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1Back to top Go down   K100 KafeRacer Build Empty K100 KafeRacer Build Sun Aug 03, 2014 10:25 pm

KafeRacer

KafeRacer
Silver member
Silver member
I thought I would post some pics of my Kafe Racer build.  There are alot of other cool projects on this site so thought I should share some of my own.

Here is the before pic.  It was such a nice donner bike I had a hard time chopping it up.

K100 KafeRacer Build Dsc06510

Here is the after:

K100 KafeRacer Build Img_2861

I bought a ducati 916 tail section and a corbin seat off of ebay, I have always loved the look of the 916's so thought I would incorporate that into the build.

K100 KafeRacer Build Dsc06610

The frame needed some modification to build the structure to support the seat.  Also the front of the corbin seat needed to be truncated to fit the shape of the K100 tank.  I may try to stitch the German flag where the Italian flag is on the seat as a final finishing touch.  Mind you since these types of projects are never really finished, who knows when I will get to that.

K100 KafeRacer Build Dsc06611

I bought a smashed K100RS with the 16 valve engine, front end, and exhaust, unfortunately the transmission back was gone, so I had to source the transmission, paralever, final drive and tri-spoke rear wheel from ebay.  I havent got all of the parts yet but this will be a 16v, paralever bike when it is done. New mirrors are on route.  I also plan to go to a Dakota Digital 7400 Instrument Cluster.

K100 KafeRacer Build Dsc06612



Last edited by KafeRacer on Fri Apr 24, 2015 9:46 pm; edited 1 time in total


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

2Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sun Aug 03, 2014 10:28 pm

KafeRacer

KafeRacer
Silver member
Silver member
Here is the side view.  The clip on bars sure change the personality of the bike...  It handles well.  The 16v RS front end stops so much better then before.

K100 KafeRacer Build Dsc06718



Last edited by KafeRacer on Mon Aug 04, 2014 1:24 pm; edited 1 time in total


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

3Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Mon Aug 04, 2014 2:22 am

Be made

Be made
Life time member
Life time member
Good luck with the build. I myself did not like the commonality of cafe's (it seems thats all people are doing these days) or the riding position so I went for a cruiser style.

A lot of fun though, these conversions, and at least you end up with what you want.

I hope it goes well for you. Will look forward to seeing your finished bike

    

4Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Wed Aug 06, 2014 12:56 pm

Fentible

Fentible
Silver member
Silver member
Wow that's nice, the ducati tail unit looks really good. I know what you mean about chopping an already nice bike. I've just finished renovating a naked K100 and keeping it standard because I couldn't bear to start hacking it up.

I'm hopefully going to follow the café racer route from the pile of spares that I got and I need to think about how it will look.

I managed to pick up a paralever rear end and gearbox for very little money but I'm mating it to a standard 8v motor because I prefer the simplicity. But that as far as I've got at the moment.

    

5Back to top Go down   K100 KafeRacer Build Empty Donner/donor Wed Aug 06, 2014 7:41 pm

Glacial

Glacial
active member
active member
Donner as in kebab
Donor as in rip my heart out.

That was such a lovely example, I would have happily swapped you my slightly dog-eared version to cut up and I would have kept the pristine original one.


__________________________________________________
BMW K75S 1990 (ABS removed)
    

6Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Thu Aug 07, 2014 6:07 am

Waz

Waz
Life time member
Life time member
The Ducati tail and seat are the best I have ever seen. Very good look.


__________________________________________________
K100 RS
K100RS with 1100 motor Premier sidecar
K100 RT KRAUSER FAIRING
R1200GS
650 Vstrom
    

7Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Tue Aug 12, 2014 7:51 am

floyd

floyd
Life time member
Life time member
The 748/916 - 998 are in my opinion the best looking bikes ever styled. Im yet to have the pleasure of riding one, but do dream of owing a 748 one day.

A mate of mine has a beautiful 748R. What a bike. 

K100 KafeRacer Build Ducati%20748R%2000%20%202

Your mod is looking nice and tidy.


__________________________________________________
K100 with lots of K1100 bits - mongrel of a thing...
    

8Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Tue Aug 12, 2014 7:41 pm

KafeRacer

KafeRacer
Silver member
Silver member
Drool..... Those 916 and 748 are gorgeous.  Would love to run the K100 Exhaust up under the tail section, but I expect I will need a lot more welding experience before I attempt that.

