Will I Never Learn?

AJ.Valente · **101** Re: Will I Never Learn? Fri Dec 13, 2013 11:21 am

AJ.Valente

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Number of posts : 440

MikeP wrote ". . . I'll be fitting K100/K75C handlebars, once I've painted them, so I've started to get the controls ready for removal. I've never stripped the bars from a K1100LT before and had never really noticed that the end-weights have a plastic cap covering them. . . . "

Mike, this is the first posting I've seen where someone is lowering the bars on an LT. affraid

I'm currently planning the same on my RT (also installing heated grips at the same time).
The big question is; why are you doing it?
Second, won't the lower bars interfere with the faring?
And thirdly, what are you doing with the slack accumulating in the cable, brake line, and wiring?

MikeP · **102** Re: Will I Never Learn? Fri Dec 13, 2013 12:40 pm

MikeP

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Number of posts : 658

AJ.Valente wrote:
Mike, this is the first posting I've seen where someone is lowering the bars on an LT.

I'm currently planning the same on my RT (also installing heated grips at the same time).
The big question is; why are you doing it?
Second, won't the lower bars interfere with the faring?
And thirdly, what are you doing with the slack accumulating in the cable, brake line, and wiring?

AJ,

The fairing has been ditched so there'll be no clearance issues.

Why? Well it's a personal thing but having ridden K1100LTPs I'm not a fan. I didn't want a faired bike (my K1 is the exception but then its Tupperware is what makes it). The RT/LT bars, again a personal, subjective thing, look wrong on a naked bike.

The excess cable length of the throttle, clutch and cold start won't be an issue. The extra wiring length can just be accommodated under the tank. The brake line will be replaced by a braided stainless for a K75/100C I expect but even if I don't, the extra length isn't an issue.

JGT · **103** Re: Will I Never Learn? Fri Dec 13, 2013 12:55 pm

JGT

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Number of posts : 260

Hi Mike.What sort of fit is the crank oil seal? Can it be levered out with a long screw driver? John

MikeP · **104** Re: Will I Never Learn? Fri Dec 13, 2013 1:25 pm

MikeP

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Number of posts : 658

John, that's what I've used in the past as my seal puller is too small. Just work around the seal a little at a time.

MT350Explorer · **105** Re: Will I Never Learn? Tue Dec 17, 2013 4:07 pm

MT350Explorer

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Number of posts : 813

Keep it up Mike, looking good! Very Happy

Cheers
Dave

88 · **106** Re: Will I Never Learn? Tue Dec 17, 2013 6:57 pm

88

Life time member

Number of posts : 3171

88KE wrote:

MikeP wrote:

One thing's for certain, I'm not going to go to the lengths I have with recent bikes.

Sure Mike, Sure!!!

No we believe you.

No really

Repost post #5.....pardon my cynicism Mike

If you keep this up I may get motivated to start the k75c!!! Congrats on the job on the headlight cowl, that turned out very well.

Last edited by 88KE on Tue Dec 17, 2013 7:12 pm; edited 2 times in total (Reason for editing : eh....editing)

MikeP · **107** Re: Will I Never Learn? Mon Dec 23, 2013 9:57 am

MikeP

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Number of posts : 658

I've lifted the engine back onto the bike lift and begun attacking it. One of the Hall Sensor cover plate screws has been sheared in the past. It's not been replaced and that has allowed corrosion to begin under the cover plate:

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Will I Never Learn? - Page 3 K1100LT%20%28295%29-L

My old K75C, despite much higher mileage and not having a fairing panel to protect the same cover:

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It just goes to show how much work a cheap cork gasket does (and can save).

The Hall Sensor retaining screws looked corroded in place. After a clean up, sure enough the upper one was solid, the hex-head began to round out even with heat applied so it was a case of resorting to the Star-key hammered in solution:

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Then it's off with the throttle body mounting rubbers, stuff tissue down the ports and then clean the mounting surfaces:

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Sealed (the tissue left inside) with good old gaffer tape:

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Two of the rubbers left their O-rings behind. I'll clean and inspect the rubbers to see if they are showing signs of perishing and replace them if necessary. New O-rings as a matter of course.

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Will I Never Learn? - Page 3 K1100LT%20%28294%29-L

Now the engine is resting upside down so that I can come at the remaining two exhaust studs and the sheared one.

sidecar paul · **108** Re: Will I Never Learn? Mon Dec 23, 2013 12:18 pm

sidecar paul

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Number of posts : 1589

Mike, is that the American type engine with the petrol tank breather into the timing chain casing?

Never seen one like that before.

Paul.

charlie99 · **109** Re: Will I Never Learn? Mon Dec 23, 2013 12:24 pm

charlie99

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good noticing paul ....same here

MikeP · **110** Re: Will I Never Learn? Mon Dec 23, 2013 1:32 pm

MikeP

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Paul, Charlie, it's definitely a Euro-spec bike.

That breather goes to the front of the airbox, not the tank.

Edit: It's a 16v thing.

Inge K. · **111** Re: Will I Never Learn? Mon Dec 23, 2013 7:43 pm

Inge K.

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It's the oil return from the cyclonic oil separator inside the air filter housing,
input to the oil separator comes from the crankcase breather.

charlie99 · **112** Re: Will I Never Learn? Mon Dec 23, 2013 8:30 pm

charlie99

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should have picked that up mike ...when I saw the injector holes stuffed in the input- bottom rubbers

good to know in any case

thanks for the explanation inge

MikeP · **113** Re: Will I Never Learn? Wed Jan 01, 2014 9:16 am

MikeP

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Number of posts : 658

Got on with cleaning and inspecting the fuel injector inlet tubes:

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One is split at the mounting:

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Another potential poor running cause. The base showed that air had been getting sucked in under the body.

Cleaned everything and checked the others, all okay so just the one needed.

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The rubbers look okay but I've ditched them and will fit new ones.

Next job, remove the discs from the old front wheel. First thing was to removed the ABS sensor ring as it's no longer doing anything. Lots of heat on the screws, three came out easy, the hex-heads rounded on three so it was another star-key jobbie and off it comes:

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The discs look as though they are fairly new, very little wear but some pitting where the pads had seized-on. More heat on the mounting screws and out they came. Then I split the discs from the carriers:

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A couple of the roll pin equipped bobbins (there are three per side) had snapped roll pins.

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The bobbins have no obvious wear on them and all the e-clips and washers are good, just need a long soak to clean the clagged-on brake dust. I'll look them over properly once they've had a soak.

The discs have been cleaned with steel wool and brake cleaner. My micrometer shows virtually no wear on them at all.

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The disc carriers have been cleaned, rubbed down and given their first coat of paint:

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MikeP · **114** Re: Will I Never Learn? Thu Jan 02, 2014 3:39 pm

MikeP

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Number of posts : 658

More cleaning and scraping today. The disc bobbins, washers and e-clips had all been soaking overnight in a jar of brake cleaner, then I scrapped away any crud and corrosion that was left. I only need three of the roll-clip bobbins.

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The disc carriers have had another rub down and the final coat of satin black so I set about removing the forks (at last). The fork brace on the 16v models is a flat steel affair on which is mounted the brake line splitter, then the whole thing is covered by a plastic cover held by a single self-tapping screw. Not many owners of this bike have ever removed it to give it a clean:

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The brake hoses are sound but scruffy. I'll clean them and paint the unions. Replacement stainless braided hoses are 40 quid for the pair, not a huge sum but my shopping list is becoming alarmingly long and it all adds up. Two new banjo bolts at 3 quid each won't break the bank.

There are a couple of things that I've not been looking forward to when it comes to the forks. The ABS sensor, or what's left of it to be precise, needs to come out:

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Someone has tried and the above is the result. Not pretty! So out with the hot-air gun and some mole-grips. It gave up in the end:

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Fair amount of white fluff in evidence. Also, someone has lost the drain screw for this leg and used a hoofing great long hex-head screw!

What's left of the ABS sensor:

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The other issue is that the side mudguard retaining screws have been replaced with stainless but no anti-seize applied. Inevitably they were seized solid. In the past I've had to drill some of these out and it can be a bit hit and miss what with the lugs being such soft metal. First try was the good old heat gun again. The lugs are not threaded so once or if the heat allows them to turn they can usually be tapped out as long as there's enough thread exposed.

I was lucky:

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Once I've got the lug to around 120 deg C, touch the exposed thread with a candle and the wax will melt and run down the thread helping to break the corrosion seal. The screws are junk:

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Well, one is done, hopefully the other will be as easy.

the.postman · **115** Re: Will I Never Learn? Fri Jan 03, 2014 4:44 pm

the.postman

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Number of posts : 330

Doing a grand job.

Looks like you'll be needing some of THESE

I also have a bag of bobbins, you can have what you need for the cost of a couple of stamps.

MikeP · **116** Re: Will I Never Learn? Fri Jan 03, 2014 6:00 pm

MikeP

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Number of posts : 658

Cheers. I have a set or two of new shims but this bike has had the ABS junked before I bought it. It will remain ABS-less.

MikeP · **117** Re: Will I Never Learn? Fri Jan 03, 2014 7:14 pm

MikeP

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Number of posts : 658

I set about the seized mudguard screws in the other fork today. If you go back to the start of this thread you'll see the photo of the bike as it arrived with me and that the forks had been fitted with gaiters. Given the general poor condition of much of this bike I was dreading what I'd find under the gaiters. I'm not a fan of gaiters. Apart from the two R100GS models I've owned that had quick-release clamps so that the gaiters could easily be pulled up now and then to inspect the stanchions and fork seals, most are held in place by cable-ties or hose clips and that discourages inspection.

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I can happily report that the stanchions are good and the fork seals appear sound. More by luck than anything as both gaiters were split:

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There was a lot of crap inside but as the original dust caps had been left in place and they'd glued themselves to the top of the slider to the point where I had to destroy them to get them off, I think that that is what had protected the fork seals more than the gaiters.

