Drilled some vent holes in the back panel and used the silicone sealant to adhere Gore-tex pieces.




Inverted shape LED's are on the left.




New clock going in and found a NOS cap on Flea-bay that is in pretty good condition.

Thanks for posting the update TWB! I'm hopeful the little DIY panties will help cut down on the fogging. Good idea about the dry packs and keep us posted on results.

OG

hmm dry packs may not work cause all your doing is collecting the moisture ....but its still within the housing for next time you have a temperature change ...

in my industry i have seen little goretex glands that penetrate into the housing that you need to vent, locally available from "rs components" and im sure across the world in speciallty electronics places ...rather than the local store .



but i like what youve done og .....great stuff

Ahh, good point mate I didn't think of that! I need to find that excellent article K-bike posted on the cluster as over 90% of what I decided to do came straight from that.

OG

i guess if your reasembling og you could always use the old hair dryer before the reassembly ...the idea being to "dry out "all the internals before assembly .....dont forget to get the seals and backing plates all mounted up before the internal temperature drops, that way you are creating a positive presure within the housing .



just a thought

Thanks mate! Excellent tips as always.

OG

Found the link for K's excellent article.

http://k100rt.aforumfree.com/t223-led-lights-in-the-instrument-pod-plus-sealing-out-the-moisture?highlight=instrument+cluster


OG

Had to do a little horking on the cluster mounting plate as my old girl suffered from the common cluster vibration badly enough that you couldn't even see the numbers at any kind of speed. I bought two new rubber bumpers as the old ones were getting pretty soft and I also cut strips of dynomat extreme and glued those down under the factory foam strips. This reduces some of the play in the design and hopefully the dynomat should quell the higher speed oscillations a bit.

holy damn! this thread is just AMAZING (i discovered it 20 mins ago;)) keep up the good work mate, i am looking forward to the end of your mission;)) good luck! i hope i will have enough money and time one day to do the same with my K haha

Blimey OG is there an item that has not seen the OG treatment, this is awsome work mate benchmark stuff, looking forward to the launch and cracking off the champers "what".



BIG D

Thanks guys! I appreciate all the support and assistance I've gotten along the way.

OG

Laying down a bead of silicone around the joint on the cover.





OG

That might help with moisture intrusion at the top where the 'glass' meets the plastic. The cluster sort of floats just below that area and doesn't make contact there. Consider the area around the top cover which is indented...this is where the new O-ring will sit against the other half, and the most likely place, other than the screw holes, that moisture will enter.

Yep mate. Doing the whole deal. Sealed the reinforcing mount plates with the Tef Gel that K liked so well. Also, the screws and the reset knob is a biggie apparently. I should be able to report back with real world bad weather results b/c at this rate she won't be back on the road until the rainy season, lol!

OG

The Pacific North Wet Rain festival, I remember it well. When I lived there it usually kicked off in September after a damp Summer, and ended in May, or June, sometimes July, and a bit of August, if it felt like it. Cheers!

Yep, mate you remember it well, lol! Must be like being on another planet being back in Oz!?

OG

Loading the five green inverted led's for the gauge backlight.





OG

Found the culprit on why the upper left quadrant bulb wasn't lighting up. The circuit foil was folded over on itself instead of going into the bulb socket fixture so it was unable to make a ground contact with the bulb holder. A free simple fix!

OG

I just had to take a pic of this little gem of a digital clock. On a motorbike from the mid eighties you just gotta luv it! Well, as long as I don't look at the receipt from Motobins!


OG

Please please tell me you used neutral cure silicone rubber because if you used acid cure the acid which gets liberated from the silicone rubber just EATS copper if there is any moisture around BTDT with IR beams outside.
Regards,
K-BIKE

No worries K as I remembered from your original posting.

OG

Got the cluster done. Really wasn't that bad, but I would definitely recommend using a plastic spudger or other consumable plastic tool to assist with prying components apart without damaging anything. Oh, and FYI the tach comes out with three of the small black flat head screws and the speedo comes out with just two.