Cheers.


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

9Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Wed Aug 13, 2014 11:19 pm

KafeRacer

KafeRacer
Silver member
Silver member
I got the paralever installed along with a progressive suspension shock and an RS belly pan.

K100 KafeRacer Build Dsc06754

New headlight and mirrors also installed. Next step is to install the Dakota Digital instrument cluster as soon as the wiring harness arrives.

K100 KafeRacer Build Dsc06757

Cheers. 

Dave.


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

10Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Wed Aug 13, 2014 11:47 pm

Waz

Waz
Life time member
Life time member
Is that progressive shock upside down? If yours is the right way mine is upside down.


__________________________________________________
K100 RS
K100RS with 1100 motor Premier sidecar
K100 RT KRAUSER FAIRING
R1200GS
650 Vstrom
    

11Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Wed Aug 13, 2014 11:54 pm

KafeRacer

KafeRacer
Silver member
Silver member
LOL, I am not sure, but it should not matter.  All of the photos on their web site show the snubber down.

Cheers Dave.


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

12Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Thu Aug 14, 2014 12:02 am

Waz

Waz
Life time member
Life time member
That would be right, two ways to do it and got it wrong.
K100 KafeRacer Build Img_0913


__________________________________________________
K100 RS
K100RS with 1100 motor Premier sidecar
K100 RT KRAUSER FAIRING
R1200GS
650 Vstrom
    

13Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Thu Aug 14, 2014 12:13 am

KafeRacer

KafeRacer
Silver member
Silver member
Its ok,  That is the correct position for you as you are located in the southern hemisphere. That shock is mounted in the the 'down under' position.

Very Happy


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

14Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Thu Aug 14, 2014 12:25 am

blaKey

avatar
Life time member
Life time member
Nice bike Waz, no doubt about it, but...


Blue zip ties?   Shocked  Very Happy


__________________________________________________
Neil
K100RS 1986 RED!

Dress for the ride and the potential slide.
    

15Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Thu Aug 14, 2014 12:57 am

Waz

Waz
Life time member
Life time member
Upside down shock and blue zip ties are an indication of the shody workmanship.

How does the light work? I don't see a battery.


__________________________________________________
K100 RS
K100RS with 1100 motor Premier sidecar
K100 RT KRAUSER FAIRING
R1200GS
650 Vstrom
    

16Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Thu Aug 14, 2014 7:38 am

KafeRacer

KafeRacer
Silver member
Silver member
I relocated the battery and fuel computer up out of the way under the seat and tail section.

K100 KafeRacer Build Dsc06644

Cheers.

Dave.


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

17Back to top Go down   K100 KafeRacer Build Empty Instruments Installed Sat Oct 04, 2014 10:03 am

KafeRacer

KafeRacer
Silver member
Silver member
After a lot of wiring I got everything installed and working on the Dakota Digital instrument cluster.  I had to use an inductive sensor to count the brake rotor bolts to get the speedometer to work, I also had to put a filter on the power that powers the instruments as I was getting ignition noise that was being picked up which was causing the speedometer to give erratic reading.  The filter solved that.

K100 KafeRacer Build Dsc06773

In order to get neutral indication working, and the start in neutral bought a gear indicator circuit board from robmack which also gave me the 7 segment led screen that I mounted in the top triple clamp.

K100 KafeRacer Build Dsc06776


I am very please with how it has turned out, I maintained all of the features from the stock cluster in a much smaller package.

K100 KafeRacer Build Dsc06777


I also have been busy making the under tail cover and fender to keep spray from the rear wheel getting where it shouldn't.

K100 KafeRacer Build Dsc06778



I also got my last LED signal lights installed, inside the tail section to improve visibility from the side.

K100 KafeRacer Build Dsc06781


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

18Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Oct 04, 2014 5:59 pm

Mossy1200

Mossy1200
Platinum member
Platinum member
Nice I was thinking about the gear indicator in the same spot.
Was wondering about using a oil level sight glass.
Is yours a washer or is there glass between the digital on that.

    

19Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Oct 04, 2014 8:32 pm

KafeRacer

KafeRacer
Silver member
Silver member
I mounted the led display in aluminum channel, and the cover is just thin aluminum cut with a hole saw and the center filed out in a rectangle.  No glass or plexi over the LCD.  So we will see how it survives rain wise.  Worst case they are only about 2$ to buy another one.


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

20Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Oct 04, 2014 9:08 pm

Mossy1200

Mossy1200
Platinum member
Platinum member
Waz wrote:Upside down shock and blue zip ties are an indication of the shody workmanship.

So is wrinkles in duct tape.

    

21Back to top Go down   K100 KafeRacer Build Empty Remus Collectors Sat Oct 11, 2014 4:58 pm

KafeRacer

KafeRacer
Silver member
Silver member
I managed to find a Remus collector from eBay.  Won if for $40 USD plus that much again for shipping.  

K100 KafeRacer Build Headers

Unfortunately the slip-on is missing the the baffle and rear cap.

K100 KafeRacer Build Exhast

Here is it is after some sanding, wet sanding, and polishing.  Still a lot more polishing to come. Now the search for a baffle and end cap, or other slip-on with a 3″/76mm inlet.  Any ideas.

K100 KafeRacer Build Dsc06786


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

22Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Oct 25, 2014 2:53 pm

KafeRacer

KafeRacer
Silver member
Silver member
Does anyone have any rebuild instructions for front forks for a 1990 K100RS or K1.

It is the earlier version marzocchi damper (left in the photo).  I plan to rebuild but my manual only has the earlier forks.  I will be putting in progressive suspension springs. and replacing all the oil an seals.

K100 KafeRacer Build B0000621


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

23Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Oct 25, 2014 5:45 pm

Inge K.

Inge K.
VIP
VIP
KafeRacer wrote:Does anyone have any rebuild instructions for front forks for a 1990 K100RS or K1.

OEM manual for K1/RS16V you find here.


__________________________________________________
Inge K.
K100RS -86. (first owner), K1100LTSE -94.
    

24Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Oct 25, 2014 9:42 pm

KafeRacer

KafeRacer
Silver member
Silver member
Inge K. wrote:
KafeRacer wrote:Does anyone have any rebuild instructions for front forks for a 1990 K100RS or K1.

OEM manual for K1/RS16V you find here.

Excellent find,  The English manual did not work, but the German one did, that coupled with some google translate did the trick.  Got the info I needed.  Forks are all disassembled now and I have the torques for reassembly.

Thanks.


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

KafeRacer

KafeRacer
Silver member
Silver member
Received a nice used Remus exhaust from Germany last week. It was from a GSXR 1100 so it was designed to be mounted on the other side of the bike. No problem I just took the canister apart and turned the aluminum tube around 180 deg so the Remus logo can be seen, drilled new mounting holes and plugged the unused ones.

K100 KafeRacer Build Dsc06894

K100 KafeRacer Build Dsc06887

Headers are all polished up now.  I painted the intake pipes on the collector black as it was much too intricate to try to polish all the nooks and crannies around the four pipes.

K100 KafeRacer Build Dsc06892

I also started the fork rebuild. I have everything dismantled and cleaned now.

K100 KafeRacer Build Dsc06885

Those springs are progressive suspension springs that I hope will firm up the front end.  Everything looks in good shape including the slider bushings.

K100 KafeRacer Build Dsc06881


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

26Back to top Go down   K100 KafeRacer Build Empty Dis-assembly Time Mon Nov 24, 2014 8:04 pm

KafeRacer

KafeRacer
Silver member
Silver member
I spent most of Saturday night striping the bike down in order to swap the 8V engine for the 16V.  Only took about 2 hours to create a large pile of parts on the floor. Too bad re-assembly won’t be as quick.
K100 KafeRacer Build Dsc06922

Here is the new 16V engine sitting on a modified transmission jack which bolts to the four M8 belly fairing bolts on the oil pan, this setup worked very well.  It raises high enough to be at a very good working level where I could re-assemble the clutch and bolt on the transmission and all of the engine accessories.

K100 KafeRacer Build Dsc06926

K100 KafeRacer Build Dsc06932

 Here are the 16V throttle bodies with 8V throttle cable tabs and guide as well as the shaft in #4 TB swapped out with the one form the 8V TB so the 8V TPS sensor could be installed and set. Next step will be to modify or build an air box to fit.

