laitch on February 24, 2020, 12:07:00 PM
Looks like you need to put a couple cans of Deoxit on the shopping list.
I buy this stuff at a musical instrument store that has a large stock of electric guitars, electric pianos and control boards. How that relates to availability in Cyprus is unknown by me, unless it's a center for Trance music. There's always the Internet, I guess.
Title: Re: 1989 K75 reanimation
Post by: koshak on February 24, 2020, 02:30:20 PM
did anybody use this set?
https://www.ebay.co.uk/itm/BMW-K1-K100-K1100-K75-1984-1997-Fuel-Pump-Filter-16121461576-16121460452/382307941512

also in need of fuel level sender. found only one in so so condition on ebay...
Title: Re: 1989 K75 reanimation
Post by: The Mighty Gryphon on February 24, 2020, 03:25:16 PM
Those parts have been noticed, but noone has tried them that we know of.  I suspect they are probably quite usable for the price since genuine BMW parts are ridiculously overpriced.  You could be doing us all a service by trying them.

http://www.motobrick.com/index.php/topic,13309.0.html

As far as the fuel sender, as long as the wiring for the pump still works, I would take care of the pump and clean out the tank while watching for a sender.  As always, dont forget to search on K1100 senders. 

I'm not sure what the difference is, but there are two different part numbers for this part.  This is one of the later versions.

https://www.ebay.com/itm/BMW-K1100LT-K-1100-LT-k589-1992-1993-1999-Fuel-level-sensor-10681249/254521704052?hash=item3b42acfe74:g:mFEAAOSwTR9eU4zb
Title: Re: 1989 K75 reanimation
Post by: Laitch on February 24, 2020, 03:40:03 PM
did anybody use this set?
https://www.ebay.co.uk/itm/BMW-K1-K100-K1100-K75-1984-1997-Fuel-Pump-Filter-16121461576-16121460452/382307941512 (https://www.ebay.co.uk/itm/BMW-K1-K100-K1100-K75-1984-1997-Fuel-Pump-Filter-16121461576-16121460452/382307941512)
That looks like a good package. The price is so low it might make you reluctant to purchase it but members here have been buying cheap equipment like fuel pumps and rear brake master cylinders from aftermarket suppliers like that one with generally good results.
Title: Re: 1989 K75 reanimation
Post by: koshak on February 24, 2020, 03:44:52 PM
level sender cannot be used, it simply does not exist anymore.
wiring is affected as well.
the pump electrically seems to be alive (produces noise well), but is not working as impeller stuck.
soaked in penetrating oil, will see tomorrow if it helps.
all stuff like inlet filter, rubber damper - kaput.

so, looks like i will be the tester of that kit, as it includes everything.

photos to follow.

thanks for link of sender. strangelly seller does not want to ship to my location, will investigate options tomorrow.

Was the transmission side of driveshaft held in place by a circlip? Yes, it was.

Such a strange and confusing construction.—It is understandable with a diagram. Intuitive construction isn't always a commodity built into affordable machinery.
It is understandable even without diagram, but the purpose is not understandable. "Automatically" folding stand, that can lead to the scratched left side one day.  boohoo

Title: Re: 1989 K75 reanimation
Post by: Laitch on February 24, 2020, 04:12:18 PM
level sender cannot be used, it simply does not exist anymore.

It is understandable even without diagram, but the purpose is not understandable. "Automatically" folding stand, that can lead to the scratched left side one day.  boohoo
Your model of fuel sender does exist if yours is the type with a float. If yours is the plastic probe that screws into the tank, then your tank is not from a 1989 moto.

The side stand's automatic folding action can be eliminated. There are posts on the site to help you accomplish that.
Title: Re: 1989 K75 reanimation
Post by: Laitch on February 24, 2020, 04:24:40 PM
Regarding the side stand: it's a safety feature to prevent riding off with the side stand down. There are other options. You don't need to leave it that way. Read this thread (http://www.motobrick.com/index.php?topic=8349.0).
Title: Re: 1989 K75 reanimation
Post by: volador on February 24, 2020, 05:01:03 PM
Soak the fuel pump in some very hot water maybe will loosen up the impeller
Title: Re: 1989 K75 reanimation
Post by: The Mighty Gryphon on February 24, 2020, 07:10:06 PM
Kashak's bike is a 1989 and the sender I linked is for 1993 and later.  Does anyone know what the difference is?  Are they interchangeable???

The photos at MaxBMW look the same for the two parts, but they have different part numbers.
Title: Re: 1989 K75 reanimation
Post by: Laitch on February 24, 2020, 11:13:29 PM
When I look in Max's fiche, the part number was the same for K75, K100 2V, K100 4V and K1100. Euro Motoelectric show differing part numbers and applications but the parts looked similar. I think the upshot of all this is that float-type of senders are still being made and can be obtained with enough cash.

koshak should clarify whether his is float-type or probe-type. His moto seems to be a 1989 but his tank could have been a salvaged replacement from an early model.
Title: Re: 1989 K75 reanimation
Post by: The Mighty Gryphon on February 25, 2020, 12:16:48 AM
There are two different "petrol gauges" with floats. 

P/N 62 16 1 459 565    PETROL GAUGE (to 01/93)

and,

P/N 62 16 2 305 558    PETROL GAUGE (from 01/93)

The photos at MaxBMW do not show what difference there may be between them.  It seems that in 1993 the wiring harness they connect to changes as well. 

I have both pre and post 1993 bricks, and I never noticed a difference in the senders.  They both work with the same fuel level gauge and instrument clusters, so I don't thing they are electrically different, and the tanks they are used with are the same, so the mount and the arms shouldn't be different.   I would guess that they're interchangeable, but someone more knowledgeable than I should confirm it.
Title: Re: 1989 K75 reanimation
Post by: volador on February 25, 2020, 12:34:46 AM
There are two different "petrol gauges" with floats. 

