Dai
Life time member
Number of posts : 5700
Any K reservoir is now old and prone to cracking. Get an aftermarket one from ebay (yes!) and a length of new hydraulic hose. Mount the reservoir on a bracket bolted behind the top footrest hanger bolt. Saves having to remove the battery/drain the hydraulic system if you need to remove the footrest hanger.
The battery tray anti-vibration mounts are another story; either a Mills & Boon romance or a Stephen King nightmare novel. It depends. I've had both. Try removing them; it's an M6 thread in the gearbox and if you are really lucky, they will come out in a rusty lump leaving the threads intact (the threads will need cleaning). Go to ebay and get a set of 20x20x6mm thread male-male anti-vibration mounts and cut down to suit. Use copious quantities of copaslip when winding them in.
If the rubber tears off the mushroom, I don't see any way of proceeding without getting the gearbox out. Clean all the remaining rubber crap off the mushrooms, then cut a slot across each one to take an impact driver bit. Get as much heat around each mushroom as you can before blattering the bejesus out of the bugger. If it starts to unscrew, great. Rinse and repeat with the anti-vib mounts as above.
Now to the Stephen King nightmare novel(s). Chances are that one or more will just rotate which is fine (to a point); a bit of penetrating oil in there and you should be able to lever it out with a screwdriver. With luck, a shitty lump of rust will come out and you will be able to clean the threads with a 6mm tap. But: in this scenario the threads in the gearbox may have been destroyed. Three of those threads go right through the casting but the forward-right one is a blind thread about 6mm deep. Drill and tap the three through holes to 8mm. The fourth (blind) hole I'm going to leave to you. If you're skilled with the hand tools you may be able to thread it with a modified bottoming tap (which is what I did).
There is not enough room in the battery tray recesses to successfully use an 8mm full nut. Get a set of 20x20x8mm thread (or 30x20x8mm - the 20mm height is the critical bit) male-female anti-vibration mounts. Also buy four 10mm long x 8mm thread button-head allen screws to hold the battery tray down. If you haven't threaded the blind hole then just cut the male thread off one mount. Drill the battery tray holes out to 8mm.
The very worst scenario (and I've been here too and I really don't want to go back) is the mushroom shearing off the thread. If you have a pillar drill you should be able to drill them out but I spent hours (well, about twenty minutes) figuring out how to level up the gearbox and hold it securely. A handheld drill is a total no-go. Call in the professionals and go up to 8mm threads...
For the exhaust, PM me with your address and I'll send you a tube of Delkovic exhaust paste.
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1983 K100 naked upgraded to K100LT spec after spending time as an RS and an RT
1987 K100RT
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