K100 KafeRacer Build Dsc06934


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

27Back to top Go down   K100 KafeRacer Build Empty Paint Time Thu Jan 15, 2015 9:19 pm

KafeRacer

KafeRacer
Silver member
Silver member
I recently got the frame back from the sand blaster. Sprayed a coat of self etching primer.
K100 KafeRacer Build Dsc06980

Now a coating of high build primer.  Next weekend will be the topcoat of urethane.


K100 KafeRacer Build Dsc06982

I had the wheels powdercoated and am very pleased with the results.


K100 KafeRacer Build Dsc06988


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

28Back to top Go down   K100 KafeRacer Build Empty Frame installation and reassembly! Mon Jan 19, 2015 10:57 pm

KafeRacer

KafeRacer
Silver member
Silver member
The frame is now all painted.  I am pleased with how it turned out.
K100 KafeRacer Build Dsc07006

The power unit is ready I will post more details later about how I have set up the bike with the 4v engine and 2v electronics.
K100 KafeRacer Build Dsc07008

 Starting to look like a bike again.
K100 KafeRacer Build Dsc07014

 Reassembly complete! I still have to install the my new wideband 02 sensor, balance the TB’s once I receive new rubber gaskets from BMW.  Then on to some tuning on a dyno.  Then it will be ready for the bodywork to get some more paint.  I am thinking about leaving the tail section and front fenders black (currently only black primer)  and painting the tank and radiator cover a bright orange.  However the maroon doesn’t look too bad so I might wait to do the orange.  Any thoughts? 
K100 KafeRacer Build Dsc07020


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

KafeRacer

KafeRacer
Silver member
Silver member
K100 KafeRacer Build Dsc07049

I built a flat aluminum plate on the under side of the frame beneath the gas tank to keep all of the wires neat.  After a lot of electric tape, wire looms and zip ties the wiring is all complete.
K100 KafeRacer Build Dsc07050

 Here is the 4v engine with 4v throttle bodies but the 2v air box which is was cut down by about an inch and had a fibreglass cover made for it in order to clear the frame. If you look close you can see the flat aluminum plate (painted black) on the under side of the frame.

K100 KafeRacer Build Dsc07052

Here are the throttle bodies from the other side and a new adjustable fuel pressure regulator. I am running the system at 3.5 bar as that is what the fuel injectors I have are designed for.

K100 KafeRacer Build Dsc07056

 Here it is with the barn door air flow meter installed and cone filter.  Also you can see the digital gauge for the wide-band oxygen sensor.  It is getting close to being ready to go to the dyno for some tuning.

K100 KafeRacer Build Dsc07058

The green bulb is the alternator charge light.  It illuminates when you turn the ignition on, and goes out once the alternator starts charging.

K100 KafeRacer Build Dsc07054

You can see the stainless steel drink container which is now the radiator overflow canister.

K100 KafeRacer Build Dsc07059

A close look at the structure that holds the fiberglass tail section.


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

30Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Wed Feb 11, 2015 11:12 pm

Two Wheels Better

Two Wheels Better
Moderator
Moderator
Dave, is that one of those 'new' Progressive-brand adjustable rear shocks? I have only seen a listing of the correct length for the Monolever swingarm and it's obvious you're using Paralever.

Never mind, I've read a previous post.
Rolling Eyes


__________________________________________________
"A long ride is the answer to a question you will soon forget!" ~ Anonymous
1977 R75/7-100, '93 K11/K12 Big Block, '93 K1100RS, '95 R100 Mystic, '96 K1100RS, 2 x '98 K1200RS, '06 K1200R & '09 K1300GT
    

31Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Wed Feb 11, 2015 11:24 pm

KafeRacer

KafeRacer
Silver member
Silver member
Two Wheels Better wrote:Dave, is that one of those 'new' Progressive-brand adjustable rear shocks? I have only seen a listing of the correct length for the Monolever swingarm and it's obvious you're using Paralever.

Never mind, I've read a previous post.
Rolling Eyes

Yes, it is Model 465-1101.  Its stock length for monolever so drops the back a bit when running it on a paralever bike. Lower is good for me.  The only thing is I had to put a washer behind the shock on the lower bolt to get the spring to not rub on the brake caliper.

If you are looking for a shock have you looked into RAM?  http://www.bskspeedworks.co.uk/ram-rear-shocks.html

Cheers. Dave.