P/N 62 16 1 459 565    PETROL GAUGE (to 01/93)

and,

P/N 62 16 2 305 558    PETROL GAUGE (from 01/93)

Bravo, the rest of you should visit your optometrist
Title: Re: 1989 K75 reanimation
Post by: Laitch on February 25, 2020, 12:52:46 AM
. . . so I don't thing they are electrically different, and the tanks they are used with are the same, so the mount and the arms shouldn't be different.   I would guess that they're interchangeable, but someone more knowledgeable than I should confirm it.
Euro Motoelectric uses the 558 photo for both the 558 and the 565.  I'd buy either if I needed one, preferably the cheaper if its in stock.  :laughing4-giggles: If he wants to spend, koshak will be able to get a gauge for his tank if it has that type of sender.
Title: Re: 1989 K75 reanimation
Post by: koshak on February 25, 2020, 03:00:57 AM
Gents, there is misunderstanding.

The fuel sender which is installed in my tank- cannot be used, as it does not exist anymore - you will see photos later.
The replacement is obviously available.
Yes, it is of float type.
Title: Re: 1989 K75 reanimation
Post by: koshak on February 25, 2020, 05:29:42 AM
splines on gerabox look good
(https://i.postimg.cc/XqhqyLLW/DSC08444.jpg)

Injectors
(https://i.postimg.cc/mZ6tqZsn/DSC08449.jpg)

cooling hoses connector removed for some cleaning
(https://i.postimg.cc/c4grNq1L/DSC08464.jpg)

had battery left after conversion of K1200GT, fits perfectly
(https://i.postimg.cc/pXwyW0yY/DSC08465.jpg)

inspection under covers.
(https://i.postimg.cc/bJVNKgKn/DSC08467.jpg)

(https://i.postimg.cc/ZR5572DZ/DSC08468.jpg)

What i am doing now, is just overall inspection of condition and making list of needed parts.
I had plans to start her on this week for a test ride, but further photos will show that it probably will not be possible.

Then next week i am leaving for business trip to Malaysia for a month. Same time will order some parts for engine overhaul, so hopefully they arrive to my return. And then will plan to strip the engine and will think about cosmetic upgrade.

(https://i.postimg.cc/YCQ0h1Wc/DSC08485.jpg)

(https://i.postimg.cc/YS3SxMRb/DSC08486.jpg)

Had on shelf Chinese master cylinder (corona virus free, as much older). It is not plug n play, fitting holes are not matching, and also rod had to be cut. So made temporary adapter for tests. By the way, not opening brakes calipers, as did not order overhaul kits yet. That will be ordered soon.
(https://i.postimg.cc/CxpLTz6c/DSC08501.jpg)

And here is the most tasty part.
As i wrote at the beginning, bike came without keys. So i just removed the tank (and it arrived filled with petrol) and put aside. So keys came, and now is time to open tank and drain fuel. But not only fuel was drained, but loose parts.......

(https://i.postimg.cc/rpcmWK1D/DSC08487.jpg)

The venting hose from filter cracked and broken in parts. Should its second side be connected to that breathing pipe near opening?
(https://i.postimg.cc/d37tvdYx/DSC08488.jpg)

Fuel level sensder
(https://i.postimg.cc/65v5mdz7/DSC08489.jpg)

Power to the fuel pump goes through the connector of fuel sender. But positive wire rot off. And the bad thing, that remaining piece of terminal does not have continuity to the plug. So to try to start the pump, cut the wires and modified, to have power to the pump.
(https://i.postimg.cc/BZynph59/DSC08494.jpg)

No power was coming anyway, found fuse of fuel system burned. Replaced. Pump gives some sound, so it was hope for pumping effect.
(https://i.postimg.cc/Z5PYT4G4/DSC08498.jpg)

Removed pump from tank, put a hose to the discharge line, dropped pump into can with petrol drained off the tank earlier, power on... Nice zzzzzz is coming, but no petrol... Holding it in hand - feels torque when starting and stopping.
(https://i.postimg.cc/RhjC0FCV/DSC08499.jpg)

So decided to look inside of the pump, as anyway it should be thrown away, and replacement will not come soon.
(https://i.postimg.cc/ZqTbnXm3/DSC08503.jpg)

Electric part looks nice, but pump does not rotate.
(https://i.postimg.cc/0Nc8wZ54/DSC08505.jpg)

So removing rotor from the rod (held by retaining ring)
(https://i.postimg.cc/Px7T6xwz/DSC08506.jpg)

Pump disassembled, but impeller still cannot turn or remove from housing. Even if put in vise. Even with hummer.
Ok, put some penetrating oil on it and left till next evening.
(https://i.postimg.cc/63qBLRyp/DSC08508.jpg)

So, for now i already placed order to the pump replacement kit we discussed earlier, and also for used fuel sender from K1100LT as per link above - it was cheaper than the same from Belgium i have found earlier.

Also, some time ago ordered original top box, and it is already arrived, will try to pick it from the post today. But it is without mounting plate. How is this plate looking? Easy to fabricate, or need to search original part?
This is the box:
(https://i.ebayimg.com/images/g/aHMAAOSwhcZeKJn5/s-l1600.jpg)

(https://i.ebayimg.com/images/g/UzgAAOSw4UReKJoP/s-l1600.jpg)
Title: Re: 1989 K75 reanimation
Post by: Laitch on February 25, 2020, 09:26:51 AM
Clearly, you know how to make your way through a mechanical labyrinth, koshak.  112350 That's good progress.
(http://www.motobrick.com/gallery/2/1601-250220091600.jpeg)
Title: Re: 1989 K75 reanimation
Post by: billday on February 25, 2020, 09:29:44 AM
Clearly, you know how to make your way through a mechanical labyrinth, koshak.

Check out the Honda thread link in his signature.
Title: Re: 1989 K75 reanimation
Post by: Martin on February 25, 2020, 02:02:56 PM
A future project at the Trades Guild for me was to look at making the retaining plates and pins. It is doable but whether there is enough of a call for them and how much time and effort is needed. Too many projects at the moment, however I'll have a talk to my engineering mate and see if it's viable.
Regards Martin.
Title: Re: 1989 K75 reanimation
Post by: The Mighty Gryphon on February 25, 2020, 05:50:17 PM
The kit for mounting the iconic 22 liter case is actually only $85 which is less than the plate alone.