So for anyone encountering seized mudguard screws on a K-Brick here's how I get them out. First use a wire brush to remove corrosion and clean the exposed thread and lug as much as possible.

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Then heat the screw and the lug to around 110 to 120 deg C. Touch a candle to the screw and the melted candle wax will run down the thread and hopefully penetrate some of the way down. Then turn the screw back and forth to loosen it a little. Once it turns you can tap it down (remember that the lug is not threaded).

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Then use a drift to tap the screw down and out:

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Whether or not you use stainless replacements, given the location of these screws it makes sense to use plenty of anti-seize whenever they are disturbed. I've got into the habit of running a drill down the lugs to make them very slightly over-sized as that will reduce the chance of them seizing again.

I went to my local dealership with my shopping list today and after checking the prices, I've placed an order for the parts that they can supply cheaper than the other main specialists. Seals, o-rings, gaskets, 3 new disc bobbins, a new intake manifold, four new intake tubes and a new water temperature sensor, it still tips the scale at just over a hundred quid.

I saved forty quid by cleaning-up these:

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A bit pitted but sound:

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The hoses are good, so they've been masked and the unions are curing with a coat of paint. Forty quid is two-thirds of the cost of a new clutch friction plate.

sidecar paul · **118** Re: Will I Never Learn? Sat Jan 04, 2014 3:35 pm

sidecar paul

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Number of posts : 1589

Hi Mike,
All good stuff.

When I did my footrests, I drilled out the alloy footrest plates so that I could add a length of heatshrink sleeving over the stainless pivot pin; the idea being to put a barrier between the alloy and the stainless pin.

It just occurred to me, seeing your post, that the same idea could be used for the mudguard bolts where they pass through the fork legs.

Keep up the good work,
Paul.

MikeP · **119** Re: Will I Never Learn? Sat Jan 04, 2014 6:16 pm

MikeP

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Number of posts : 658

Good idea Paul. I've used heat-shrink for sleeving screws on Ram-arms to stop them scratching handlebars in the past but it hadn't occurred to me before.

MikeP · **120** Re: Will I Never Learn? Tue Jan 07, 2014 4:24 pm

MikeP

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Number of posts : 658

While waiting for the three roll-pin bobbins to arrive, I cleaned the disc mounting screw threads and reassembled the offside disc:

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Will I Never Learn? - Page 3 K1100LT%20%28321%29-L

and fitted it to the "new" wheel:

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I've set about this:

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Cleaned back to bare metal, painted, cleaned the hoses and painted the banjos, new banjo bolts and washers:

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Will I Never Learn? - Page 3 K1100LT%20%28327%29-XL

Time to set about cleaning the clutch parts:

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Much scraping and wire brushing:

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There was quite a build-up of old friction material and some rust on the rim of the diaphragm spring where it contacted the spacer ring.

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All cleaned, paying particular attention to the three locating dowel pins of the cover so that hopefully it will come apart easier next time. I've renewed the balance marks as the cleaning left them a bit difficult to see:

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Time to reassemble the stands. New pivot pins:

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Another sub-assembly finished, just needs the wrap of protective tape on the cross bar:

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Still much to do.

klamityboy · **121** Re: Will I Never Learn? Tue Jan 07, 2014 5:25 pm

klamityboy

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Number of posts : 204

Mike,

You are setting the bar so high I am not sure that many of us can even see it anymore.

Keep up the great work! Very Happy

MikeP · **122** Re: Will I Never Learn? Thu Jan 09, 2014 2:16 pm

MikeP

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Number of posts : 658

Not much of an update, just to say that Gaz80 very kindly offered me the small deflector screen from his K75C. These are NLA.

Well it arrived in Blighty all the way from Oz, beautifully packaged and I've been buffing it up a bit (about half done here).

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Cheers Gary. Will I Never Learn? - Page 3 112350

JGT · **123** Re: Will I Never Learn? Thu Jan 09, 2014 2:33 pm

JGT

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Number of posts : 260

What have you used to buff it up? John

MikeP · **124** Re: Will I Never Learn? Thu Jan 09, 2014 2:47 pm

MikeP

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Toothpaste, then a quality polish (Autoglym super resin).

charlie99 · **125** Re: Will I Never Learn? Thu Jan 09, 2014 3:09 pm

charlie99

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onya gary !!!

progressing well mike

88 · **126** Screen buffing Thu Jan 09, 2014 4:16 pm

88

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Number of posts : 3171

Thatscreen buffed up well Mike. I'm looking forward seeing the finished front end.

Can you post a pic of the finished stand (with tape) when you have a minute. My K1100 stand didn't come with any tape so I'm keen to see what I'm missing.

Will

MikeP · **127** Re: Will I Never Learn? Thu Jan 09, 2014 4:45 pm

MikeP

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Number of posts : 658

Will, the tape I use is helicopter tape. It's a clear self-adhesive material that is used to protect the leading edge of rotor blades.

