Hi All,

I've finally been able to get back to getting my ol girl back on the road so I thought I would post in the resto section in the hopes that some or any of this could be useful to folks. I've already gone thru about 60% of the bike, mostly simple things, like spline lube, mounting new tires, rebuilding the seat, cleaning the starter motor and alternator, LED light kit and ventilation in the instrument cluster, brake caliper rebulid, and very modest re-finishing where required like the centerstand and battery compartment. The download section and the members of this board have been a huge help with all this and I simply wouldn't have been able to do it without these resources so kudos to Bert and all you fine members!
Anyway, the bike has a fuel delivery problem, way rich, which was one of many reasons why I was able to get her at a very cheap price so I will be concentrating on going thru the fuel system from tank to engine as per Bert's flow sheet, and I'm sure some other small things will be posted as well as one thing usually, Ok always, leads to another.

Hey Folks,
So after reading K-bike's post on electricity I couldn't help but dig out my little multi meter and sneak out into the garage for a little break and I learned some good stuff. Started with the airflow meter as it cleaned up well and the flapper worked smoothly and I was eager to test if the sensor was causing any problems. At first I couldn't even get a stable reading on the meter and I thought maybe it was going to have to be replaced with a better quality unit, but after a closer look I saw that the pins were in pretty tough shape with a lot of buildup on them. So after some very fine sand paper and than a little cheap electrical cleaner a nice steady reading comes up on the meter. :-) After a final treatment of Deoxit Gold reading dropped a couple more points to pretty much right on target for my room temp as per Bert's Temp/Resistance graph. So as many of the experienced guys always say clean those connections!

Got the rest of the fuel system pulled last night and started to clean things up in my little tank. Found an inexpensive shop to send the fuel injectors out to be cleaned and serviced after all the resistors tested out OK in the 16 ohm range.



Getting the injectors out was a bear so definitely go at them one at a time with wiggling them about 15-30 degrees off center really helping, thanks Bert! The four manifold stacks were in Ok condition and cleaned up well, but the four rubber plenum boots were not in such good shape. Two of the four were split half way around and this was not apparent when they were mounted on the bike.

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So I've ordered new boots and clamps and hopefully all will be in by the end of next week. Fingers crossed!

Brilliant!

How much did the ultrasonic cleaner cost you?

Harbor freight tools for $69.99 and its some of the best money I've spent on a tool. Once I realized I was in a long term relationship with the ol K I started using a silly amount of brake cleaner! This is much cheaper long term and soo much easier.

www.harborfreight.com/25-liter-ultrasonic-cleaner-95563.html

OG

great job .......thanks for the pics as well

at a guess i would be thinking the clean up of the flow meter would be getting your mixtures back closer to normal and a bonus for doing the rubbers on the throttle bodies.
did you replace the crankcase breather tube / what condition was it in ?

Yep, new breather tube as small little cracks were forming on both ends.

How will you sync the flow after rebuilding?
I`d love to do the same job as you`ve done but I`m a bit worried to mess with the synchronisation of the four inlets.
Please feel free to share your experience.
Cheers,Wikur!

Wilkur,

I just took at feeler gauge, a 0.25 or 0.35 I think, laid it up against the inside of the TB throat and marked where the butterflies closed down on it.
Certainly not a flow bench, but I'm thinking it should be sufficient.

OG

just a quick update today as I'm taking care of some house projects. Pulled the water connector and the temp sensor last night actually found a fair amount of gasket maker material wrapped around the sensor so I'm sure that wasn't helping accurate readings! Anyway, after some side by side testing with a new unit it appears my sensor is fine. Will need to get a new water hose as it was the last one I haven't replaced and is starting to show those tell tale signs of very fine cracks and bulging.





Will probably do the radiator and clean the fan motor while I'm there and injectors should be arriving by Tues. Rubber and clamps already arrived so hopefully next weekend she is up and running again with proper fuel mix.



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Finally got the seat reassembled after a little resto so I thought I would post the results. The seat originally had a couple of tears in it and had definitely seen better days with the handles having a few cracks as well. This was all done on the cheap with stuff I had around the garage mostly, and than I purchased a cover from an Ebay vendor for around $50. There are basically two vendors on the US EBay doing quality covers. One is a two piece design and the other is one piece. I went with the one piece design as I liked the OEM look more, but the one draw back to this is that the cover doesn't lie perfectly flat on the foam even with the batt installed underneath as recommended. I'm thinking this may require a partial re-stretch and installation of new revits once the fabric stretches out some more after use. Anyway, a fairly cheap straight forward fix to a common problem on bikes that have seen a lot of weather.

Re-did the handles with simple body shop supplies.








Seat foam was in fairly good shape except for some damage on the bottom from all the rust. Just covered this up with a piece of Dynomat as I've used this on my cars for years and loved it. Great for reducing NHV! Pan had extensive rust and I stripped it and sandblasted, applied a rust sealer, and than put a top coat of the bedliner on it as the rust sealer isn't UV stable.






Purchased some 1/8"x 5/16" rivets at the hardware store, applied a layer of quilting batt, like $5 at wallmart, and simply stretched and riveted the new cover over the cushion.

Oh, forgot to mention. I need a plastic seat cap that goes on the front so if anyone has one please get in touch with me.
Thanks!
OG

Injectors arrived today and I just wanted to give a quick shout to Bill at Mr. Injector! Very reasonable price, 24hr turnaround, and outstanding customer service!
If I can get the radiator and fan pulled tonight it will be on to tank testing soon!

I tried that same seat cover (from Canada?), and had the same issue of not laying entirely flat in the contours. I eventually gave up and bought a good used seat, and sold my other one.