P/N  46 54 2 316 755  Set, mounting parts

By BMW standards, the price is a real deal.
Title: Re: 1989 K75 reanimation
Post by: tjg79 on February 26, 2020, 05:31:23 PM
You should build a vapor blaster to clean up the parts.
Title: Re: 1989 K75 reanimation
Post by: Laitch on February 26, 2020, 07:32:10 PM
You should build a vapor blaster to clean up the parts.
Is that so he can answer your question (http://www.motobrick.com/index.php/topic,13318.msg118723.html#msg118723) about how well it works, tjg?  :laughing4-giggles:
Title: Re: 1989 K75 reanimation
Post by: koshak on February 28, 2020, 08:23:50 AM
overhauled fuel pump. now it is not only turning easily, but also pumps the fuel.  :laughing4-giggles: Tested in bucket filled with that antique drained fuel.
But just received call from FedEx, and am going to pickup that replacement aftermarket pump  44271
so no chance old pump to be tested in tank (which was actually planned for tonight), it will remain as emergency kit.

Have the question. I am in search of driveshaft. New one seems to be available, but costly. Will go for it, if not find alternative.
Here is the photo of one used, from ebay. What can you say about splines? look much better than mine, but shows overheating signs (? how it can be just in one section, not at whole?) at about 5 o'clock, and some wear already started.

(https://i.ebayimg.com/images/g/YRAAAOSws11eJBtu/s-l1600.jpg)
Title: Re: 1989 K75 reanimation
Post by: Laitch on February 28, 2020, 12:08:10 PM
If we number the topmost spline as 20 and the one to the right of it as 1, continue numbering clockwise then take a photo of splines 6, 7, 8, and 9 with increased lighting. As it looks now, I'd be happy to use it in my moto, or sell it to somebody.  :laughing4-giggles:
Title: Re: 1989 K75 reanimation
Post by: koshak on March 01, 2020, 03:25:21 PM
take a photo of splines 6, 7, 8, and 9 with increased lighting

Cannot, it is available photo from ebay.
Quote
Pump disassembled, but impeller still cannot turn or remove from housing. Even if put in vise. Even with hummer.
Well, that because that rod is not a shaft, but just a rod pressed into lower "flange". So, soaking in penetrating oil over the night helped, next day it was possible firts to turn, then to disassemble.
(https://i.postimg.cc/tgjbM0nv/DSC08509-resize.jpg)

parts cleaned and polished, to allow rotor to rotate in the pump housing.
(https://i.postimg.cc/3RLHNdSz/DSC08511-resize.jpg)

Test run in the bucket of petrol. nice fountain. by the way, if to assemble pump covers turning for 90 degrees from original, pump will make pumping effect... do not ask how i know that...

(https://i.postimg.cc/W3pvsMnM/DSC08513-resize.jpg)

Out of curiosity disassembled rear master cylinder... Strange that braking liquid became that solid here, but same time in front brakes remained liquid, and brakes are working... well, more or less working...
obviously, all calipers will be overhauled when receive seals.
by the way, rear brake, even with the installation of the alternative master cylinder, did not come back to life.
(https://i.postimg.cc/hv6W8Nqr/DSC08519-resize.jpg)

And the new pump arrived, surprisingly fast. So, will not install old pump into the tank, will keep it as an emergency kit.
(https://i.postimg.cc/MHvJQqgH/DSC08521-resize.jpg)

Ordered complete kit, but it is strange that in the bag with rubber sleeve they did not include nuts, but electric terminals, same as with pump itself.
(https://i.postimg.cc/tgNb0rhq/DSC08522-resize.jpg)

Aftermarket pump looks exactly as original.
(https://i.postimg.cc/FKNtxjw2/DSC08523-resize.jpg)

Before installation, decided to make a pumping test, just to compare it with the old one... Hmm, did i say old one will be used as emergency? Now not sure, that requires checking fuel pressure on the bike.
(https://i.postimg.cc/KYN6p124/DSC08524-resize.jpg)

This what happens when anti-seize compounds are not used. Studs for exhaust manifold were turned out, instead of nuts. One stud broke. And only one nut came off as should be.
(https://i.postimg.cc/0QyLT9kn/DSC08525-resize.jpg)

So, pump in, bike assembled back, test start and test ride.
(https://i.postimg.cc/6pRwc6qG/20200229-121300-resize.jpg)

(https://i.postimg.cc/nVPJt9QD/20200229-122119-resize.jpg)

20 years old tyres, not working rear brake... Challenging... So careful low speed ride around for 38 km, to see how she works.... So far not bad.

(https://i.postimg.cc/wTRdxxhb/20200229-122126-resize.jpg)

Getting ready to leave for a month. Put bike to the workshop.
(https://i.postimg.cc/gJtfd1rW/DSC08529-resize.jpg)

Now during this month should order parts for engine overhaul (most of the seals already bought locally), brakes etc.
Would like to replace all braking hoses to braided, but ebay shows "standard" pictures in lots for K75. To trust or not to trust, that is the question... Does anybody know reliable and proven source of the hoses kit for K75, preferably in Europe?
Title: Re: 1989 K75 reanimation
Post by: koshak on March 01, 2020, 03:29:12 PM
By the way.
Fuel sender is on the way to me.
But there is no fuel level indicator on the bike. What is the correct/suitable level indicator for it?
You remember i was asking about an empty connector? As per the wiring diagram, that is connector for optional accessories, and one of them is the fuel level indicator.
Title: Re: 1989 K75 reanimation
Post by: Martin on March 01, 2020, 03:47:56 PM
You will have a low level light.
Regards Martin.
 [ Invalid Attachment ]
Title: Re: 1989 K75 reanimation
Post by: volador on March 01, 2020, 03:55:17 PM
To trust or not to trust, that is the question... Does anybody know reliable and proven source of the hoses kit for K75, preferably in Europe?

Tills.de has hose kits and Jurman will custom make hoses to your spec https://www.tills.de/bmw-k75-67/bmw-k75xx-133/ (https://www.tills.de/bmw-k75-67/bmw-k75xx-133/)

But there is no fuel level indicator on the bike. What is the correct/suitable level indicator for it?

Fuel level telltale light will come on approx. 5-7 litre

Optional accessory connector is the white 4-pin plug in the relay box.

(http://www.motobrick.com/gallery/2/5332-010320162456-27692275.png)
Title: Re: 1989 K75 reanimation
Post by: koshak on March 01, 2020, 04:22:02 PM
yes, i know about low level light.
but there is another functionality of fuel sender - to indicate actual level in tank, for which i would like to have suitable gauge.
Title: Re: 1989 K75 reanimation
Post by: volador on March 01, 2020, 04:47:30 PM
The Motometer gauge kit is 62132325549 or 62131459963. One is petrol guage, one is temperature gauge

https://shop.maxbmw.com/fiche/PartsSearch.aspx?&searchtype=undefined&parts=62%2013%201%20459%20963 (https://shop.maxbmw.com/fiche/PartsSearch.aspx?&searchtype=undefined&parts=62%2013%201%20459%20963)

https://shop.maxbmw.com/fiche/PartsSearch.aspx?&searchtype=undefined&parts=62%2013%202%20325%20549 (https://shop.maxbmw.com/fiche/PartsSearch.aspx?&searchtype=undefined&parts=62%2013%202%20325%20549)
Title: Re: 1989 K75 reanimation
Post by: Laitch on March 01, 2020, 05:43:10 PM
yes, i know about low level light.
but there is another functionality of fuel sender - to indicate actual level in tank, for which i would like to have suitable gauge.
As you'll discern from the links supplied in the previous post, this gauge and its splitter wiring isn't available in the States. You'll need to search the used market for BMW gauges. If you want to use gauges from a different maker, you'll need to reconfigure the wiring of your fuel sender—something probably well within your skill set. Read the boxed note in the second section of this post (http://www.k100-forum.com/t9265-messing-with-the-in-tank-fuel-sender).
Title: Re: 1989 K75 reanimation
Post by: koshak on September 27, 2020, 07:53:45 AM
Month ago placed order for set of spares for rebuild from my usual supplier in Germany.
All parts collected already, but the connecting rod bolts are still missing. The delivery date was shifted, shifted, until they did not change it to status "Date unknown".  boohoo

The good thing is that i am abroad now, so not working on the bike (which is now stripped to the last bolt, by the way). But if within two weeks it will not be solved, need to search alternative.

From where can i get this connecting rod bolts? New. Need 14 pieces (for K75 and K1).
Title: Re: 1989 K75 reanimation
Post by: Laitch on September 27, 2020, 08:27:42 AM
From where can i get this connecting rod bolts?
Motorworks (https://www.motorworks.co.uk/vlive/Shop/Parts.php?T=5&NU=15&M=40&Ct=BA&SbCt=BA_15_40_BA_15&spPage=2)  Scroll down the page to find crankshaft bolts.

It would be helpful for you to tell us who your usual supplier in Germany is.
Title: Re: 1989 K75 reanimation
Post by: Martin on September 27, 2020, 04:56:37 PM
I have fitted a Quantum kit the one without the pump to a mates Brick. The quality of the kit seemed good. We didn't fit the plastic Flexi Hose due to old guy bias but it's probably OK. I've been running a Chinese clone pump since July 2017  with no problems it even survived a couple of 1700 Km runs on 40C plus days.
Regards Martin.
Title: Re: 1989 K75 reanimation
Post by: koshak on September 28, 2020, 02:41:01 AM
Motorworks (https://www.motorworks.co.uk/vlive/Shop/Parts.php?T=5&NU=15&M=40&Ct=BA&SbCt=BA_15_40_BA_15&spPage=2)  Scroll down the page to find crankshaft bolts.

It would be helpful for you to tell us who your usual supplier in Germany is.


Motorworks keeps them in stock or also suborder from somewhere?

I use KFM-Motorräder.
Title: Re: 1989 K75 reanimation
Post by: Laitch on September 28, 2020, 06:39:02 AM
Motorworks keeps them in stock or also suborder from somewhere?
I operate on the belief that If they have the parts in stock, they'll sell them to me and ship them. Their listings tend to indicate when a part might not be available. If you are sensitive to where they source their parts, how long it will take you to get the parts, or disappointment in general, you probably should email them for reassurance.
Title: Re: 1989 K75 reanimation
Post by: koshak on September 28, 2020, 11:13:04 AM
Noted. I will wait some more time for my supplier, then will see.
Title: Re: 1989 K75 reanimation
Post by: koshak on September 28, 2020, 11:23:27 AM
found alternative external parts, test fit
(https://i.postimg.cc/Hsbq0J8n/01.jpg)

replacement drive shaft
(https://i.postimg.cc/zG59xJTj/02.jpg)

rear brake rebuild
(https://i.postimg.cc/d1zfrvqG/08.jpg)

(https://i.postimg.cc/MZQNxcD5/09.jpg)

start stripping
(https://i.postimg.cc/kXPZ5nYm/10.jpg)

(https://i.postimg.cc/x1tFgLff/13.jpg)
Title: Re: 1989 K75 reanimation
Post by: DavidATL on September 28, 2020, 08:01:48 PM

replacement drive shaft
(https://i.postimg.cc/zG59xJTj/02.jpg)



Excellent comparison of old and new splines. Do you mind if I include this image in a guide I am (slowly) writing? With credit and thanks to "koshak on motobrick.com"
Title: Re: 1989 K75 reanimation
Post by: koshak on September 28, 2020, 09:10:45 PM
You may use any photo from this blog.
But not kosher (what is that?) - koshak is the correct one.
Title: Re: 1989 K75 reanimation
Post by: DavidATL on September 28, 2020, 09:54:15 PM
You may use any photo from this blog.
But not kosher (what is that?) - koshak is the correct one.

Sorry - yes, Koshak. An autocorrection that I missed. My apologies. (corrected above for posterity ;-) )
Title: Re: 1989 K75 reanimation
Post by: koshak on September 28, 2020, 11:37:09 PM
(https://i.postimg.cc/s2xHL1xp/14.jpg)

(https://i.postimg.cc/tgcvGyn8/15.jpg)

(https://i.postimg.cc/k4t1nZxG/16.jpg)

piece of rusty metal strip with drilled holes replaces special BMW tool 11 2 800
(https://i.postimg.cc/vTFPDzzz/17.jpg)
Title: Re: 1989 K75 reanimation
Post by: koshak on September 29, 2020, 04:07:04 AM
typical condition of all engine bolts
(https://i.postimg.cc/L4LCwc90/19.jpg)

checking camshaft marks
(https://i.postimg.cc/NftJcdLG/20.jpg)

(https://i.postimg.cc/HstSsb7w/21.jpg)

(https://i.postimg.cc/7ZsmSD9b/23.jpg)

Title: Re: 1989 K75 reanimation
Post by: koshak on September 30, 2020, 02:41:15 AM
findings after removing cylinder head  boohoo

(https://i.postimg.cc/vmChSzps/24.jpg)

(https://i.postimg.cc/85W48vSr/25.jpg)

(https://i.postimg.cc/0QdSd0vZ/44.jpg)
Title: Re: 1989 K75 reanimation
Post by: koshak on September 30, 2020, 02:42:44 AM
control drain hole from mechanical seal completely blocked

(https://i.postimg.cc/qvRGJSrr/31.jpg)

(https://i.postimg.cc/qv5xzwB3/32.jpg)
Title: Re: 1989 K75 reanimation
Post by: Martin on September 30, 2020, 03:11:16 AM
Green gunge is I believe from mixing two incompatible coolants, not all coolants can be mixed. I've had my Brick over 20 years and always used the same brand coolant mixed with distilled water and the radiator the last time I gave it a flush was totally clean.
Regards Martin.
Title: Re: 1989 K75 reanimation
Post by: koshak on September 30, 2020, 05:36:05 AM
As it was said in the initial post, the bike was abandoned for 15 years. I am not aware what was happening with her before or during that period.

The bright green color - traces of the new liquid i put in, when was testing bike, original color of "gunge" you can see on the last close up photo of the drain space.
Title: Re: 1989 K75 reanimation
Post by: koshak on September 30, 2020, 11:10:36 PM
(https://i.postimg.cc/1XQHyzm7/26.jpg)

(https://i.postimg.cc/0j0Cjqrk/27.jpg)

(https://i.postimg.cc/y6mjv0jM/28.jpg)

(https://i.postimg.cc/sDKcRytK/30.jpg)
Title: Re: 1989 K75 reanimation
Post by: koshak on October 01, 2020, 07:54:37 AM
tool for filter removal does not fit into hole.
(https://i.postimg.cc/6Q4LRZT1/33.jpg)

will solve that later. but now for removal bottom cover to be removed
(https://i.postimg.cc/xCrGPdzj/34.jpg)

that makes job easy
(https://i.postimg.cc/JnbNYWNN/35.jpg)

(https://i.postimg.cc/MHqyhr5h/36.jpg)
Title: Re: 1989 K75 reanimation
Post by: Falco144 on October 05, 2020, 08:00:32 PM
Subscribed
Title: Re: 1989 K75 reanimation
Post by: koshak on October 16, 2020, 02:46:19 AM
further progress

(https://i.postimg.cc/HnzQH4Pj/37.jpg)

output shaft

(https://i.postimg.cc/NGk81BfY/38.jpg)

Title: Re: 1989 K75 reanimation
Post by: koshak on October 16, 2020, 02:48:10 AM
time for crankshaft

(https://i.postimg.cc/15RGB2fF/39.jpg)

(https://i.postimg.cc/9FxGnb7n/40.jpg)

(https://i.postimg.cc/kgzWn5wN/41.jpg)
Title: Re: 1989 K75 reanimation
Post by: daveson on October 16, 2020, 04:49:13 AM
Hi,

Thanks for posting this deep build.

Question, I'm curious, could you measure or post a photo of the width of the tangs and grooves on the balance shaft gear to the balance shaft? I'm thinking from other threads that the gap might be excessive on later models, compared to the earlier ones, like yours.
Title: Re: 1989 K75 reanimation
Post by: The Mighty Gryphon on October 16, 2020, 07:55:56 AM
Yes, I'd like to see what yours looks like.  This is my 1994 K75RT.  Clanks between about 1200 and 2000 rpm.

 [ Invalid Attachment ]
Title: Re: 1989 K75 reanimation
Post by: koshak on October 17, 2020, 12:17:55 AM
Question, I'm curious, could you measure or post a photo of the width of the tangs and grooves on the balance shaft gear to the balance shaft? I'm thinking from other threads that the gap might be excessive on later models, compared to the earlier ones, like yours.

Can measure anything, why not.
But i am now not at home, but faraway. To measure need to return back first.
Bike is stripped to parts. I am just slowly posting photos of what is done.

Now busy with different thingy:
Title: Re: 1989 K75 reanimation
Post by: daveson on October 17, 2020, 06:21:57 AM
Good one thanks I'll be keeping an eye out.