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crikey !!!! only 47,000 miles og ....shes just a "new born"





omg that looks sweet ....^5s brother

About sealing the cluster with silicone: don`t forget the small rubbers at the clock.
Put in a small amount and make it a bit cup shaped, so you don`t get a continiously adjusting clock.

Did have problems with moisture in the clock area (also), solved after I`ve done that.

Inge K.

Looking at the last picture..........it seems that this post was a bit late .

Inge K.

It's never to late to pass on good information Inge and that pic was just a dry test fit so I can do the clock holes if needed. Thanks!

OG

Well, Charlie it's an 85 without full service records so we all know what that means, but the compression test and wear and tear on most of the major components makes me think it's fairly close.

OG

yeah i guess age is the real culprit og ....



like the old fellow who turned 110 .....the press asked "what do you atribute you longetivity to ?"

he responded

"a good clean life with no evil thoughts ....no booze ..no cigarettes ...no chasing wild women" ...but they noticed a frown on his face begging the question ...."oh ! why so sad ?"



"it aint worth it" he says ... .

OG

Final set of screw going in and the cluster is done. The newer model cap had a redesigned reset knob with a metal shaft and a rubber gasket which was great. It all tested out leak proof under water and with the Gor-tex panties and LED's fingers crossed it will be ready for the worst of the pacific northwest winter weather.







OG

OG, you ever thought of being tested for OCD? Don't do it until your finished the K tho.

super work og ......as usuall







if you keep going, there wont be much that this thread hasn't covered

Yeah Oldgoat...make a list of you haven't worked on! It'd be shorter...

Exceptional work indeed!

Lol! Yeah, Club C close friends and family have been recommending that for years!

I don't know guys as I was looking over the to-do list last night and it still looks plenty long! With my play time becoming so short this summer I'm thinking I need to come up with a defer until later list so I can get her back on the road sooner. Not my strong suit, but we shall see...

OG

awww poor old friend ...yes...get her going ....do that ride

Thanks mate. I'm going to look into shifting some things around so I can quit pissing about and get her done!

OG

Hey folks a little good news this week. A buddy who builds high end computers schooled me in how to perform proper lapping technique to the pump surfaces and she is now holding both water and oil. Apparently he does a bunch of lapping on the bottom of the CPU's to increase cooling efficiency.

OG

yea!!! good find og ......in hadnt thought to mention it

Yep, always luv the low cost solutions!

OG

Ok guys I've started getting up at zero-dark-thirty in the mornings so I can do a little work on the girl each day and get her back on the road.

Third time was the charm with the intake. I apparently didn't have the boots on right side up and thus they weren't flush with the throttle bodies. Once this was finally discovered it was very simple to build them up from the head and with a little Ryu-glide the intake box slide right on with no clearance issues and there is now a least a quarter inch of clearance to the main loom as well.







OG

way cool og .......this is the ultimate reference ....giggles

Thanks mate. I don't know about ultimate, but hopefully there are some bits and pieces to help folks along the way. As usual I was wishing I had taken more pics prior to disassembly because I'm thinking the rubber boots were not installed correctly prior to this as there was nowhere near the clearance with the frame that there is now, and as I mentioned a ways back in the thread the intake plenum was actually rubbing thru the main loom. Anyways just another one of the half dozen issues that could have been contributing to the fuel mixture issues.

OG

Gee that wrinkle finish paint looks nice on the cam cover. I might do that with the K11 on both sides.

Yeah Freak I would highly recommend the wrinkle finish powder. They should have come that way IMHO.

OG

Insulated fuel lines were a tight fit, but was able to get everything in without problems.




OG

mmmmm......so good ...

almost there og .........

Looks like the Venhill throttle cable I got from motobins is the wrong size. It's a little over 97cm instead of the 93.7 it's suppose to be. I should have know when I had to file the end cap to fit into the throttle bodies that I didn't have the correct cable! Well, I'll have to look into the options here state side as I would really like to get her started this week. While I'm waiting going to finally pull the FD again and do the seal.

OG

was it leaking before og ?

Yeah mate, its been leaking since I got her and somewhere in my pile of little parts I've got a new seal. Just gotta find it!

OG