This is more of a light makeover and cosmetic tidy up than a restoration but I decided to start a thread as a record of the ground I'd covered.

I bought the bike in May '10. At the time I had serious dose of cabin fever and was minding 2 small children while nursing my wife who was seriously ill. Most evenings I was trolling the web for amusement when I happened across the LT.

A couple of days later I inspected it test rode it and loaded it into a horsebox to transport it to a friends house for storage, where it sat for almost a year.

The first thing it needed was a new battery but it wouldn't stay running so I gave it to professional mechanic who owed me a favor. He did a full lube service and diagnosed the conking out to the ICU which he arranged a secondhand replacement for and all at a resonable cost. And so I was able to ride although it looked shabby. Biggest let down was the screen which was almost nicotene stained colour. So I polished it up a bit.

Before...



After...



The write up on how I polished it is in this thread.

After sorting the screen I turned my atention to the panniers. The hinges had split and the top box came with a lock that didn't fit the keys so I go that rekeyed...

This thread



and the pannier/koffer hinge repair....covered here.

By now I had a bike I was getting the odd spin on but the back tyre was veryt square and the front getting low...so on went new tyres

Whilst I had the wheels off I painted the rear carrier and heat shield too.

I simply enjoyed the riding for a while when I decided it was time to paint the front forks and disks.

I posted a thread on that too but in brief here's the before n afters...





and here's the full thread on that job..

While I was doing the fork legs and disks I decided to paint the radiator grill which was very rust but when I went to remove it I discovered damage to the more delicate top section so I repaired that see this thread.

before and afters....





I also spotted the tank leak at this point and repaired that while it was all apart.

While fitting a rear brake disk last week I wrung off the two set screws and had to remove the exhaust to get a better drill angle. Of course a couple of exhaust studs wrung off in the process and on the suggestion of Rick G I went in search of a matress to lay the bike down on for better access to drill out the remains.

Last night I stripped the fairing and found a couple of problems on the way. The Radio was incorrectly fitted (a blauplunkt but not an original anyway) and I had to destroy it to get it out. Stripping the top fairing has been on my "to do" list for a while but I must confess to being intimidated by all the plastic and risk of damage to it but I got it off to reveal some horrors.....

broken mount



absolutely grotty front stay bars..



and the backing plate of the instrument pod needs to be painted too. So I'm going to attempt to get all those things tidied up and repainted before reassembling.

So this is how we look at present..



I'd also like to polish up the exhaust headers and paint the engine covers before reassembly.

a good thread 88

keep em comming ...hope you add some of the other fixes ...centre and side stand ?

the old girl is looking better after each little bit ..

One of the dangers of working from home is that you have a little wander out to the shed at lunch time and get distracted..

I've had this sitting on my desk for the past couple of days.

url=https://servimg.com/view/16818459/108][/url]

its a cuttable LCD bar per CF's modifiaction all the details are here. My parking light has never worked and replacing it with and LCD style DRL has been on my radar for a year. With all the bits on the floor it was too much to resist spending lunchtime at a clean little job..

I opened up the headlight and cleaned it. The led strip comes with a socket at both ends and the cable also has two plugs. I split the cable in two then cut two stips from the bar and glued them together lining up the LED as best I could (they are not perfectly symetrical). Then I soldered and heatshrinked the connections to a wire tail..



On his mod CF removed the parking light reflector. I kept it in and using the hot glue gun, glued the bar in the middle. It can be bent a little to fix both ends .



The wire tail was fed out through the hole for the bulb holder which I sealed with a grommet. A couple of insulated spade terminals will connect to the loom, The lamp was then reassembled.



Now I'm looking for a nice white H4 bulb around 80w to match the LCD's if anyone has any recommendations. I didn't photograph the LCD's working (yes I did check they work) because they are so bright it's really hard to capture on camera but trust me they are really really bright (See CF's Photo's if you don't believe me )

That's probably all I'll get done this weekend as I'm off to vist the aged parents in the Wesht of Oire land tomorrow!

88

charlie99 wrote:a good thread 88

keep em comming ...hope you add some of the other fixes ...centre and side stand ?

the old girl is looking better after each little bit ..

Yep Charlie, "slowly, slowly catchy monkey" - thanks for that . Looking at it all in one thread I feel like I 've done a fair bit over the year.

I'll add some of the other upgrades like the k1100 stand as I find the threads. I also need to paint the frame, the front of it is gone a bit scabby so I want to see what I can do without stripping too much out of the frame.

88KE

Good thread 88,
Wonder Wheels is good for removing the brown stains from the exhaust, finishing with Solvol.
Cheers,
Paul.

Thanks Paul, I just started on them with some 800 grade wet'n'dry and it's shifting pretty well. I might try the solvol to finish.
88

I've finally got as far as laying the bike on it's side to drill out the offending exhaust studs. I'll be replacing all the studs, crush washers and refitting with the copper faced nuts.

I'm going to swop the stand while I'm at it.

Are there any other jobs that having it on it's side gives a good opportunity to do?

88KE

hehe i am sure it would have been easier to drop the engine out than laying the beast on her side!

twincarb wrote:hehe i am sure it would have been easier to drop the engine out than laying the beast on her side!

Probably Twincarb. I removed all the plastic except the tail and front mudguard to be safe. But I had loads of jobs I wanted to do that for anyway.
88KE

have to say i love the led's within the headlight, something to add to the list of jobs for mine i think

Wow 88KE just came across your thread really good mate keep them comming your doing a great job really like your work. Amazing after all these years these old girls still get the pampering treatment all around the world it's great.

Halo

Amazing after all these years these old girls still get the pampering treatment all around the world it's great.

And so they should, rather than let them go to the K Bike graveyard in the sky

Mike

Cheers Mike D and Halo. I don't know if I'd call what I'm doing "pampering" though

Halo - yours and OG's threads were the inspiration for pulling all these random posts and threads together into one record of my journey with the LT, So thanks for that.
88

Thanks 88KE. Keep posting the pampering of your baby. We enjoy seeing the progresses.

It may be an inspiration for others too.

Thanks CF!

Last night I got the bike down on its side (I learned how to do that on a filling station forecourt! ).

Here's the problem...the one on the right is broken off in the hole/socket the other wrung off proud of the casing but not enough to get a good grip with two nuts on it..



I started on the right hand hole and after a few attemps at centering and slow patient progress I was delighted to find I was really on the money. You can see the stud is perfectly drilled out leaving the old threads just visible and ready for a clean up with a tap...



For the other one I cut off the bolt flush with the casing using a little dremmel which was an impulse buy in Aldi or Lidl. Thank God I had it as I don't know what else I would have been able to get in there with..

.

This one didn't work out so well as the oil filter cover spoiled the line for drilling and the bit ended up wandering off centre preferring to travel in the soft aluminium of the casing rather than the stud. I then had a bright idea (well bright for me at that hour of the night!) - I used a header flange to help keep the drill on centre...



After drilling I cleaned up all the holes with the tap and I'm just waiting for the studs to arrive..I'll be refitting them with copper grease, hopefully I can find some heatproof stuff locally.

While that was going on I had my repainted clock backing plate and front fairing bracket baking in my little "oven" and I had glassed the mounting back onto the fairing but I think I'll put some more fiberglass around that to strengthen it.

Here's the clocks "after" pic..



then it was time for bed!

88

Would have been a better idea to weld a nut on to the second one. The heat from the welder would help to shift it. That is of course assuming you had a welder handy.

Never thought of at avenger GT.... Lessons learned!

88KE wrote:Never thought of at avenger GT.... Lessons learned!

Or to cut the stud and screw a nut on it to make a guide for centering your drill bit

"Or to cut the stud and screw a nut on it to make a guide for centering your drill bit "

Noted for next time it happens!

K1100 Side stand is ready to go on... all rebushed greased etc etc. Here's the thread I started on it. I'm looking forward to seeing the difference.



I had to swap the link arm and swivel plate from the old stand (for the side stand safety) in place of the K1100 one held.

When I took off the old stand with the bike down for doing the exhaust studs this little spring dropped off..

url=https://servimg.com/view/16818459/120][/url]

Can anybody Identify it?

88

looks like the preload return spring off the foot brake / master cylinder ...on the right hand side 88

you wil find 3 grooves on the right hand side ...2 for the centre stand lift springs ...and this little sucker fits between them and the master cylinder push rod thingy bob .

ill take a pic and post it for ya ...!

charlie99 wrote:looks like the preload return spring off the foot brake / master cylinder ...on the right hand side 88

you wil find 3 grooves on the right hand side ...2 for the centre stand lift springs ...and this little sucker fits between them and the master cylinder push rod thingy bob .

ill take a pic and post it for ya ...!

You insomniac Charlie . I had it figured for a rear brake component and was wondering about that 3rd groove the other day - didn't put the two together - DOH!

Pic would be appreciated.

Thanks

88

here ya go ...laying o my back upside down in the moonlight ...under the bike and big cover over it .....taking pics ..wonder what the neighbours think ......bugger them ..they dont have a clue ...



see how quick it was ...my internet works much better this time of night ....giggles (like a mad man )

and berts black paint and center stand mod still amazes me ,,

Well done Charlie!

charlie99 wrote: ..wonder what the neighbours think ......bugger them ..they dont have a clue ... ,,

You're a gem Charlie!

I used to get funny looks off my neighbours for cutting my grass at night but thats why my ride on has lights right? Anyway ya gotta do what ya gotta do!

Thanks again

88

Well I've been poking away at small jobs around the bike most nights and taking the opportunity to tackle the "long finger" list while all the fairings are off the bike.

I polished the headers and got the exhaust and stand mounted....



Got the fairing repaired...



and I've been getting some paint on the frame under the tank where there was a bloom of fine surface rust. I've been moving the components and masking everything, doing one bar at a time. A rub down, treatment with rust remedy then two coats of plasticote. It's not a total solution and the frame really needs to be blasted and powder coated but that's not on my agenda for this year at least so my short term aim is to stop the frame deteriorating until I can do that.



you can see the before and afters looking at the bottom right of the picture..

My plans have taken a turn this afternoon when my car "spat out the dummy" (thinks its piston rings) in a bad way. I'm going to have to defer doing the back part of the frame and the engine covers and put the bike back together as I'll need it for transport for work next week.

I put the repainted front bracket back on tonight ...



Just need to fettle the wiring on that and removed the air box to get at the petrol line from the tank which is perished and an accident waiting to happen. So I'll be off to town in the morning for some hose then I can continue reassembling...

Looking forward to a spin at this stage actually!

88KE

really getting stuck into it 88 ...

great looking pics and work mate .....

cheers from down under

Well the reassembly went well. Some new fuel line purchased on Saturday morning and the game began.

After bolting the top fairing up to the frame the reason for the broken stud became apparent. The frame is out of kilter but I didn't notice until I went to put the lower side panels on. I used a couple of ratchet straps hooked to the frame further back to straighten it..



There doesn't appear to be any accident damage or repairs to the frame, steering head or forks (I got no history with the bike) so I'm guessing the damage is from a drop at some point.

I was amazed at the number of screws and bolts left out/missing and mixed up by previous owners or mechanics and I put everything back as it should go but I found myself running out of them towards the end and had to hunt in the workshop for suitable replacements.

I also found I had lost one of the battery tray mounting rubbers, which explains why it was cockeyed when dismantling. I stuck a chunk of high density foam in there until my next parts order.

This morning was wet and very windy - not ideal test drive conditions but the bike ran well. I couldn't decide if I was hearing new noises or just paying extra attention to old ones after dismantling. Maybe they just changed because I put the screws back differently. The new rear brake disc was noticeable as it beded in towards the end of the ride.

The k1100 side stand is way easier to get the bike up on but definitely a bit harder to get it down off. That said the longer lever gives more control ( I always take the bike off the centre stand before mounting it).

2 things I have to check on the adjustment of the side stand clutch inhibitor;

1. the clutch seemed a bit stiffer than before

2. I can put the bike in gear with the stand down.

Any tips on adjusting the link rod more effectively?



The LED running lights are great only ten minutes into the ride I saw a guy pull out of a side road a bit, look at me move forward again then stop. I'm sure the super bright LEDs caught his attention and made him think twice about how far away I was. Definitely a great safety mod.

I got a brilliant white H4 buld to go with it and I also have 3M white reflective flashes on the wing mirrors to give the bike a good wide front profile.

I will have to look at doing the water pump seals soon also I have a bit of oily crud under the Rad/top of the timing cover but cant see where it's coming from..



The top of the engine under the air filter box was very clean, any ideas?

88KE

"I will have to look at doing the water pump seals soon also I have a bit of oily crud under the Rad/top of the timing cover but cant see where it's coming from.."

Hit it with degreaser and keep an eye on where it starts to leak.

"The top of the engine under the air filter box was very clean, any ideas?"

Umm...that's good isn't it?

Yep that's good. Blakey, I was pleasantly surprised at conditions in there, I thought I might see years of oily crud.
88KE

the oil at the front could be comming from the timing chain case covers 88 ...looks like someone has tried to seal up the cables going through the front face of the timing cover as well . doesnt look too hard to solve ....when you get round to it

Great work mate. Really impressed with the stand mod. I find stripping and painting rusty bits one of the most satisfying jobs.

PS I'm still loving the colour!

All the Best
Dave

Cheers all. Went out and got some heavy duty degreaser today so we'll clean up the covers and bottom and observe the leak rate.

The colour is staying, Dave.....for now anyway
88

A bit on an unscheduled dismount today has added quite a bit to the "to do" list...



A car took a bend a bit wide to say the least, forcing me into a gateway where I had to quickly choose between hard braking on loose gravel while banked over or take to a muddy open drain...I chose the drain as a better chance and softer landing. Damage is mostly to the lower side panel (which was all ready weak and had many cracks), the top fairing and radiator shroud came away with minor damage and scratches as did the crank cover. The R/H pannier popped up and took off the rear indicator. I was muddy but completely unhurt as I wasn't going that fast (about 35kph) and due to a good set of boots my foot/ankle which was under the bike was totally protected. The scary thing is that I looked at the boots this morning and thought "I'm only popping into town" then I though ATGATT.

I've cleaned it, bolted on the indicator temporarily until I get a new one, put back the mirror and re-riveted the frame latch onto the pannier and it doesnt look too bad at all. I also stripped off the side covers and made a bracket for the radiator shroud.....I'll be travelling "Charlie 99" style for a while!

88KE

phew !! glad to hear your ok 88

Glad that you are OK and unhurt. Side panels can be repaired and won't suffer from arthritis later in their life. You could...

On the funny note, there is a nice k110lt donor in Australia. You jut have to talk to GITH

Sorry for the smilie. You crash is not funny at all and I feel the pain too.


CF

Thanks guys. Thanks for the smile too CF, GiTH is sharpening his tools as we speak!

Engine bars have just gone on my wish list!
88KE

Bad news for the bike glad you are OK and that the lightning fast decision was correct and now you are able to start the fix.
Saw a fireblade go into a very soft muddy drain some time ago and except for the mud and grass it and rider were pretty much unscathed but what a show when he hit, mud flying everywhere.

Phew, that wasn't a nice picture to greet me tonight, glad you are OK and I hope the picture looks worse than it really is.
I feel quite subdued.
Paul.

I'm quite uplifted Paul. Just been for a spin in the evening sunshine to check everything is ok and aside from feeling a bit weird without the lower fairings and inserts everything is spot on.
Broken fibreglass always looks worse than it is.
88KE

Oh no 88KE as Paul said that wasn't a nice picture to see when I looked at your thread I'm glad your ok bloody tin tops they will never learn, it should be compulsory to make everybody ride a bike for awhile before they get into a car.

Glad to hear your OK though mate

Halo

it should be compulsory to make everybody ride a bike for awhile before they get into a car.

Gosh! my dad said that to me in 1970 when he bought my first two wheels, a 150cc Vespa Scooter for £16.00 ( ), Before I had even passed my test, and had bought a 500cc triumph (well he bought it actually with my savings), I wasn't allowed to ride either until he had educated my in stripping them down and understanding how they worked. Afterwards he wouldn't let me out of the road on the Vespa until he was satisfied I had the gist of what I was in control of. He said 'The throttle works both ways'

It is still in my heart those nights spent in an unheated garden shed with him showing me how to strip them down and rebuild (more than once!!)

He had ridden numerous British bikes, the last being a Vincent Black Shadow, so knew his onions !

Mike

Mike D, this women could be your grand mother and you would only agree with her.
We should ask her to join the forum

Sounds like your dads a good man Mike D with some smarts with bikes

Halo

Well CF, I bet she would be prepared to chip in with the odd forum comment

Thanks Halo, he is in his eighties now, with a bad ticker, but can still be a bit cantankerous when he wants!

SWMBO says I am just like him at times, especially the cantankerous side

Mike