Various suppliers on ebay. I use it to replace those clear little patches that BMW use on the frame where things will rub. I've used it for some years now on leading edges of belly pans.

Have a look at this:

You may be able to make out the tape on this:

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Will I Never Learn? - Page 3 BMW%20K75S%20%28367%29-L

Again here:

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Ghost who rides · **128** Re: Will I Never Learn? Thu Jan 09, 2014 6:05 pm

Ghost who rides

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Amazing tape! Thanks Mike.

sidecar paul · **129** Re: Will I Never Learn? Thu Jan 09, 2014 6:08 pm

sidecar paul

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Another thanks, Mike. Will I Never Learn? - Page 3 112350

I've just ordered some.

Paul.

Gaz · **130** Re: Will I Never Learn? Sun Jan 12, 2014 4:28 am

Gaz

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Number of posts : 1376

Good to see the parcel arrived safely. I was wondering how you would get the yellowing off it - looking good.
Slightly off this build Mike, on your K75S Spruce Up when you were refurbishing the fuel cap you mentioned giving the gasket a going over with "rubber treatment". Would you mind letting us know the product or method you use?
Cheers Gaz

MikeP · **131** Re: Will I Never Learn? Sun Jan 12, 2014 6:16 am

MikeP

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Number of posts : 658

Gary,

Years ago I was given a tube of BMW Gummi-Pflege by my local dealership to sort out some drying door rubbers on a 7 Series.

It's a paste that reconditions rubber (and it really works well).

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It's no longer available in the UK from BMW (try the part number on the tube with your nearest dealership). There is another version on ebay, it's more liquid than paste but seems to do the same thing.

http://www.ebay.co.uk/itm/Einszett-Gummi-Pflege-Stick-Rubber-Door-Seal-Restorer-Suit-Saab-Merc-BMW-TT-/261372566487

Amazon list a version too:

http://www.amazon.co.uk/SONAX-GummiPflege-04991000-Rubber-Treatment/dp/B000U42S42/ref=sr_1_1?s=automotive&ie=UTF8&qid=1389521918&sr=1-1&keywords=gummi+pflege

Rick G · **132** Re: Will I Never Learn? Sun Jan 12, 2014 7:04 am

Rick G

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Sounds like something Mr Toad would just have to have.

MikeP · **133** Re: Will I Never Learn? Fri Jan 24, 2014 4:01 pm

MikeP

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Number of posts : 658

Frame has been cleaned down, rusty bits dealt with and a few coats of satin layered-up

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Meanwhile, I've been getting on with the forks. Having got the seized ABS sensor out of it's mounting, there was a snapped screw left:

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I know it may seem a bit pointless as the ABS has been removed but like with the loom, I want to leave everything so that if a cheap, working ABS brain and modulators come my way, I or another owner, at some stage in the future could re-fit it.

Some heat and pipe grips got the snapped screw out, then the threads were cleaned:

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With the usual prep done, the sliders have been painted:

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A nice new temperature sender has arrived:

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So I've made a start on cleaning-up the block:

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That stained oil sight glass will have to go. I'll use the spare that's travelled around in my tool roll for years.

Scrape, scrape, brush, brush:

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It doesn't have to be perfect, it's not visible when it's all back together. I just want to be rid of the worst of the crap:

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Next job on the sump fins is to use some grit paper now that the loose stuff has been removed:

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The sump, the timing chain cover plus the crank and cam covers will be re-painted black eventually and the bellhousing will be silver like the transmission.

Still a fair bit to do before anything substantial can start to go back together but it shouldn't be too long now. I'm looking forward to getting to that stage.

robmack · **134** Re: Will I Never Learn? Fri Jan 24, 2014 4:25 pm

robmack

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Number of posts : 2334

Slow, methodical work, Mike. I found those crevasses on the top of the block to be nearly impossible to clean completely because of deep nearly hidden corners. The same goes for the intricate castings around the exhaust ports. I did the best I could and hope that the engine enamel I used will remain for some time yet to come.

MikeP · **135** Re: Will I Never Learn? Fri Jan 24, 2014 5:01 pm

MikeP

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Number of posts : 658

Rob,

I considered using the same enamel silver paint that I've used on the transmission. I'm still in two minds. As little of the block is actually visible once it's all back together it's not really necessary on a bike that's intended as an everyday use machine.

I've got some heat resistant aluminium coloured enamel. I may use that.

As you say, there are some recesses that are almost impossible to get into.

MikeP · **136** Re: Will I Never Learn? Tue Jan 28, 2014 2:23 pm

MikeP

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Number of posts : 658

After much scraping and rubbing down, I removed the sump plate and cleaned the mating surfaces before putting it back dry using a couple of old screws to hold it in position. Then it was out with the old oil sight glass, cut a piece of card to mask the hole, mask the oil and temperature senders plus a bit of masking just to stop too much paint getting onto the areas that are yet to be sorted.