That thingy's a biggy.
Title: Re: 1989 K75 reanimation
Post by: koshak on October 22, 2020, 01:57:48 AM
(https://i.postimg.cc/7hH2BJY4/45.jpg)

(https://i.postimg.cc/cCF8P1rn/46.jpg)

(https://i.postimg.cc/J7xJsxPz/47.jpg)

Title: Re: 1989 K75 reanimation
Post by: koshak on October 24, 2020, 12:06:35 AM
Engine is ready for treatment

(https://i.postimg.cc/SNK9C9v7/48.jpg)

Lapping valves

(https://i.postimg.cc/ZKDdcRkk/49.jpg)
Title: Re: 1989 K75 reanimation
Post by: koshak on November 03, 2020, 02:00:12 AM
my conrod bolts are on the way, as well as other spares.
So before i broke anything better ask - is there any trick (apart from hammering) to remove old conrod bolt?
The heavier hammer the better?
And then on refit new bolt - hammer it back?

Title: Re: 1989 K75 reanimation
Post by: Laitch on November 03, 2020, 07:04:26 AM
If you haven't tried heating the bolts with a heat gun, applying a penetrant like Liquid Wrench, waiting a few minutes then using a socket on a breaker bar or impact wrench, you might try that.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 03, 2020, 08:02:07 AM
to heat bolt? Will not it expand and be even more tight than now?  :johnny
Title: Re: 1989 K75 reanimation
Post by: koshak on November 03, 2020, 09:46:02 AM
Question, I'm curious, could you measure or post a photo of the width of the tangs and grooves on the balance shaft gear to the balance shaft? I'm thinking from other threads that the gap might be excessive on later models, compared to the earlier ones, like yours.

I was asked to make some measurements. Here it is.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 03, 2020, 09:48:21 AM
Filter wrench was adopted for the available opening by lathe.
Now should fit well.

Title: Re: 1989 K75 reanimation
Post by: Laitch on November 03, 2020, 10:15:48 AM
to heat bolt? Will not it expand and be even more tight than now?  :johnny
I wouldn't have recommended it if I hadn't used the method successfully numerous times. You're heating the bolt head and nut; a heat gun isn't precise. Heating the bolt can crack up corrosion and helps conduct the penetrant down the shaft into the threads. You let it cool then you loosen it.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 03, 2020, 11:52:55 AM
Laitch, did you use this method on conrod bolts? They are not screwed in, they are tight pressed as i understand.
Title: Re: 1989 K75 reanimation
Post by: Laitch on November 03, 2020, 12:19:50 PM
Laitch, did you use this method on conrod bolts? They are not screwed in, they are tight pressed as i understand.
No, but I wouldn't be shy about using this method on con rod bolts. The principle is the same. The flanges of both the nut and bolt might be seized to the rod so you're not only try to break corrosion on the threads beneath the nut but also on the nut flange and the bolt head.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 03, 2020, 12:56:45 PM
The flanges of both the nut and bolt might be seized to the rod so you're not only try to break corrosion on the threads beneath the nut but also on the nut flange and the bolt head.

ok, seems we are talking about different bolts.
(https://i.postimg.cc/sDKcRytK/30.jpg)
Title: Re: 1989 K75 reanimation
Post by: Laitch on November 03, 2020, 01:03:47 PM
ok, seems we are talking about different bolts.
We aren't. With your depth of experience rebuilding motorcycles, I was surprised you even asked the question, but I answered. I'm not invested in your compliance with the suggestion. I'm sure you'll get it done one way or the other.

Once penetrating oil has been used, a deadblow hammer can be used to drive out the bolt. After the bolt bores have been cleaned and lubricated, the replacement bolts shouldn't pose a problem during insertion.
Title: Re: 1989 K75 reanimation
Post by: The Mighty Gryphon on November 03, 2020, 01:57:49 PM
I was asked to make some measurements. Here it is.

Hmmm, that looks exactly like the gap in my engine as well.  Makes me think it's designed in.

Now the question is WHY???  All I can see it do is make the engine clank like a can of scrap metal when it's coming off idle.

Here's a photo of mine:

 [ Invalid Attachment ]
Title: Re: 1989 K75 reanimation
Post by: daveson on November 03, 2020, 02:30:37 PM
Thanks Koshak, that's really surprising, I felt sure it was going to be less. Maybe it's too small a sample, but the handful of times I've read about the problem have all been about 1993 models. Now I'm wondering if it might be reduced tension in the output shaft circlip that could cause a noise.

P. S. I'm wrong, I've since read about earlier models with the problem.
Title: Re: 1989 K75 reanimation
Post by: The Mighty Gryphon on November 03, 2020, 03:12:26 PM
Daveson, that tension has nothing to do with the output shaft clank. 

It's not a circlip, but a spring that preloads the anti-lash gear.  It has nothing to do with the tab in that slot.  As far as I can tell, it's free to bang around all it wants as the engine runs.  Any unevenness in rotation speed from cylinder to cylinder at low rpm is going to make that tab bang around like crazy. 

That effect of imbalance is the reason I work hard to have valve gaps as uniform from cylinder to cylinder as possible, and balance throttle bodies frequently.

My engine had a perfect spring and still clanked like someone was hammering on the insides of the engine.  While gear lash can probably make the clanking worse, eliminating the lash won't make it go away. 

I was able to get temporary relief from the noise by cleaning all the oil from the faces of the clutch basket and the balance shaft and torquing the clutch nut to a few pounds above the spec.  Got rid of the noise for maybe 3-4,000 miles or about half of my riding season.

The only thing that prevents that tab banging around in the slot is the friction between the clutch hub and the balance shaft which isn't very much because both surfaces have pretty smooth surfaces.

It's a pretty shiity design.
Title: Re: 1989 K75 reanimation
Post by: daveson on November 03, 2020, 03:51:08 PM
Agree about the clutch basket and anti lash gear comments. I wasn't meaning to point to the anti lash. Realise I'm reaching a bit. Was surprised the gap was the same. Did your tabs have marks consistent with banging? It's about time I got familiar with suppliers catalogs and part numbers,  then I might be able to find a difference around 1993.

On mine (a k100, but same deal I think) the circlip (the castellated type) ties the bearing with the gear.

I better leave it at that, I feel I've thread jacked this a bit.
Title: Re: 1989 K75 reanimation
Post by: The Mighty Gryphon on November 03, 2020, 09:40:29 PM
The K100 doesn't have a balance shaft or that tab-in-slot thingie, thus the clank is part of the K75's unique charm. 

As far as any wear or distortion, there was none visible on my parts.  The gap was made at the factory when the parts were machined.  Like I said, shiity design.
Title: Re: 1989 K75 reanimation
Post by: daveson on November 03, 2020, 09:51:03 PM
Yep the K100 is way different, was referring to the circlip, which seems to be the same.

The circlip on mine was also cone shaped so acted as a spring too. Strange to also act as a spring, since it's open ended. That makes me wonder how it could be tested for reduced tension.

If yours was the castellated type, the concave side should have been facing the bearing.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 04, 2020, 01:53:34 AM
critical spares did not arrive yet, but there is still a lot to do. so, slowly progressing with assembly.

Title: Re: 1989 K75 reanimation
Post by: koshak on November 04, 2020, 02:32:22 AM
when installing output shaft, make sure marks on crankshaft and output shaft are aligned.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 04, 2020, 08:51:20 AM
cannot continue with the crankcase until spares arrive (some gaskets, oil sight glass, conrod bolts), so wrapped it in plastic and placed aside.

will play with other stuff.

rusty stand assembly. why not to bring it in better order now?
as i told earlier, originally here is self-folding side stand.
such confusing construction, and i found it inconvenient for me.
(https://i.postimg.cc/bwgBRBVJ/DSC08437.jpg)

so already replaced to the "non-self folding type". Also have parts to connect it to the clutch gear, but did not decide yet if will do this connection. May be do test after final assembly and then decide.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 04, 2020, 08:53:07 AM
now nice clean and shiny.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 04, 2020, 08:57:14 AM
cleaning starter

Title: Re: 1989 K75 reanimation
Post by: daveson on November 07, 2020, 05:44:01 PM
Hi Koshak,

Would you be able to do me one more favour, if your engine is still in pieces?

If you remove the output shaft from the gear and rotate it 180 degrees, do the tabs prevent it from re-engaging  with the gear? If so, maybe that's their purpose.

Unless somebody else already knows the answer?
Title: Re: 1989 K75 reanimation
Post by: koshak on November 10, 2020, 02:00:21 AM
not sure if understood your question properly.
On photos:
1. proper installation (yellow dots matching)
2,3. Shaft turned 180 degrees.
Title: Re: 1989 K75 reanimation
Post by: daveson on November 10, 2020, 02:18:33 AM
Yes, that's what I meant. Thanks heaps for going out of your way to help me understand this funny little unit.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 17, 2020, 08:59:43 AM
to install valves seals, suitable socket was used.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 17, 2020, 09:28:04 AM
By the way, to remove that valve stem seals was quite a pain without proper tool, due to quite deep wells. I did not need such tool in my other projects, but now, sitting in Malaysia, purchased such puller. Since there is another brick in the queue, will see how it works.

Title: Re: 1989 K75 reanimation
Post by: koshak on November 17, 2020, 09:34:51 AM
Shopping in Malaysia was not bad.
Got the tool for the springs.
However, if center stand assembly removed completely to work on bench, this tool is not needed. :laughing4-giggles:

Title: Re: 1989 K75 reanimation
Post by: koshak on November 17, 2020, 09:35:49 AM
Springs compressor
Title: Re: 1989 K75 reanimation
Post by: koshak on November 17, 2020, 09:37:32 AM
Holder. Good thingy, already used to remove rear brake disk.

Title: Re: 1989 K75 reanimation
Post by: koshak on November 17, 2020, 09:40:23 AM
Original rear master cylinder was terrible, as was shown before. Found original used part, but it was not pumping either. 177381
So took an overhaul kit, now all ok.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 17, 2020, 09:43:03 AM
Installing valves
Title: Re: 1989 K75 reanimation
Post by: koshak on November 17, 2020, 09:47:22 AM
Brembo forks.

What is correct oil volume????

I drained 200 ml.
In Haynes says 420 when dry
In Maintenance manual says 0.330 for K75.

Title: Re: 1989 K75 reanimation
Post by: Laitch on November 17, 2020, 11:04:38 AM
The 420ml figure is for Showa forks from 1991 on when the oil is drained completely.
The attached chart from IBMWR is widely accepted and shows the figures for Showas, sport forks and Brembos. Brembos are identified by an imprint on the slider.

(http://www.motobrick.com/gallery/3/1601-171120105838.png)
Title: Re: 1989 K75 reanimation
Post by: koshak on November 17, 2020, 01:13:49 PM
thank you. that appears i have K75 Sport and will need 280 ml.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 18, 2020, 03:40:35 AM
front brakes overhaul.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 18, 2020, 03:41:54 AM
such amount of "substance" remained in caliper after draining
Title: Re: 1989 K75 reanimation
Post by: koshak on November 18, 2020, 03:43:15 AM
inspection of rear drive - before cleaning and after
Title: Re: 1989 K75 reanimation
Post by: koshak on November 18, 2020, 03:44:58 AM
internal inspection
Title: Re: 1989 K75 reanimation
Post by: koshak on November 18, 2020, 03:45:35 AM
seal replaced
Title: Re: 1989 K75 reanimation
Post by: koshak on November 18, 2020, 04:31:50 AM
i am changing low seat to high seat.
that also requires change of the seat lock.

This is lock for high seat.

Title: Re: 1989 K75 reanimation
Post by: koshak on November 18, 2020, 04:32:57 AM
to avoid having many keys (individual per lock), decided to replace lock insert from original lock to the new one.
this is original lock for low seat.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 18, 2020, 04:34:44 AM
Unfortunately, these inserts are not interchangeable, they are of different construction of the actuator (not very seen on this photo)

Left is high seat lock, right is low seat lock.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 18, 2020, 04:36:51 AM
therefore, the pins were removed from each lock and interchanged. 112350

Title: Re: 1989 K75 reanimation
Post by: koshak on November 18, 2020, 04:38:46 AM
Ignition coils cosmetic maintenance

Title: Re: 1989 K75 reanimation
Post by: koshak on November 23, 2020, 04:45:42 AM
today is one month since parts for engine were sent by supplier in Germany. And delivery date is still not know, as per tracking they are in the middle of nowhere.... When this worldwide craziness already finish?
However, sometimes long waiting time is good. Thus, i was looking yesterday through the pictures of disassembly, and suddenly realized that i installed output shaft wrongly.  boohoo Original mark almost lost its paint mark.

