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TECHNICAL MOTOBRICK WRENCHING In Remembrance of Inge K. => Project Custom Motobricks => Topic started by: tahitianrider on November 06, 2017, 07:31:11 AM
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Hey guys!
Loving bikes and riding some for 10 years now (I'm 25), I was dreaming of building my own café racer for a while now. My favourite base bike for this? the Brick of course! especially the K75 because I find the engine beautiful and love its 3 cylinder configuration and sound :)
I finally got my very own K75 about two weeks ago, a 1994 K75 RT ABS that had 138 000 km. The bike was running fine on the road test which was the most important part for me. But I did noticed that the bike was pretty rusted in some areas.
Once I strip it down, I noticed that the bike was probably left outside under the rain or rode a lot in rainny/snowy days, the engine covers and frame were not in great condition. Giving it a new life into a cafe racer was therefore a perfect turn for this bike :)
The biggest difficulty for me on this project is that I do not have access to a workshop... All I have is parking spot in my basement with no power outlet. So I have to be creative in my build and avoid anything that requires power like a welder/ angle grinder, etc.
I would have loved to remove the whole frame to re paint it too but unfortunately this is not possible for me at the time on my parking spot :(
So far, my project is about 60% completed. I have mounted the new seat, exhaust, headlight, made some side panels with integrated temp/fuel jauge, re painted the engine covers, relocated the ignition switch under the tank, changed the bars to clip ons and few other stuff.
What I still have to do :
- Paint the wheels black
- Mount the turn signals (just waiting to receive them)
- Re paint the subframe on the rusty points
- I will have the tank and seat repainted by a professional once the bike is completed.
- Remove the front fender (stuck bolts)
- Change all the fluids
Here are few pics of the bike when I got it and how it is now, I will post detailed pictures of each step later on.
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Here are few more pictures of the engine before and after, the igniton switch I relocated with a custom made support made with my 3D printer and the custom side panels.
The 3D printer is really helpfull for this project as I made custom speedometer mount, ignition switch mounts, license plate holder and top clamp decorative parts.
I'd like to change the stock speedometer as it is really big... but I read a lot of thing on this forum on aftermarket speedos and it seems pretty complicated...
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Welcome, tahitianrider! Thanks for the clear images. Working in a small space is a difficult challenge to meet. You could probably tap into the light switch box and wire up a utility socket, if it were your property.
Those forward frame-to-engine mounting bolts need to be replaced, of course, and their mounting tabs need to be thoroughly cleaned and inspected to see how much they have corroded so the engine doesn't partially detach from the frame if the bike hits a pothole at speed.
Aftermarket speedometer installation does seem complicated but like everything else mechanical, a patient and orderly disassembly process including labeling will help. If I were intending to use a different instrument cluster, most important to me would be choosing instrument makes and models that have been well-covered by discussion here. Those would be Acewell, Motogadget, and Koso.
I'm not that adventuresome though. The only thing I'll do other than mechanical maintenance is wash off the road grime. I just want to ride. :giggles
Good luck with your project. You're moving it right along. :2thumbup:
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Hi Laitch and thanks for the warm welcome :)
Unfortunately this ain't property so I can't tap into the light switch box, I've already put a tape on the switch to prevent the lights from turning off every 4 minutes haha.
Thanks for the heads up on the engine mounting bolts, I'm gonna get some new stainless steel one and inspect that frame mount. I did soak the bolts in vinegar to remove the rust though but didn't thought they needed to be replaced.
Yeah I was thinking about the same cluster too, I like the looks of the Acewell one, I'll continue to read about it and wait till I have a little more budget too.
Haha that is still the best part, mine is sitting there in my garage for 2 weeks and I can't wait to ride it back!
Thanks! :)
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Little update on the project,
I've mounted the rear tail light, its a LED strip which is very bright and goes perfectly with the line of the tail. Also mounted the turn signals and license plate.
Change the engine mounted bolts, the mounting bracked on the frame is indeed corroded but I don't think that there's structural damage under the layer of rust.
Also ordered some stainless steel M10x35 bolts for the other engine mounting points.
There was a problem with one of my strap-ons being 22.5mm instead of 22mm so I just mounted a steel tubing from the hardward store waiting to receive my replacement bar.