Regarding the rubber mounts between the head and TBs, use a sealant to seal to the head, in addition to the o rings and allen head bolts. Prone to leaks otherwise (ask me how I know). I think TWB also said the same in his write up.

good stuff oldgoat ....love how this resto is going .....thanks for all the great pics

Yep, C it was the one from Canada. I looked used as well, but couldn't find anything in my price point that wasn't beaten to death. If the re-stretch doesn't go well I might look into those new non-OEM seats they are selling at Motobins. Thanks much for the heads up on the manifold leakage! Did you just use a liquid gasket like ThreeBond 1194?

Thanks for the encouragement Charlie!

Great work on the seat!

I'm reading this post with a lot of interest! Well done so far!

Thanks Blakey! Waiting on some more hose parts before moving on to the tank tests.

OG

Goat, the 1194 should be good. Just let it totally set up before you start the bike or you'll do it twice (ask me how I know).

Thanks C! Was just out at the dealer getting more rubber bits and the tech said exactly the same thing. My modus operandi has always been why do something only once when you can screw it up, do it again, and really learn something, lol!

OG

So we'll see if I can salvage the clock out of this disaster...



OG

That doesn't look good. Did you buy this one from New Orleans???

Got it from Florida C for $14 with zero shipping so if nothing else I thought I might learn something, but yeah you're right it is simply a mess. Probably pulled about half a cup of dirt out of it, lol!
Definitely seen better days!


OG

Might find some parts at Beemerboneyard.com

Hey Folks,

Just a quick update as I've been workin my tail off! Finally got some bags for the old girl and a used tankbag as well. No cracks in the bags but they definitely need some resto work and will be in a later installment. Parts should arrive tomorrow so some proper work can be done this weekend. Time to get the old girl running again!



OG

Ahh, the ebay ones? Correct? Thought about bidding on those myself.

When I got my bike, I gave these away. STOOPID MISTAKE.
I kick myself now.

aww poor blakey !!!! ....comiserations

Hey Oldgoat, not the same ones obviously...I'm over her and you're over there.

I feel so bad about getting rid of the bags Charlie99, you can kick me when we finally meet!

Ouch Blakey! Were they in good shape? Yes, these were a Flea-bay deal and I had a 10% off coupon so went ahead and pulled the trigger. They are going to need some work to clean up though.

OG

Just a quickie folks. Got the old flea-bay purchased Ohlins pulled and its off to Oregon City to be rebuilt and re-valved for my setup. Thanks for the heads up Kevin!



Pulled the radiator and fan and that was simply a thing of joy. After pulling off the rubber rad guard its just one allen bolt and the rad. swings forward from the bottom, disconnect the fan plug and hoses and it's out. Cleaned up the head with some acetone and will be sealing the manifolds up tonight. Will also be cleaning and lubing the fan while its out too.

Hope to get some more progress posted up tonight. Just been real busy this week!

OG

Great stuff OG!

Are you trying to rewrite the shop manual?

Well, you know Bert. One thing leads to another!

Radiator cleaned up nicely. Flushed with Lubro Moly inside, citrus cleaner outside, and a little fin cleaning/alignment with the dental tool and it should be ready for the hot days of summer.





OG

Goodonya, OG! Nice work. She'll be a goer when you're done.

Just a thought...but aren't those Öhlins shockies things of pure beauty!?

Yeah TWB my roommate calls it bike porn for the terminally bent, lol!
Now I've just got to figure out a plan of action for the front...

OG

lookin good oldgoat .....keep it going mate


great set of pics

ive got to start looking for a new rear shocker soon also ....the local mob are charging $290 for a reco factory job ...i guess they know the market and charge accordingly .

this realization came to pass as we was cruizing over those twisty bits on our recent ride ...

can i drool on your ohlin a bit longer ...promise i won't leave a trail of yucky stuff .....giggles

Just a quickie folks. Fan was in surprisingly good shape. Just cleaned out with electrical solvent and lubed up with the Microlon and she is purring like a kitten! Off to get some catalyst for the gasket sealer as its still cold here.





OG

Fantastic resto job that you are doing, the induction parts are a joy to behold in pristine as new condition by the look of them.

For fan motor oil on an MB list I inhabit where debates rage long and hard about oils and people debate exactly how many angels can dance on the head of a pin so to speak, the consensus was that ATF oil was the best for fan motors. Several used engine oil and it did not last as long as ATF. Personally I favour mixing in a little molybdenum disulphide for use in a bush bearing or even some titanium nitride just mixed in with the oil.
Regards,
K-BIKE

Thanks K. All you guys have been great with all the assistance and encouragement!

There are always multiple ways to get the job done with regards to lubes and fluids. I'm always a little surprised how excited people seem to get about their choices. Sounds like we have similar taste as the Microlon oiler is very similar to the nitride mixed in the oil.

OG

Scored some activator at Napa so intake manifolds are in and curing. Little dab of oil on the injector o-rings as per Bill's instructions and they popped right in. :-) Time to run some cables and then its on to testing the tank.



OG

beudi mate ...!!!!

Thanks Charlie!

OG - That's going to be one fine looking machine, I'm sure once up and running it will be trouble free for many miles.
Great stuff

What did you put on the intake tube to head mating surface?

Thanks Ungaas! So far things have been cleaning up real well for the most part. Fingers crossed!

OG

Hey Chrish.
I just used ThreeBond 1194 and some surface prep activator as its still cold here. This combo worked on a very stubborn water/oil pump that I thought I was going to have to get lapped to seal it. Anyway, just make sure to at least let it cure overnight.

OG

thanks

Finally found a tank bag on Flea-Bay so I think I'm finally set for luggage. :-)
Thanks for pointing me in the right direction TWB!