could this be the day that the head goes back on ?

bit more work in preparation yesterday



waiting for silicon sealant to go off on the case covers

Mate let me know if you need a hand.

thanks marky

going along just fine ....just the heat and humidity takes its toll  ....uuuggghhh

yep ...ill have to do the starter soon ....bit of a hesitation as it rotates ....ill put it in the gearbox bearings replacement ...to do soon

mmm new to me 4 hole injectors  






whilst in there I modded the conversion throttle cable adaptor plate to the throttle bodies ...I was only getting about 60 % throttle opening ....the cam for the throttles was hitting the bracket and the cable was too short

More throttle!   Yes to that idea.

The noise they make when loaded up and you give her a big hand full, the sucking of air into the still air box whilst coming up onto cam. One of my favourite things to hear. Dam, think I'll go do it right now.....

I like it when a plan comes together.

starting to look like a bike again ,,,,exhaust on,  but loose at all the joints till it gets some heat in there



bit more work, then calling it a day ,,,about time to measure the camshaft journals for clearances as these are off the restored head and the cams out of gerty ....best to be sure ...to be sure ...plastiguage ...wonderful stuff .



made up a box last night to hold electronic bcd converter to decimal gear indication thingy for rick





its all happening ...kind of ,,,grin

dang just spotted some corrosion on one of the fuel rail insulator caps ....bugga !!

a little investigation into clearances shows some differences between cam journals ....a little more work is required ...would like to get them all back to .75- 1 thou

lucky I looked and tested


oh well, some more work later tonight ....but overall not too bad....  for an old one that im restoring
inlets are all good  ...much like the wider squish of the plastiguage on all ...now ...outlet cam tomorrow

almost done ...lost some time today due to nana nap ......well its Christmas isn't it ?





will need to charge the old girl overnight ...been nearly a month since last running  and its tight ...more likely the battery is on its way out

problematic to start the first time ...rechecked everything

but some "start ya bastard "  worked fin ...just a squirt down 3 of the vacuum take off lines

wonder full stuff



now the old girl cracked into a start in maybe 2 seconds and an even one ...well kinda ....things still loose and clamps not done up

old gerty ... a short clip

https://www.facebook.com/video.php?v=10202017850688034

enough parts thrown together for a test ride, and all good so far

cheers

charlie99 wrote:old gerty ... a short clip

https://www.facebook.com/video.php?v=10202017850688034

enough parts thrown together for a test ride, and all good so far

cheers

Nice. Well done man. Good for another 300,000 now huh 

Push On......

Almost there.....

I was pacing you, I got Bluey back together two days ago, still a couple of issues but a run soon would be good.

I started a page:-

https://www.k100-forum.com/t9223-she-is-all-in-one-place

For the moment when she is all back together "In one placed"......


I'm really interested to hear what you have to say about the exhaust system and the new injectors.......

that problematic start yesterday has resurfaced today ,,,bugga

fi relay tested ...fuel pump tested (and run in the reverse direction ...just to be sure ) and consistently pumps ,,,that blooming fuel tank connector ??!!!  changing out for a new one ...lets see how this goes


oh !   some thing you may not see again ...well for a while

the underside all shiney  ...including free finger in the corner ...giggles

Now you have got my attention, looking good there Charles old bean. Clean pipes clean mind.

it must be Christmas

duff battery ...9 volts on crank and less to the fuel pump by the time it gets there (about 8 ) now I fixed up all the connections

charlie99 wrote:

the underside all shiney  ...

Nice. And I see you are still using OEM header stud nuts! Awesome!

why not ?...they have worked well for almost 30 years ...brass as well

charlie99 wrote:why not ?...they have worked well for almost 30 years ...brass as well

Yeah . . . nice. I replaced mine on the old engine (not oem though). Cannot remember why. I think they were still servicable

I do use a different socket driver on my nuts ...(oops sorry about that)   but it grips the nuts on the flats rather than the corners ...brass is known to strip off pretty well when bound on "tight as"

Batteries that are ready to drop the bundle often do it after a month of work.

yeah guessed that rick .....when started its all good,  oh well lets see whos open after boxing day ...I have a battery warehouse I usually use ( good prices  but not back till I get back to work on the 5 th )

battery is in but

found another issue ...but wish it was yesterday

have a look at this



one of the cage retention bolts from the reluctor plate (near the hall sensors) has come somewhat loose ...removing the magnets from the assembly as it unscrewed .

that would explain why the ecu is looking for rotation signals coming from the hall effect sensors ... but not seeing any


oh well monday well see what's around locally  (jaycar et all )

nearly there

cheers

Mate do you want to pinch it off mine.
I have a bit to do before I need the spark up the engine again...
Newstead,,,,

na  its all good marky

ill head over to jaycar and pick up a couple Monday   (siemens units )  about 40    all good
thanks for the thought mate

hall effects got

might have to fix them with screws rather than rivet method

there is life.....yaaahhoooo !

now to rebuild all the electrics again

cant believe it .... started about 2 seconds after hitting the starter and pressure through the fuel rail

relief !!!