I've finnaly ordered a KOSO speedo and TGPI board from rbm as the stock cluster looks way too big with the clip ons bars.
I'll try to paint the rear wheel this weekend and the subframe which is pretty corroded too, I will also changed the shock bolt that does not look good at all.
Chaging the engine oil and coolant is also on the to do list of the weekend.
New pictures soon!
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Did some more work on the project during the last two weeks:
- Changed the stock cluster for a KOSO DL03SR Speedo with a TGPI board and LED display for the gears.
- Painted the front & rear wheels black
- Changed the engine oil & filter
- Made an aluminium side panel for the right side
- Changed the grips
- Re painted the subframe that was corroded and change the corroded shock bolts
- Finished the seat with new turn signals & a led plate light
- few other stuff
What's left to do:
- Have the fuel tank & seat repainted by a professional
- Change gearbox & final drive oil and coolant
- Fix or remove the ABS and install SS braided brake lines
- Make a custom front fender
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Well done! :2thumbup:
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Thanks :)
A quick before and after on the subframe.
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Can I get a close up pic of your rear brake light and blinkers setup?
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Wow, you have done an outstanding job! This looks damn close to what I'm envisioning for mine. Only other thing I'll do to mine is to get the airbox changed out for pod filters.
Could you please post links to some of the items you purchased, especially the following:
-The seat
-The strap-ons
-The rear led strip and bracket
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Yep, here it is.
The tail/brake light is a LED Strip with integrated blinkers ($4 from Aliexpress) but I don't use the blinkers as they are not very visible with the tail light on.
It is stick to the back of the custom seat mount I made from wood.
I've had some blinkers to the set up be sure that everything is road legal.
I've 3D designed and printed the license plate holder and integrated a LED license plate light.
I've also 3D printed beveled frame plugs for the cut frame as they look way better than standard flat plug.
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Wow, you have done an outstanding job! This looks damn close to what I'm envisioning for mine. Only other thing I'll do to mine is to get the airbox changed out for pod filters.
Could you please post links to some of the items you purchased, especially the following:
-The seat
-The strap-ons
-The rear led strip and bracket
Thanks!! :)
Here are the links :
Seat : http://cafe4racer.eu/en/universal-partially-upholstered-seat-for-customized-bikes/377-universal-upholstered-seat-cafe-racer.html
Clip ons : https://www.aliexpress.com/item/High-Quality-Black-Universal-Motorcycle-CNC-37mm-strap-ons-Handlebars-Aluminum-strap-ons-Fork-Handle-Bars-For/32385715573.html?spm=a2g0s.9042311.0.0.0Mczsu
Rear Brake light Led strip : https://www.aliexpress.com/item/32-LED-Modified-Cafe-Racer-Tail-Light-Motorcycle-Strip-Tail-Brake-Stop-Turn-Signal-Flexible-Led/32822770880.html?spm=a2g0s.9042311.0.0.BdThnK
The bracket is custom made, I 3D printed one and integrade a license plate Led light. You can easily make one from an aluminium sheet too.
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Rode the bike twice this weekend, it rides really good! I love it.
It's nice to see people stopping by to like at the bike :)
ABS is fixed and works nicely, turns out it was just the battery that needed to be fully recharged in order for the ABS calculator to work perfectly.
Just needs to mount the fork boots better now.
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Nice Work.. what rear shock is that?
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Thanks! it's an EMC Sport shock.
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I made a full timelapse video (not photos) of the whole build, here it is :)
https://www.youtube.com/watch?v=-oIFhkVYLLI&feature=youtu.be (https://www.youtube.com/watch?v=-oIFhkVYLLI&feature=youtu.be)
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Wow, you have done an outstanding job! This looks damn close to what I'm envisioning for mine. Only other thing I'll do to mine is to get the airbox changed out for pod filters.
Could you please post links to some of the items you purchased, especially the following:
-The seat
-The strap-ons
-The rear led strip and bracket
Can you say more about changing airbox, because i would like to do same but i'm not finding any info how to get rid off AFM (air flow meter)?
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You can't get rid of the AFM unless you go to a Mega Squirt or use a carburettor. http://www.motobrick.com/index.php/topic,936.msg3735.html#msg3735
Regards Martin.
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Nice work! :2thumbup: :clap: