Rusty's K100 Scrambler (lets try that again)

[RustyK]

This painting prep phase is doing my head in. This is just taking so long.

So I decided to take a break and go for a ride. Great time to hit the Ardennes just ahead of Victory day.









Anyways, back to reality and the paint should have cured by now. So into the oven it went.



However the filler on the pump cover seemed to not like the heat.



And now its back to blasting that again and re-painting. I think the Simonez paint wins, this enamel with a primer is just balls. 

Look at how nice this came out. Complete with new sight glass.





Also rebuilt the starter motor with the new replacement part. Is it safe to put in a vice and "test" by connecting a battery? 

[lewisnort]

This painting prep phase is doing my head in. This is just taking so long.

It may take a while but fail to prepare, prepare to fail.
The lower section haS come out nice, what filler did you use on the pump cover? Ive got some big boy metal filler I was hoping to use on the crank cover

[FTR]

That does look nice with the new sight glass, mine is so discoloured you can’t see anything through it. Can’t wait to pull that out and replace it.

Very interesting to watch your progress in things I will shortly be grappling with. Hit a slight snag in that I cannot get one of the Allen head bolts out of the WP cover. Extracted everything else without sheering or rounding off ( inc eventually the exhaust studs) but the central WP bolt decided to fight back. Awaiting an extractor for it … 

[Kaos]

Hit a slight snag in that I cannot get one of the Allen head bolts out of the WP cover.

Oh Hi there general kenobi.
My name is Kaos -a.k.a vlad the extractor- may i redirect you to: https://www.motobrick.com/index.php?topic=15867.msg140718#msg140718
Its not a major bolt extract post but contains the basics, before you start a thread jack.

[RustyK]

Yikes, sorry to hear! I can say that this BMW's bolts are better quality than KTM's 990s - there are a few times where I was very very nervous with the torque bring required and I swore the bolt snapped with suddenly freeing itself, compared to when I've snapped a few on the KTMs.

I did buy new studs for the internal of the waterpump, and will be using my standard mercury quicksilver extreme grease to everything going back in.

The ones I'm the most nervous about are the hex bolts that bolt the sump to the block. How they didnt thread/snap coming lose I have no idea - I needed my lever bar to undo them.

[LFC09]

Loved reading through the build, I’m at the tear down phase and buying stuff……… I’m going to use moto gadget switches and the m-unit. Would the gsxr levers and throttle work on a 7/8” handlebar with stock front end?  I can’t find an easy answer to the aftermarket lever and front master cylinder question.

[RustyK]

My renthal handlebar is 22mm (equivalent to 7/8) which work with the GSXR levers, although I'm not using any of the BMW switchgear I believe it would have worked. I've seen loads of builds using the switchgear on these size bars.

I'm yet to connect up the throttle however, but that should just be a case of making the cable ends.

[LFC09]

Thanks Rusty. Appreciate the reply.

[Laitch]

My renthal handlebar is 22mm (equivalent to 7/8) . . .

7/8 inch is equivalent to 22.3mm. That is why customizers run into trouble fitting BMW 22mm gear onto them. That some advertisers worldwide assert the two measurements are equivalent is a sad fact of retailing. Low 22mm handlebars for BMWs are sold at Flanders.

An important fact to consider during shopping is how much linear space switch gear, brake lever units, phone mounts, radar detectors, pinwheels, and etc. will occupy on the straight run of the bar. Some bars might not have enough. The K75 in my avatar has a Flanders sidecar bar.

[RustyK]

Eeeerm, I thought about being pedantic when I wrote that, but I think if you are struggling with 0.3mm on controls perhaps modifying motorcycles isn't for you. 

So lets re-phrase that. You should have no problem making them fit. 

[Laitch]

Eeeerm, I thought about being pedantic when I wrote that . . .

It wouldn't have been pedantry, it would have been accuracy.

[RustyK]

I checked the specs of my renthal bars, and they are indeed sold as 7/8" and some sites list as 22mm. To be even more accurate they measure 22.19mm on the verniers. I don't know what the accuracy of the calipers are to be accurate. 

[Laitch]

Maybe there are widespread vernier caliper quality control issues being instigated by a cabal of abrasive pad manufacturers.

[RustyK]

The build has started! After reading all the threads on sealant, its hopefully all in the prep and it holds - I really dont want to come back here because its leaking.





The problem with the red is its a little visible.


But it comes off nicely once set.




Waterpump rebuilt and on.

[LFC09]

Well that’s very exciting, following along earnestly

[RustyK]

I have a small confession to make. I did not replace the water pump impeller bolt and the spacer. Am I going to die in a fiery crash? The irony is I actually had a new spacer. But it was very nicely pressed into the impeller and I cant think of what difference it would make.

[Laitch]

I did not replace the water pump impeller bolt and the spacer. Am I going to die in a fiery crash? The irony is I actually had a new spacer. But it was very nicely pressed into the impeller and I cant think of what difference it would make.

You'll find out if it makes a difference, don't worry.     

[Kaos]

You'll find out if it makes a difference, don't worry. 

Hahahaha. That one i just felt deeply. Spend this weekend stressing over finding out on my current build.
All I will say is salad dressing, the rest is up to you.
Drove 3 hours to fix what I had found out.
However mine was caused by a worn out shaft.
Result would still be the same tho.

[Kaos]

Upside is, i got to upgrade to the 32teeth fancy smancy impeller.

[Laitch]

Choke light:
http://www.kbikeparts.com/classickbikes.com/ckb.tech/0.ckb.tech.files/choke/choke.htm

If riders haven't enough attention span to close the choke without a light bulb prompting, motorcycling probably will be overall more dangerous for them in many other ways than it is inherently.

[RustyK]

Well - I wasn't going to have a choke light, but now I just may.... 

Rear main seal done....


Bottom "end" complete, including my bash plate which I hope will protect my paint a little from the front tire sandblasting.


Now just to paint the rest of the motor.




Now all thats left is to paint the front and side covers. Although thats going to get sand blasted too.

I also popped down to makers and got to work on the frame. No

No going back now.








A lot "cleaner".

[Kaos]

Bottom "end" complete, including my bash plate which I hope will protect my paint a little from the front tire sandblasting.

damn, nice progress.
When you use a good engine enamel the impact of the front tire's blast wont be that high. Sad part is,  its the pump cover that will suffer the most impact, the skid plate sadly doesnt cover the lid.
But now that you've installed it, would the skid plate have or leave enough clearance for crashbars? I personally love the looks of crashbars on a Scrambler and maybe the addition of the plate would be a nice addition.

[RustyK]

Thanks. Yeah, not all perfect but given its very unlikely to get serious long term abuse I think it should hold up.

I need to think about the crash bars.... I'm not even sure I still have them. But, I think you would be able to use a longer bolt (and some rubber spacer to replace the OE) through the bash plate, and then use about 3/4mm spacer on the top mount and they would work. I cant see why not.

[RustyK]

I've looked at the crash bars. The left-hand-side will fit - but I'm trying to figure out how the right worked. I must be missing a part, as the right side first of all is at a bit of an angle at the bottom, and the rear mounting point does not extend to the rear bolt hole on the sump plate. 

[RustyK]

I've had my wheels and a couple bits over at the professionals.

Sneak peek -

I cant tell you what fantastic service this guy gives - could spend hours with him in his workshop - proper enthusiast.



All energised after seeing them I set to work on getting the covers off - what a ballache. Took my eye off the "bolt" for a moment and rounded the head of probably the most inaccessible bolt on the front cover. Thankfully after taking a breather and then smashing a lovely new torx driver onto it it came free