Since engine is open, the situation was immediately rectified.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 23, 2020, 04:46:50 AM
after that engine was wrapped in plastic again, to wait for parts to arrive.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 23, 2020, 04:49:56 AM
time to do forks
Title: Re: 1989 K75 reanimation
Post by: koshak on November 23, 2020, 04:52:10 AM
new cap and old, with accumulated dirt inside.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 23, 2020, 05:02:05 AM
look at that seal ring on that bolt. same for another fork. :nono2:

Title: Re: 1989 K75 reanimation
Post by: koshak on November 23, 2020, 05:03:48 AM
some dirt inside
Title: Re: 1989 K75 reanimation
Post by: koshak on November 23, 2020, 05:05:33 AM
disassembled
Title: Re: 1989 K75 reanimation
Post by: koshak on November 23, 2020, 08:17:54 AM
Apart from sealing rings on bolts, gasket ring on the valve was damaged.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 23, 2020, 08:19:42 AM
tubes received some treatment
Title: Re: 1989 K75 reanimation
Post by: koshak on November 23, 2020, 08:22:56 AM
To install piston with guide ring is not easy, ring is too loose.
Hayness recommends to fabricate a guide, so i took a brass foil, hard enough.
Title: Re: 1989 K75 reanimation
Post by: koshak on November 23, 2020, 08:24:49 AM
O-rings installed, ready to assemble
Title: Re: 1989 K75 reanimation
Post by: koshak on November 23, 2020, 08:25:51 AM
after 280 ml filled into each fork, assembly is finished.
Title: Re: 1989 K75 reanimation
Post by: koshak on December 07, 2020, 01:10:30 PM
Result of Black Friday:

Title: Re: 1989 K75 reanimation
Post by: Rcgreaves on December 07, 2020, 02:30:48 PM
Soooo, just curious:


My recollection is you are ON the lsle of Cyprus correct?  So do they have Harbor Freight there? (Maybe that's not a HF branded lift? (Very nice btw!)  Or, maybe you bop around the world and these black Friday pics are in the USA?

Title: Re: 1989 K75 reanimation
Post by: koshak on December 08, 2020, 01:33:39 AM
Huh, i thought i am alone here  :laughing4-giggles:

We do not have Harbour Freight here, AFAIK.
I took it from the local bikers shop. It is not a HF branded lift.

(https://scontent.fnic1-2.fna.fbcdn.net/v/t1.0-9/56852690_1143145399209340_4362496147672006656_n.png?_nc_cat=109&ccb=2&_nc_sid=cdbe9c&_nc_ohc=NhZSab2vlJMAX-mTMvl&_nc_ht=scontent.fnic1-2.fna&oh=e0f431816d99d4bcf231fc599001bc6d&oe=5FF69EE8)
Title: Re: 1989 K75 reanimation
Post by: Past-my-Prime on December 09, 2020, 08:11:36 PM
Huh, i thought i am alone here  :laughing4-giggles:


You are most assuredly NOT alone here. Enjoying the photos and the time and dedication you are putting into your rebuild.  :1thumbup
Title: Re: 1989 K75 reanimation
Post by: koshak on January 15, 2021, 11:46:55 AM
conrod bolts still did not arrive, so basically nothing to post.  boohoo
meantime assembled frame with electrics.

but i have a HELP request to the society.  177381

i have found in workshop snap ring as shown on photo.
several days silly me tried to identify from which part of bike it was coming, could not find any reference and it is missed on all photos i took. 177381

can anybody point me where this ring should be installed?
Title: Re: 1989 K75 reanimation
Post by: The Mighty Gryphon on January 15, 2021, 02:44:27 PM
Judging from the size, my first guess is that it came out of one of the fork tubes.
Title: Re: 1989 K75 reanimation
Post by: daveson on January 15, 2021, 05:22:42 PM
Another vote for the forks.
Title: Re: 1989 K75 reanimation
Post by: koshak on January 16, 2021, 03:07:35 AM
my thoughts were same.
on photo all parts from one fork, there is no this snap ring.
(http://www.motobrick.com/index.php?action=dlattach;topic=13326.0;attach=80446;image)

I opened another fork, which has extra parts, and regretfully also did not find suitable place for possible missing snapring. Also did not find it on the drawing of the forks. Required snap ring is installed.
Title: Re: 1989 K75 reanimation
Post by: Martin on January 16, 2021, 03:25:57 AM
 [ Invalid Attachment ]
Regards Martin.
Title: Re: 1989 K75 reanimation
Post by: koshak on January 16, 2021, 04:55:50 AM
no, wrong type. And if not installed - will not hold springs inside.
Title: Re: 1989 K75 reanimation
Post by: Laitch on January 16, 2021, 08:14:37 AM
can anybody point me where this ring should be installed?
Did you reinstall this?
(http://www.motobrick.com/gallery/3/1601-160121081313.png)
Title: Re: 1989 K75 reanimation
Post by: koshak on January 16, 2021, 12:12:03 PM
Did you reinstall this?
(http://www.motobrick.com/gallery/3/1601-160121081313.png)
yes I did . that is kind of "wire" spring. mine is "plate" type.
Title: Re: 1989 K75 reanimation
Post by: daveson on January 16, 2021, 07:55:57 PM
I spose you already checked this, but I'd be looking to see if both forks are identical.
Title: Re: 1989 K75 reanimation
Post by: koshak on January 17, 2021, 02:45:26 AM
I spose you already checked this, but I'd be looking to see if both forks are identical.

brembo sport are not identical by construction.