On with the paint:

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Although my garage is dry and relatively warm, paint does take a while longer to cure fully at this time of year so it was a case of being patient and then I could whip off the sump plate to remove any paint that might have leached:

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Same goes for the sump plate and oil filter access plate:

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Remembering to remove the oil sight glass aperture masking:

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I rummaged through my box of spares to find:

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It has been all over with me in my tool roll for years. It's about time that it earned its keep! A wipe with rubber paste to help ease it into place, then a 30mm socket makes a perfect drift and its in:

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A new oil filter fitted, then the mating surface of the sump was given a bead of Three-Bond and the plate screwed back down with stainless fasteners (plenty of Alu-slip), before being torqued down.

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Finally, the oil filter access cover went back on with a new O-ring and the drain plug a new crush washer.

Will I Never Learn? - Page 3 K1100LT%20%28355%29-XL

Will I Never Learn? - Page 3 K1100LT%20%28355%29-XL

The excess Three-Bond will be trimmed off after it's had twenty-four hours to set fully.

Next job is the bell-housing painting.

JR_K100RS · **137** Re: Will I Never Learn? Tue Jan 28, 2014 6:22 pm

JR_K100RS

Life time member

Number of posts : 387

I love reading your threads Mike , looking forward to the next installment

JR

MikeP · **138** Re: Will I Never Learn? Wed Jan 29, 2014 1:56 am

MikeP

Life time member

Number of posts : 658

Thanks JR.

MikeP · **139** Re: Will I Never Learn? Sat Feb 01, 2014 1:02 am

MikeP

Life time member

Number of posts : 658

So, it was time to mask and paint the bell-housing. I've used Halfords heat resistant Aluminium silver enamel this time (colour coat on, awaiting the clear coat):

Will I Never Learn? - Page 3 K1100LT%20%28357%29-L

Will I Never Learn? - Page 3 K1100LT%20%28357%29-L

While the engine is on its nose, I decided that it would make fitting the new output shaft seal easier. The old seal on the left and the new pattern one:

Will I Never Learn? - Page 3 K1100LT%20%28358%29-L

Will I Never Learn? - Page 3 K1100LT%20%28358%29-L

With it oiled-up, I pressed it in a little way by hand. Just enough to start it and to make certain that it was going in square. Then, using the old, single use retaining nut and the collar, I used the clutch carrier to press the seal home:

Will I Never Learn? - Page 3 K1100LT%20%28360%29-L

Will I Never Learn? - Page 3 K1100LT%20%28360%29-L

The shoulder on the rear of the clutch carrier is almost a perfect match for the seal but rather than wind the nut a few turns and have to check that the seal is flush, something between the clutch carrier that is a wider diameter than the seal, will ensure that it seats properly first time. Fortunately, the rear wheel spacer is perfect for this:

Will I Never Learn? - Page 3 K1100LT%20%28361%29-L

Will I Never Learn? - Page 3 K1100LT%20%28361%29-L

Done:

Will I Never Learn? - Page 3 K1100LT%20%28362%29-L

Then it was a case of fitting the new O-ring, the collar and the new retaining nut. The nut is then tightened to 140 Nm to seat the O-ring, loosened off completely and then tightened to between 50 and 100 Nm. I chose to split the difference and set my wrench to 75 Nm.

Will I Never Learn? - Page 3 K1100LT%20%28363%29-L

Will I Never Learn? - Page 3 K1100LT%20%28363%29-L

I'm awaiting a new friction plate and will finish the clutch re-fit once it arrives. In the meantime, the engine is right side up and on the beam jack so that I can raise it when I re-fit the transmission.

Will I Never Learn? - Page 3 K1100LT%20%28365%29-L

Will I Never Learn? - Page 3 K1100LT%20%28365%29-L

There's still a little cleaning to do on the top of the block. A few areas that I couldn't access properly when it was on its side. For that reason the crank, cam and cam chain covers are staying on until I can be sure that no crap can find its way into the oily bits.

charlie99 · **140** Re: Will I Never Learn? Sat Feb 01, 2014 1:09 am

charlie99

VIP

Number of posts : 11701

nice work !!!

MikeP · **141** Re: Will I Never Learn? Sun Feb 02, 2014 8:53 am

MikeP

Life time member

Number of posts : 658

I've spent a bit of time, now that the paint has had plenty of time to cure properly, cutting back and polishing the frame.

First thing though, I used some short mushroom head screws to blank-off the fairing spider mounting holes in the headstock:

Will I Never Learn? - Page 3 K1100LT%20%28366%29-XL

Will I Never Learn? - Page 3 K1100LT%20%28366%29-XL

Then things like the swing-out lifting handle and the seat/helmet lock reassembled and fitted:

Will I Never Learn? - Page 3 K1100LT%20%28367%29-L

The cam and crankcase covers came off for tidying up. Then the timing chain cover presented me with a problem, the ignition trigger rotor didn't want to pop off:

Will I Never Learn? - Page 3 K1100LT%20%28369%29-XL

Will I Never Learn? - Page 3 K1100LT%20%28369%29-XL

The corrosion was caused by a broken screw on the cover plate letting moisture into the housing and has allowed the locating pin to corrode. Much scraping of rust and squirting with shock-unlock, then cautious tapping forward of the timing cover did the trick.