Good work Chas ,I know it's on the forum somewhere but could you lay us the Jaycar numbers and how many spondoolies please ?

try here ghosty

just 19.95  each

http://www.jaycar.com.au/productView.asp?ID=ZD1900

note the store I attended only had 2 on hand ....so might pay to call ahead to your nearest store first ?

Thanks Charlie, think I'll buy 3 (ha ha ha) and that should see me right for the future.

might just add ...the fixings for the hall effects seem to be riveted with some sort of steel

it would pay to obtain a really sharp centre punch  to mark the position of the centre for drilling out .... I would in retrospect use a bench drill for this rather than freehand with a cordless battery drill  as it does wander

2,5 mm drill is good ...and after  go with a 9/64 th drill bit ...final clearance with a 3mm rat tale file  or something  (the posts measure bout 3.72 mm as supplied )

2,5 mm screws are a little undersized for the holes supplied in the sensors ...but it seems hard to get some of the ba sized bolts that should fit perfectly ...fortunately the posts hold the sensors in place if you have drilled sized the holes properly the screws just provide the clamp - sheer tightening ..I used inverted star type shakeproof washers  and some thread locker ...tipex (liquid paper )...don't laugh it works

charlie99 wrote:I do use a different socket driver  ...brass is known to strip off pretty well when bound on "tight as"

pssst. I don't wish to say this too loud, but the flange nuts are assembled the other way round. The expansion ring goes against the flange. But, you didn't hear it from me. :suspect:

charlie99 wrote:it would pay to obtain a really sharp centre punch  to mark the position of the centre for drilling out .... I would in retrospect use a bench drill for this rather than freehand with a cordless battery drill as it does wander

Grind the rivet head off and punch it out that's what I did with Marg's K75.

AJ.Valente wrote:pssst. I don't wish to say this too loud, but the flange nuts are assembled the other way round. The expansion ring goes against the flange. But, you didn't hear it from me. :suspect:

Quite interesting..........can you explain a bit more...

If you turn the nut around the flanged part will point away from the mounting
surface, making use of a socket impossible....so you must use a spanner,
would be complicated on the nuts closest to the sump.

To bad that BMW must have mounted these nuts the wrong way around on
a awful lot of bikes.

righto ....time for a test ride

U Beauty!

was running lean on one cylinder or cylinders  ...maybe not sealling properly (built up injector deposits and oil gunk sitting there for a few days ?) till i loaded her up with wot in 4th till 4 k ...idle eceptional now ...running a bit warm ...but acceptable for 39 c and new rings and stuff ....think ill have to put in lots of killometers tonight (when its a good deal 15- 20 c cooler ) till it loosens up ..i guess

a heap of torque and very smooth running, takeoff ...bit hard to tell till it loosens up over the next few hundred k s ....and I change the oil - filter then take it up to 6 or so ...but very promising and a great big grin .




thanks for the bling stan (ainsjack)

Its' a good day!

.

Marky Boy OZ wrote:Its' a good day!

What with Charlie back on the road AAAAAAAAAAAARRRRRRRRRRRRRRGGGG

quite possibly ghosty .....thanks for the reminder was a good event that one ...eh ?

its a rewarding feeling to fumble along and get a result ...maybe not first time ...but a result all the same

150 ks around about the city,  Mt koutha and bay area ....still running hotish ...lets see if an early morning run out in the country will do something ....happy that all the subsystems are holding together ...so far  and I figured out why these pics were blury ...blooming sweat over the camera lens ....blast     giggle








an icy cold beer help the day to finish as a reward


cheer blokes !!!

well this thread is coming to an end .....just a few more posts and it will reach the 1000 number  and alas break up the journey as new posts will be blocked and closed to further  contributions

any thoughts to what I should do ?

start a new thread ...with a similar name and conventions ?

ill leave it to you all


cheers

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https://www.k100-forum.com/viewtopic.forum?t=10084