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

32Back to top Go down   K100 KafeRacer Build Empty Warm-Up Sequence Sat Mar 07, 2015 5:45 pm

KafeRacer

KafeRacer
Silver member
Silver member
Does anyone know how an L-Jetronic system is affected by the water temp sensor?

As I have installed a wide-band O2 sensor I can monitor the AFR.  The way it is configured now is as follows:

Bike Idles at 1070 shortly after starting and warm enough to not need choke - AFR hovers at 14.
Bike continues to warm up idle slowly increases to about 1250 after 10 minutes - AFR hovers at 14.
Note:  If I press the start button, it riches the mixture (as notes many places on the forum)  With the starter button pressed the AFR richens to about 12, release button and it goes back to 14.

After the bike warms up further there is a distinctive point where idle shoots up from 1250 to 1600, and AFR richens from 14, down to 11.8.  Note: Once this occurs, pressing the starter button no longer richens the AFR. At this point pressing the starter button has no affect on AFR.

I assume this is normal, and just a change in the fuel map after the bikes water temp reaches a certain point.

I am also assuming that if I adjust the AFR to be leaner at operating temp, it will be quite lean before the L-Jet changes to its operating fuel map.  Should I be concerned?  I am assuming not, and that running lean during warm-up will simply result in reaching operating temp faster?

I also notice that once the bike is at operating temp the spring tension on the air flow meter has virtually no affect on the AFR at idle. Does the L-jet not look at the air flow meter when the throttle is closed? And simply apply only a fixed amount of fuel?

Just looking for thoughts.



Last edited by KafeRacer on Sat Mar 07, 2015 6:03 pm; edited 1 time in total


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

33Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Mar 07, 2015 7:33 pm

Rick G

Rick G
admin
admin
AFAIK you cant fit a O2 sensor to an L-Jetronic. If your engine is 16V then it's a Motronic


__________________________________________________
"Man sacrifices his health in order to make money.
Then he sacrifices money to recuperate his health.
And then he is so anxious about the future that he does not enjoy the present; the result being that he does not live in the present or the future; he lives as if he is never going to die, and then dies having never really lived."   Dalai Lama


Bikes 1999 K1100 LT with a Big Block 1200
    

34Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Mar 07, 2015 7:38 pm

KafeRacer

KafeRacer
Silver member
Silver member
RicK G wrote:AFAIK you cant fit a O2 sensor to an L-Jetronic. If your engine is 16V then it's a Motronic

I have a stand alone Innovate LC-2 Wideband O2 Sensor: http://www.innovatemotorsports.com/products/db.php

And I am running a 16V engine with with all 1985 8V - L-Jetronic FI system.

Cheers.


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

35Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Mar 07, 2015 7:58 pm

Rick G

Rick G
admin
admin
So in essence all it does is monitor the AFR but doesn't interface with the L-Jetronic?


__________________________________________________
"Man sacrifices his health in order to make money.
Then he sacrifices money to recuperate his health.
And then he is so anxious about the future that he does not enjoy the present; the result being that he does not live in the present or the future; he lives as if he is never going to die, and then dies having never really lived."   Dalai Lama


Bikes 1999 K1100 LT with a Big Block 1200
    

36Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Mar 07, 2015 8:07 pm

KafeRacer

KafeRacer
Silver member
Silver member
RicK G wrote:So in essence all it does is monitor the AFR but doesn't interface with the L-Jetronic?

Exactly,  just gives me a readout on a little digital guage so I know accurately what the AFR is IOT tune the bike.  Since I have L-Jetronic on a 16V engine, and higher flow injectors that I am running at their designed 3.5 bar (I have an adjustable FPR) the factory set tuning is not correct any more.

I can adjust the AFR by changing the spring tension on the vane air flow meter.  Currently 5 tooth tighter seems about right, but I do plan to put it on a dyno and try a few settings as well as fool around with the timing to see what produces the best combo of HP and Torque.

What I am trying to understand a bit better is how the logic inside the L-Jet ECU works.

The bike certainly seems to run well, and sounds pretty mean with its current setup, and higher flowing REMUS exhaust.

Cheers.


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

37Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Mar 07, 2015 8:18 pm

Rick G

Rick G
admin
admin
The water temp sensor will make it lean out as it gets hotter.
I do hope you are using the 8V temp sensor.
Graph for the sensor
K100 KafeRacer Build Water_10


__________________________________________________
"Man sacrifices his health in order to make money.
Then he sacrifices money to recuperate his health.
And then he is so anxious about the future that he does not enjoy the present; the result being that he does not live in the present or the future; he lives as if he is never going to die, and then dies having never really lived."   Dalai Lama


Bikes 1999 K1100 LT with a Big Block 1200
    

38Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Mar 07, 2015 8:27 pm

KafeRacer

KafeRacer
Silver member
Silver member
RicK G wrote:The water temp sensor will make it lean out as it gets hotter.
I do hope you are using the 8V temp sensor.
Graph for the sensor
K100 KafeRacer Build Water_10


Yes I am using an 8V Temp Sensor,  The interesting thing is AFR stays the same up until a certain point then all of a sudden it richens alot.  (By about as much as the starter button richen the AFR).  It seems like what is happening is once temp reaches a certain point something changes in the L-Jet ECU.

Cheers.


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

39Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Mar 07, 2015 9:13 pm

charlie99

charlie99
VIP
VIP
if its running lean at idle

you could try to adjust the air bypass on the afm ..( 5mm allen key through the air box at the top and behind a rubber bung ...if its still there )

by closing the screw , less air goes through the port so more air affects the flap opening .
there is a certain flow rate that this becomes ineffective

this Is also where you would adjust the mix for idle co  on standard machines ....( there is at least one documented way to do this "lean drop method " )


have you thought about running the injectors at 3 bar perhaps ....they work quite well at that pressure ....the 3.5 bar would reflect the normal operating pressure in a given application ...like an m3 car  but work happily  from 2.8 bar up

good luck


__________________________________________________
cheezy grin whilst riding, kinda bloke ....oh the joy !!!! ...... ( brick aviator )

'86 K100 RT..#0090401 ..."Gerty" ( Gertrude Von Clickandshift ) --------O%O
'86 k100 rs.. #######..  "Fred " (f(rame) red ) ( Fredrick leichtundschnell ) - -
bits and pieces from many kind friends across the k100 world ...with many thanks ..
1987 k100rs ########   "Red"  - (red sports rs TWB style )
1989 K100rt #009637   "Black Betty"  (naked rt ala Nigel , now sporting an rs main fairing )
    

40Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Mar 14, 2015 12:43 pm

KafeRacer

KafeRacer
Silver member
Silver member
Well I just figured out what was causing my AFR to richen and idle to increase after the bike is well warmed up.   It was the vacuum switch that I have read is only on 1985 models, and most forum posts say to ditch it which is what BMW did from 1986 and on.

As soon as I unplugged the vacuum switch the idle returns back to a reasonable number, and the AFR returns to a more normal reading.

Mission accomplished.


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

41Back to top Go down   K100 KafeRacer Build Empty The Final Product Sat Mar 14, 2015 10:22 pm

KafeRacer

KafeRacer
Silver member
Silver member
The bike is done, all of the paintwork is complete.  Only thing left is to find a local dyno to do some fine tuning of the AFR and Ignition Timing.
K100 KafeRacer Build Dsc07066

K100 KafeRacer Build Dsc07068

K100 KafeRacer Build Dsc07070

K100 KafeRacer Build Dsc07072

K100 KafeRacer Build Dsc07074


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

42Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Tue Apr 21, 2015 10:40 pm

KafeRacer

KafeRacer
Silver member
Silver member
Well, I have now had several rides on the kafe and decided to move the O2 guage up into the dash area for the time being (at least until I get the fine tuning done).  The bike also developed a rattle/vibration which turned out just be the metal mesh in the radiator shroud which was an easy fix.  I also found a new to me rubber tank gasket that sits on the frame under the tank which I installed yesterday.  The bike seems to be running real strong. I have been very pleased with it so far.


K100 KafeRacer Build Img_2847

K100 KafeRacer Build Img_2849


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

43Back to top Go down   K100 KafeRacer Build Empty New Photos Fri Apr 24, 2015 9:28 pm

KafeRacer

KafeRacer
Silver member
Silver member
Some more photos of the completed bike.
K100 KafeRacer Build Img_2852
K100 KafeRacer Build Img_2861
K100 KafeRacer Build Img_2866
K100 KafeRacer Build Img_2869


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

44Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Fri Apr 24, 2015 11:03 pm

Holister

Holister
Life time member
Life time member
Great read. Sounds like you've adapted the systems quite well and she's running smooth. Would be good to hear the results from the dyno and what your final FP setting is.
Just some questions, considering you've used a 4V motor.
Why didn't you use a motronic instead of the L-Jet?
What injectors are you using (oem #)?

Very sexy machine all round . Well done.


__________________________________________________

1989 K100RT     VIN  0097367 (naked)  
1996 K1100RS   VIN  0451808
 K100 KafeRacer Build Austra12    Fuel:  95 Octane
Engine Oil: Nulon Full Synthetic 15W50
Gear Box Oil:  Nulon Synthetic 75W90
    

45Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Fri Apr 24, 2015 11:31 pm

KafeRacer

KafeRacer
Silver member
Silver member
Kaptain Holister wrote:Great read. Sounds like you've adapted the systems quite well and she's running smooth. Would be good to hear the results from the dyno and what your final FP setting is.
Just some questions, considering you've used a 4V motor.
Why didn't you use a motronic instead of the L-Jet?
What injectors are you using (oem #)?

Very sexy machine all round . Well done.
Thanks,

I started with a 2V L-Jet bike and had all the wire harness with Fuel and Ignition ECU's, the only reason I switched to the 4V engine was because I stumbled across the smashed bike with engine cheap (200) so I figured I would try this combo.  The Motronic ECU and harness was already gone from the smashed bike. I also kind of liked the Idea of trying to see if I could get the odd combo to work.

I also considered the following ECU, but havent had the budget for it, and what I have now seems to work very well.

http://www.bskspeedworks.co.uk/engine-management-package.html

I am using the following injectors and running at 3.5 bar pressure currently.

0-280-150-415EV14 hole60.515.9130.0050.753.5071%BMW 6-2.5l, 3.0l


I am looking to find a dyno, the one shop I found won't let me be there to tune the bike, he wants me to leave him with the bike and a blank check...which wont be happening.

Cheers.


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

46Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Apr 25, 2015 4:15 am

Comberjohn

Comberjohn
Life time member
Life time member
Looks really smart, although you don't half do things the hard way.
Was getting dizzy trying to remember if it was an 8v or 16v as you went along!
Good resource for anyone else going done the same path.
Nice job and still think that having the radiator cowl sets it apart from most other custom jobs. Just would look unfinished without it. Are getting hard to find, though.


__________________________________________________
Life is not a rehearsal.
2010 VFR 1200F DCT 
2010 R1200GS(gone)
1986 K100 Silver(gone)
2012 K1600GT(gone)
1984 K100RT Madison Silver(gone)
1989 K100LT Stratus Grey(gone)
1984 K100 Red(gone)
http://www.johnsdrivingschool.co
    

47Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Apr 25, 2015 6:20 am

Mossy1200

Mossy1200
Platinum member
Platinum member
Like the air filter. 🆒

yours comes out on a sharper angle than mine what is the leg position like?

    

48Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Apr 25, 2015 6:51 am

Holister

Holister
Life time member
Life time member
KafeRacer wrote:Does anyone know how an L-Jetronic system is affected by the water temp sensor?
There are 3 stages the L-Jet goes thru while warming up.
Cold Start Enrichment: Only when the starter button is pressed the ECU
increases the injection time considerably after checking the coolant temp. This is to compensate for fuel condensing in the intake chambers and cylinders and not vapourising completely prior to any ignition. If temps are very low ie <0°c, injection times can be doubled by the ECU.
After Start Enrichment: When the starter button is released and the motor is running (>720rpm), The ECU goes into After Start Enrichment mode for around 30 secs. The ecu monitors the coolant temp and increases injection times by 30 to 60%.
Warmup: At this point the ECU monitors air flow and temp and adjusts fuel injection times so as to maintain idle untill the engine reaches operating temperature and the ECU produces a base injection time.


As I have installed a wide-band O2 sensor I can monitor the AFR.  The way it is configured now is as follows:

Bike Idles at 1070 shortly after starting and warm enough to not need choke - AFR hovers at 14.
Bike continues to warm up idle slowly increases to about 1250 after 10 minutes - AFR hovers at 14.
Note:  If I press the start button, it riches the mixture (as notes many places on the forum)  With the starter button pressed the AFR richens to about 12, release button and it goes back to 14.
AFAIK the ECU ignores any further signals from the starter button once the engine is running over 720rpm.

After the bike warms up further there is a distinctive point where idle shoots up from 1250 to 1600, and AFR richens from 14, down to 11.8.  Note: Once this occurs, pressing the starter button no longer richens the AFR. At this point pressing the starter button has no affect on AFR.

I assume this is normal, and just a change in the fuel map after the bikes water temp reaches a certain point.

I am also assuming that if I adjust the AFR to be leaner at operating temp, it will be quite lean before the L-Jet changes to its operating fuel map.  Should I be concerned?  I am assuming not, and that running lean during warm-up will simply result in reaching operating temp faster?
I would guess that your #415 injectors would be producing a reasonably rich mix at 3.5bar so leaning it out would be good but running 'lean' would not be ideal.

I also notice that once the bike is at operating temp the spring tension on the air flow meter has virtually no affect on the AFR at idle. Does the L-jet not look at the air flow meter when the throttle is closed? And simply apply only a fixed amount of fuel?

Just looking for thoughts.


__________________________________________________

1989 K100RT     VIN  0097367 (naked)  
1996 K1100RS   VIN  0451808
 K100 KafeRacer Build Austra12    Fuel:  95 Octane
Engine Oil: Nulon Full Synthetic 15W50
Gear Box Oil:  Nulon Synthetic 75W90
    

49Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Apr 25, 2015 8:33 am

KafeRacer

KafeRacer
Silver member
Silver member
Mossy1200 wrote:Like the air filter. 🆒

yours comes out on a sharper angle than mine what is the leg position like?


Thanks,

First I tried to tuck the filter in close to the frame and have my leg on the outside, but that did not work, so I moved it forward and now my knee fits snugly behind it.  New rearsets should give me all kinds of room when I get around to making some, or biting the bullet on some BSKs.

Cheers.


__________________________________________________
Dave Evans
'Kafe Racer'
kaferacer.wordpress.com

1990 K75RT
1985 K100 Kafe Racer
http://kaferacer.wordpress.com
    

50Back to top Go down   K100 KafeRacer Build Empty Re: K100 KafeRacer Build Sat Apr 25, 2015 11:09 am

charlie99

charlie99
VIP
VIP
as I understand it

at idle 


the afm has a bypass path that allows unmetered air to bypass the vane

this is controlled by a threaded plug of sorts and is designed to adjust the mixture at idle within a certain range

the bypass screws on the throttle bodies allow for a adjustable idle speed ....and because they are separate require synchronising  for a swiss sewing machine idle

the afm has a closed value of about 1.61 volts back to the efi computer (under seat ) which determines ...along with the water temperature and the thermistor (air temperature ) on the input of the afm  the relative duty cycle of the injectors (how much fuel per squirt )  this can be changed to make the extra fuel injection balance better with the air flow ...but tricky to do without some form of feedback - meter display

if you are getting a change in idle speed once warmed the idle mix is probably too lean ...and could be adjusted via the afm air bypass screw - slug



whilst cold , and additionally under speed (700 or so revs ) and increasing to  running temperature  the predetermined map for cold start conditions apply , along with an adjustable throttle opening device ie the choke lift bar via cable and electronic enrichment from the switch on the throttle bodies - choke lever

the start switch applies extra fuel above and beyond all the above .......and generally  a totally computer generated start sequence during start conditions  ...some have noted that there is a change in mix by pressing the start switch when running above the magic 700 or so revs

a good indication of fuel mix can be achieved by pressing the start button at temperature and noting the revs change ...or lack of  and to be read into the designed carbon emissions standards and adjusting techniques.
 

hope that helps a little


__________________________________________________
cheezy grin whilst riding, kinda bloke ....oh the joy !!!! ...... ( brick aviator )

'86 K100 RT..#0090401 ..."Gerty" ( Gertrude Von Clickandshift ) --------O%O
'86 k100 rs.. #######..  "Fred " (f(rame) red ) ( Fredrick leichtundschnell ) - -
bits and pieces from many kind friends across the k100 world ...with many thanks ..
1987 k100rs ########   "Red"  - (red sports rs TWB style )
1989 K100rt #009637   "Black Betty"  (naked rt ala Nigel , now sporting an rs main fairing )
    

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