It's only held by the single dowel pin once the three screws are out. The plate behind is held by the same screws and dowel so tapping the cover forward and away from the block free'd it.

Will I Never Learn? - Page 3 K1100LT%20%28370%29-L

Will I Never Learn? - Page 3 K1100LT%20%28370%29-L

This has been my first opportunity to have a good look at the cams, crank and timing chain to check for wear or damage. All seems to be fine.

Before I start cleaning and painting the covers I need to get the broken screw out:

Will I Never Learn? - Page 3 K1100LT%20%28372%29-L

Will I Never Learn? - Page 3 K1100LT%20%28372%29-L

I have a new seal for the timing chain/ignition trigger drive so this one was popped out:

Will I Never Learn? - Page 3 K1100LT%20%28371%29-L

Last time I replaced one of these seals it was with the cover in place and it was a bugger to get it to start square. This time I'll be able to work with the cover flat on the bench.

MikeP · **142** Re: Will I Never Learn? Sun Feb 02, 2014 5:38 pm

MikeP

Life time member

Number of posts : 658

Well I've had to indulge in a little bit of reassembly therapy.

First job remove the gaffa tape covering the intake ports:

Will I Never Learn? - Page 3 K1100LT%20%28373%29-XL

Will I Never Learn? - Page 3 K1100LT%20%28373%29-XL

Then give the surfaces a good clean and run a tap down the threads:

Will I Never Learn? - Page 3 K1100LT%20%28374%29-XL

Next, refit the temperature sensor tower. A new O-ring, a smear of Three-Bond to fix the O-ring and some Loctite 243 for the screws:

Will I Never Learn? - Page 3 K1100LT%20%28375%29-L

Will I Never Learn? - Page 3 K1100LT%20%28375%29-L

Then screw it down (only 9 Nm);

Will I Never Learn? - Page 3 K1100LT%20%28376%29-L

The throttle body manifolds are next to go on. Again, new O-rings and I've replaced the screws with stainless:

Will I Never Learn? - Page 3 K1100LT%20%28377%29-L

Will I Never Learn? - Page 3 K1100LT%20%28377%29-L

A squirt of Three-Bond in the O-ring recess:

Will I Never Learn? - Page 3 K1100LT%20%28378%29-L

Then smear the excess over the face of the mating surface:

Will I Never Learn? - Page 3 K1100LT%20%28379%29-L

Obviously, the stainless screws have a coating of Alu-Slip anti-seize. All back (again only 9 Nm for the screws) and new intermediate rubbers:

Will I Never Learn? - Page 3 K1100LT%20%28380%29-L

Will I Never Learn? - Page 3 K1100LT%20%28380%29-L

The injector rail can then be reassembled (here with the old O-rings on the injectors, new ones in the bag):

Will I Never Learn? - Page 3 K1100LT%20%28381%29-L

Will I Never Learn? - Page 3 K1100LT%20%28381%29-L

The injector rail mounting bushes were treated with Gummi Pflege. They're a lot easier to fit if you push the metal insert out:

Will I Never Learn? - Page 3 K1100LT%20%28382%29-L

Will I Never Learn? - Page 3 K1100LT%20%28382%29-L

I struggled with these on another bike not realising at first that the metal sleeve isn't bonded into the bush.

Will I Never Learn? - Page 3 K1100LT%20%28383%29-L

Will I Never Learn? - Page 3 K1100LT%20%28383%29-L

Injectors with new O-rings fitted, back in the rail and the clips replaced:

Will I Never Learn? - Page 3 K1100LT%20%28384%29-L

Then they slip nicely back in with the Gummi Pflege acting as a lubricant (red rubber grease would do the same but the Gummi Pflege will be absorbed by the rubber and help keep the O-rings from hardening):

Will I Never Learn? - Page 3 K1100LT%20%28385%29-L

Will I Never Learn? - Page 3 K1100LT%20%28385%29-L

Must resist further reassembly until the engine covers are at least prepared for painting.

RT · **143** Will I Never Learn? Sun Feb 02, 2014 5:58 pm

RT

Life time member

Number of posts : 1925

Great write up Mike, inspiring me. Can I ask if you are happy with the screw up clamps on the T/B rubbers?, as I
don't have the correct tool to fix the jubilee clamps as original on mine, was wondering if the screw clamps would work OK/
Thanks for all the tips.
RT

MikeP · **144** Re: Will I Never Learn? Sun Feb 02, 2014 7:04 pm

MikeP

Life time member

Number of posts : 658

RT,

I'm just re-using the screw clamps that were on the bike when I got it. Lots of people replace the one-time use clamps and have no issues.

I won't know until start-up if I need to replace the screw clamps.

