Hi all , a quick line to say hello. Found this forum searching for info on the bike. Located 8 miles east of the city of Liverpool, UK.

Battling with a recently acquired 89 K100 RS cat C insurance write off with fault after fault.

Almost 61 years old [and starting to feel it] I just cant leave bikes alone.


Cheers all

Dave

Dirk

We understand - there are a lot of us with the same condition here! Plenty of info to be found here for those faults - I'm sure you'll get them sorted.

88

Welcome Dirk. We all suffer the same (or similar) affliction, us blokes. My missus reckons I spend more time with the bike than with her...it's true, but not because I don't like a bit of the Boogieng. If I can't sleep it's Nights in the garage. It's hard to keep a good man down. Or is it the other way round?

welcome dave ...in the end you wont be disapointed ...a great beast to ride

enjoy the experience ...and happy riding when you get to it

Welcome to the forums Dave from another UK member - pretty much anything you need to know will already have been answered here somewhere - if not it is a simple case of asking the question

Thanks for the kind welcome guys.

After rebuilding the water pump I don't seem to be able to get the fan to activate in the garage whilst its idling, note that I have never seen it run anyway as I haven't had it long. I rebuilt the water pump seals because I had oil leaking. The oil leak/weep was from the flange directly behind the oil pressure switch. Changing the seals didn't cure it and I think now that I did all this work for nothing, and the original seals were fine. I used blue Hylomar for the sealant and despite an email to Hylomar asking would it be suitable for the seal and it says on the product it is, it still leaked in exactly the same place (grrrr). The second attempt at sealing I went to the local car accessory shop and picked up a tube of 'ABRO' black silicone sealant. This now appears to have done the trick.

One thing that I did not do was to fill the cooling system with the full amount of coolant, it was well short by about 50%. This was not intentional but a mistake. I saw the level on the expansion tank and wrongly assumed it was correctly filled to the right amount. What happened next for me was very very bad. Whilst underneath the bike with engine running looking with a torch to see if I had fixed the oil weep, the bottom radiator hose literally blew off from the water pump. The resultant extreme steam and very hot water spewed all over me giving me severe scalding to most of my left arm, right arm, right thigh, neck and face. The main damage being to my left arm. I just got out of hospital this afternoon. This was my fault entirely, I am convinced now by not filling the cooling system with the full amount. Stupid mistake, yes I know.

I'm still wondering if the radiator cap should maybe have relieved such pressure as it must have been quite high to blow off the hose, the cable clamping band was very securely tightened that I am sure of.

So a lesson learned there how things can very easily go wrong if one is not careful (and I usually am), and a very painful one at that as I have now severe burns to parts of my body that will take weeks to heal.


I still don't know if the fan will run/cycle although I do know the fan itself is ok. Waiting for my wounds to heal and the bandages to come off.

So now I have plenty of time to trawl all the info here on the fan problem......if I get stuck I'll start a thread on it.

Cheers

Dave

Well that surely sucks Dave. I know just how frustrating waiting to heal is at the moment I have my left arm in a cast up to my armpit and don't even know when its comming off.
I would expect the relief valve in the cap to open before the pressure got that high.

Sorry to hear that you have invented the steam engine, but it isn`t that much used anymore.

About Blue Hylomar, I`m also quite fond of that one.....but at the oilpump/sump joint it`s useless due to the oil pressure....tried a lot of different...ended up with Permatex black RTV.

To test the function of the fan itself, remove the relay and short terminal 15 and A2 in the socket.......first check that the fan isn`t stucked (not unusual).

To test the relay itself put positive feed to 9, negative to 31....and when you then add negative to E you should hear and feel the relay clicks.

I do agree that the relief valve should have opened, and maybe it did..but couldn`t cope with the volume through the small opening.

When water turn into steam things happens amazingly fast, and with a lot more empty volume to build up the steam pressure...............

But it could be a idea to pressure test the cap....should open at 1,0 bar +0,15.

Guys


Rick G
Yes it sucks and very very painful it is, but my fault entirely for not filling the cooling system to the correct full amount, I hold my hands up. Reasonbly convinced now that is what caused the problem.


Inge K

About Blue Hylomar, I`m also quite fond of that one.....but at the
oilpump/sump joint it`s useless due to the oil pressure....tried a lot
of different...ended up with Permatex black RTV.

The anoying thing is I sent an email to Hylomar asking if it would be suitable as I was unsure and the reply came back as yes.
The second attempt was with ABRO black silicone sealant. Seems to be OK, wont know for sure till I get the bike running again.

I do agree that the relief valve should have opened, and maybe it
did..but couldn`t cope with the volume through the small opening. When
water turn into steam things happens amazingly fast, and with a lot
more empty volume to build up the steam pressure...............But it could be a idea to pressure test the cap....should open at 1,0 bar +0,15.

Well the hissing noise when the bottom hose blew off was extremely loud, quite frightening really. So I gues your probably right there over the amount of pressure.

Lesson leanrned the hard way I'd say, I will be more carefull in future but as I get older the accident do seem to be more common duh!

Thanks very much for on how to test the fan. I know the fan works because I put 12V on the connector when I repaired and painted the radiator recently.

I have another question if I may ask?

This bike has the ABS removed, I know that for sure as there are no pumps on it, there is a fluid line bypass loop on the rear mudguard, there is a very large multiway connector hanging in the rear cowling, and there is also a relay missing in the big box under the seat where all the other relays are.

My question is this guys.

Is there a picture available of the relays in this box under the seat with what they are and the pin connections anywhere please? So I can carry out the suggestions re testing the relay. There are two big relays in that box. One has been removed, the one on the LH side when sitting on the bike. I'm guessing thats ABS but not sure.

Just waiting now a little for pain to drop somewhat so I can take a look, although the ear-ache I'm going to get from the wife the minute I set foot in the garage will be far more painful! That I am quite sure of

Thanks again.


Dave

Dirk Digler wrote:My question is this guys.

Is there a picture available of the relays in this box under the seat with what they are and the pin connections anywhere please? So I can carry out the suggestions re testing the relay. There are two big relays in that box. One has been removed, the one on the LH side when sitting on the bike. I'm guessing thats ABS but not sure.

Dave

Have a look at the pictures close to the end in this thread,
which shows the relay box from a ABS euqipped bike.

Wiring diagrams and relay pinouts, you find at the portal.
(Pinouts in trouble shooting guide).
Wiring diagrams is to a older model than yours, so all isn`t identical............but most.

Hi Dave,
Welcome aboard. One tip please post your question/s in the section of the forum which relates to the fault because not all of the really smart guys read this bit but only read the bits they are interested in so you may be missing a vital nugget of info that they can offer.
Regards,
K-BIKE

Dave,

When my oil/water pump seal failed it allowed oil into the cooling system which caused the rubber radiator cap seal to swell quite alarmingly. This prevented the flow between the radiator and header tank. As a temporary solution, I cut 1/4" out of the seal and superglued the ends together.

It may be worth checking your seal, it should be about 36mm od, 26mm id.

Paul.

Inge K, K-BIKE & sidecar paul

Thanks for the advice , I will check soon as I can
Regards to all



Dave