One thing I do know from experience with screw clamps on the inlet tubes on 4-valve Boxers is that you're just as likely to get leaks if you over-tighten them.

RT · **145** Will I Never Learn? Sun Feb 02, 2014 10:40 pm

RT

Life time member

Number of posts : 1925

Oh goodie, another way I can screw up. Thanks Mike, saves me trying to find the correct tool if it works.

MikeP · **146** Re: Will I Never Learn? Tue Feb 11, 2014 5:58 am

MikeP

Life time member

Number of posts : 658

I popped the throttle bodies and airbox back on. It seemed a better way to keep crap out of the intakes than bits of paper towel stuffed in them:

Will I Never Learn? - Page 3 K1100LT%20%28386%29-L

Will I Never Learn? - Page 3 K1100LT%20%28386%29-L

It's so much easier to connect things like the crankcase breather pipe when it's like this:

Will I Never Learn? - Page 3 K1100LT%20%28387%29-L

Plus the timing chain case breather:

Will I Never Learn? - Page 3 K1100LT%20%28388%29-L

So there's no excuse but to get on with the various engine covers. Those with bare ali highlights, I first set about polishing the highlights. It's easier to then remove masking or paint from a smooth polished surface later. Good old grit blocks (the bit up to the 'W' is done):

Will I Never Learn? - Page 3 K1100LT%20%28390%29-L

Will I Never Learn? - Page 3 K1100LT%20%28390%29-L

Then the paint can be flatted/keyed with 400 grit paper followed by a wash and degrease:

Will I Never Learn? - Page 3 K1100LT%20%28389%29-L

Once dry and any masking done, they have a swift, light squirt of satin black:

Will I Never Learn? - Page 3 K1100LT%20%28391%29-L

Then the coats are built-up:

Will I Never Learn? - Page 3 K1100LT%20%28392%29-L

The front covers done, just need to fully harden and then they can have a buff with polish:

Will I Never Learn? - Page 3 K1100LT%20%28398%29-L

In between coats of paint I decided that it was time to fit the replacement bearing and seal to the final drive. First job was to pop the crown wheel into the freezer for an hour, then out with the old pan and heat the new bearing:

Will I Never Learn? - Page 3 K1100LT%20%28393%29-L

Will I Never Learn? - Page 3 K1100LT%20%28393%29-L

The chilled crown wheel resting in the vice ready for the toasty bearing:

Will I Never Learn? - Page 3 K1100LT%20%28394%29-L

The toasty bearing slips over with a satisfying sizzle. It needed just a light tapping fully home (tapping on the inner of the race only).

Will I Never Learn? - Page 3 K1100LT%20%28395%29-L

Will I Never Learn? - Page 3 K1100LT%20%28395%29-L

The new seal pressed in:

Will I Never Learn? - Page 3 K1100LT%20%28396%29-L

Then the bearing (and shims) can go into the housing and the cover screwed and torqued down with a new O-ring in this case.

Will I Never Learn? - Page 3 K1100LT%20%28397%29-L

Will I Never Learn? - Page 3 K1100LT%20%28397%29-L

A nice new clutch friction plate arrived yesterday morning so that means that I can get on with more reassembly:

Will I Never Learn? - Page 3 K1100LT%20%28401%29-L

Will I Never Learn? - Page 3 K1100LT%20%28401%29-L

The gearbox input shaft splines got a final clean and lubed with Optimol TA paste:

Will I Never Learn? - Page 3 K1100LT%20%28403%29-L

Then the gearbox can go back on (much easier when you don't have to slip it between the rear frame mountings):

Will I Never Learn? - Page 3 K1100LT%20%28404%29-XL

Will I Never Learn? - Page 3 K1100LT%20%28404%29-XL

The six screws are surprising low torque settings (16 Nm). Anyway, now I can add an old scissor jack under the gearbox and at a few turns at a time, raise both engine and gearbox:

Will I Never Learn? - Page 3 K1100LT%20%28405%29-XL

Will I Never Learn? - Page 3 K1100LT%20%28405%29-XL

To re-fit the stands:

Will I Never Learn? - Page 3 K1100LT%20%28406%29-L

That'll do for now.

charlie99 · **147** Re: Will I Never Learn? Tue Feb 11, 2014 7:07 am

charlie99

VIP

Number of posts : 11701

great post mike .....
thanks

MT350Explorer · **148** Re: Will I Never Learn? Tue Feb 11, 2014 3:12 pm

MT350Explorer

Life time member

Number of posts : 813

Tremendous Mike, keep it going!

Cheers
Dave

MikeP · **149** Re: Will I Never Learn? Fri Feb 14, 2014 9:50 am

MikeP

Life time member

Number of posts : 658

Thanks for the nice comments. This tart-up is a useful distraction at the moment.

So with the gearbox back on, it's time to replace the clutch pushrod plus spring and fit the new cover boot and clip. To make fitting the boot, which is under pressure from the spring, easier, I hold the clutch arm up with a couple of cable ties:

Will I Never Learn? - Page 3 K1100LT%20%28407%29-L

Will I Never Learn? - Page 3 K1100LT%20%28407%29-L

That makes helping the cover boot over the lip a lot easier:

Will I Never Learn? - Page 3 K1100LT%20%28408%29-L

Then fit the retaining clip. With the screw vertically there's a better chance to get at it to tighten it later if required (the eagle eyed may spot that I've used a couple of Phillips screws to hold the gear position indicator instead of the hex head ones which are awkward little sods to get at even with a tiny socket):

Will I Never Learn? - Page 3 K1100LT%20%28409%29-XL

Will I Never Learn? - Page 3 K1100LT%20%28409%29-XL

The Paralever arm can go back on now along with the shaft (making a mental note of the position of the universal joints for correct phasing of the other end when it is ready to go on):

Will I Never Learn? - Page 3 K1100LT%20%28410%29-L

Will I Never Learn? - Page 3 K1100LT%20%28410%29-L

The swingarm is next. First re-fit the gearbox end rubber boot and its internal spring clip, then some Staurbergs paste to ease re-fitting and to help seal it from the elements:

Will I Never Learn? - Page 3 K1100LT%20%28411%29-L

Will I Never Learn? - Page 3 K1100LT%20%28411%29-L

Slip it over the shaft and re-fit the pivots:

Will I Never Learn? - Page 3 K1100LT%20%28413%29-L

Then the frame can go on. I wasn't planning on dropping it back on yet but a mate was here yesterday so I took advantage of his extra hands:

Will I Never Learn? - Page 3 K1100LT%20%28420%29-L

Will I Never Learn? - Page 3 K1100LT%20%28420%29-L

Only the front mountings have been fitted. The rear are resting on the bolts. That's so that I can hinge it upwards to help re-fitting the main loom and relay box.

Will I Never Learn? - Page 3 K1100LT%20%28421%29-L

Will I Never Learn? - Page 3 K1100LT%20%28421%29-L

On with the final drive:

Will I Never Learn? - Page 3 K1100LT%20%28423%29-L

Rear disc, brake and wheel on. I'm not happy with the disc, I've been on the look-out for a non-ABS one in decent condition as this one is a bit pitted and the ABS ring makes getting the wider wheel out more of a problem.

I feel a bit happier now that I can at last add a hold down strap over the rear wheel:

Will I Never Learn? - Page 3 K1100LT%20%28424%29-XL

Will I Never Learn? - Page 3 K1100LT%20%28424%29-XL

I've been doing other stuff but I'll detail that when the parts are going back on.

klamityboy · **150** Re: Will I Never Learn? Fri Feb 14, 2014 1:11 pm

klamityboy

Gold member

Number of posts : 204

MikeP wrote:Thanks for the nice comments. This tart-up is a useful distraction at the moment.

So with the gearbox back on, it's time to replace the clutch pushrod plus spring and fit the new cover boot and clip. To make fitting the boot, which is under pressure from the spring, easier, I hold the clutch arm up with a couple of cable ties:

That makes helping the cover boot over the lip a lot easier:

Then fit the retaining clip. With the screw vertically there's a better chance to get at it to tighten it later if required (the eagle eyed may spot that I've used a couple of Phillips screws to hold the gear position indicator instead of the hex head ones which are awkward little sods to get at even with a tiny socket):

The Paralever arm can go back on now along with the shaft (making a mental note of the position of the universal joints for correct phasing of the other end when it is ready to go on):

The swingarm is next. First re-fit the gearbox end rubber boot and its internal spring clip, then some Staurbergs paste to ease re-fitting and to help seal it from the elements:

Slip it over the shaft and re-fit the pivots:

Then the frame can go on. I wasn't planning on dropping it back on yet but a mate was here yesterday so I took advantage of his extra hands:

Only the front mountings have been fitted. The rear are resting on the bolts. That's so that I can hinge it upwards to help re-fitting the main loom and relay box.

On with the final drive:

Rear disc, brake and wheel on. I'm not happy with the disc, I've been on the look-out for a non-ABS one in decent condition as this one is a bit pitted and the ABS ring makes getting the wider wheel out more of a problem.

I feel a bit happier now that I can at last add a hold down strap over the rear wheel:

I've been doing other stuff but I'll detail that when the parts are going back on.

Great to see the progress Mike. This will be the cleanest cafe-racer ever when you finish (o)

robmack · **151** Re: Will I Never Learn? Fri Feb 14, 2014 1:24 pm

robmack

Life time member

Number of posts : 2334

Hey Mike,

Great progress on your build. I'm loving the photo documentation of your progress. I totally get it when you say it's hard to get at the tiny cap-head screws that hold the switch to the transmission. I'm thinking of going with small socket-head screws myself.

Did you use a paper gasket under the TGPI switch as recommended by BMW when you installed it?

BTW I got irritated with myself this week because I scratched some of my fresh paint work on my triple tee when a drill I was using slipped Mad

. Something else to fix now.

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