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TECHNICAL MOTOBRICK WRENCHING In Remembrance of Inge K. => Project Custom Motobricks => Topic started by: Trash Hauler on April 07, 2020, 06:53:41 PM

Title: Trash Hauler’s first K100 Cafe Racer Project
Post by: Trash Hauler on April 07, 2020, 06:53:41 PM: Disassembly

I started the disassembly last week after cleaning out the garage. The biggest challenge was working out how best to work on the engine once I have removed it from the frame. With the clutch gearbox arrangement being similar to a car, I could see an automotive engine stand would work nicely. So I purchased the cheapest stand I could get ($117) and the photos below show the progress.

I also made up a steering lock and left the front end on while I separated the frame. This way I could sit the rear seat frame on a bench and the bike was stable while removing the gearbox and engine.

1. Bike before the project (I bought the bike sans the fairings and luggage)

85F17153-71E0-4E34-B8E5-471F5779ACAB.jpeg (50.83 kB . 432x576 - viewed 765 times)

2. Initial disassembly

2CE89121-A5CB-406D-862D-52643D1A74B9.jpeg (47 kB . 432x576 - viewed 777 times)

3. Steering lock

8E65BC1A-CF2C-4A63-A37A-3DCDB61D4899.jpeg (44.72 kB . 431x576 - viewed 744 times)

4. Seat frame on bench for gearbox / engine removal

C448C80D-790C-4FD9-9E11-803EEB64BBA1.jpeg (51.1 kB . 432x576 - viewed 754 times)

5. Gearbox removed

26E64FFE-01E9-4000-839E-E996CD5E9898.jpeg (47.42 kB . 452x576 - viewed 767 times)

6. Engine removed and on stand

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7. Frame with front end and loom still to be removed.

6E2BFCFA-F75B-40A6-84DB-02999F113168.jpeg (75.88 kB . 768x574 - viewed 778 times)

TH

(Edited to correct orientation of images)
Title: Re: Trash Hauler’s first K100 Cafe Racer Project
Post by: volador on April 08, 2020, 09:46:50 AM: Looking good you're off to a good start. Where did you get the engine stand?
Title: Re: Trash Hauler’s first K100 Cafe Racer Project
Post by: Trash Hauler on April 08, 2020, 06:14:20 PM: Supercheap Auto Parts - Sydney Australia

Engine Stand. https://www.supercheapauto.com.au/p/sca-sca-engine-stand-560kg/219511.html (https://www.supercheapauto.com.au/p/sca-sca-engine-stand-560kg/219511.html)
Title: Re: Trash Hauler’s first K100 Cafe Racer Project
Post by: Martin on April 08, 2020, 06:46:29 PM: :welcome
Regards Martin.
Title: Re: Trash Hauler’s first K100 Cafe Racer Project
Post by: volador on April 08, 2020, 07:15:07 PM: Quote from: Trash Hauler on April 08, 2020, 06:14:20 PM
Supercheap Auto Parts - Sydney Australia

Engine Stand. https://www.supercheapauto.com.au/p/sca-sca-engine-stand-560kg/219511.html (https://www.supercheapauto.com.au/p/sca-sca-engine-stand-560kg/219511.html)

Crikkey, was thinking Sydney Nebraska not another downunder bloke

there's a tribe of you'll here you just met chief 'Regards Martin'
Title: Re: Trash Hauler’s first K100 Cafe Racer Project
Post by: volador on April 08, 2020, 07:42:17 PM: Bonzer engine stand

Can you give us a piccy of stand mounting to intermediate housing.
Just an observation I would be concerned to exert to much force on that intermediate housing maybe a support under the oil pan would alleviate some of the engine weight
Title: Re: Trash Hauler’s first K100 Cafe Racer Project
Post by: Trash Hauler on April 09, 2020, 02:33:50 AM: Quote from: Martin on April 08, 2020, 06:46:29 PM
:welcome
Regards Martin.

Thanks Martin - good to be here
Title: Re: Trash Hauler’s first K100 Cafe Racer Project
Post by: Trash Hauler on April 09, 2020, 02:35:11 AM: Quote from: volador on April 08, 2020, 07:42:17 PM
Bonzer engine stand

Can you give us a piccy of stand mounting to intermediate housing.
Just an observation I would be concerned to exert to much force on that intermediate housing maybe a support under the oil pan would alleviate some of the engine weight
Title: Re: Trash Hauler’s first K100 Cafe Racer Project
Post by: Trash Hauler on April 16, 2020, 09:52:25 PM: Frame and engine disassembly complete ready for blanking, degreasing and glass blasting.

FDDF6407-035B-487B-BB01-B7D92601C088.jpeg (67.28 kB . 768x574 - viewed 717 times)

3B682375-F6E1-48FE-9303-61BDACDC820E.jpeg (43.29 kB . 428x576 - viewed 712 times)
Title: Re: Trash Hauler’s first K100 Cafe Racer Project
Post by: Trash Hauler on April 23, 2020, 07:02:00 PM: I have ordered an Injector Pulser Tester from AliExpress to go with my ultrasonic cleaner. $26 USD.

I will post a review once I have used it.

https://www.aliexpress.com/item/33008882556.html?spm=a2g0s.9042311.0.0.3a854c4dPKo9W9 (https://www.aliexpress.com/item/33008882556.html?spm=a2g0s.9042311.0.0.3a854c4dPKo9W9)

A277F4FD-8C99-4E63-8E3F-5A1E22AC9D61.jpeg (34.09 kB . 611x576 - viewed 705 times)

TH
Title: Re: Trash Hauler’s first K100 Cafe Racer Project
Post by: Martin on April 23, 2020, 08:27:53 PM: You might want to get a 250 ML graduated vessel to compare injectors. Home brew supply shops have them. I built an air powered test unit set to 35 PSI due to not wanting to blow up my workshop. On the advice of a local injector workshop I use lacquer thinners to clean the injectors which is a lot cheaper and more effective. The vapours however do melt some types of plastic for example the lid of my sonic cleaner which did eventually solidify. I would remove the pintle caps, filter screens and "O" rings if using thinners. The thinners did however restore a set of Ford injectors that nothing else would clean and had been rejected by another injector shop.
Regards Martin.
Title: Re: Trash Hauler’s first K100 Cafe Racer Project
Post by: Trash Hauler on April 23, 2020, 08:33:08 PM: Thanks Martin - great advice.
Title: Re: Trash Hauler’s first K100 Cafe Racer Project
Post by: Martin on April 23, 2020, 08:56:04 PM: TH see here http://www.motobrick.com/index.php/topic,12153.msg107177.html#msg107177 The test unit has changed a bit since it's inception the plastic bottle has been changed to a graduated vessel and I'm now using a Sun test pulser.
Regards Martin.
Title: Re: Trash Hauler’s first K100 Cafe Racer Project
Post by: Trash Hauler on April 23, 2020, 11:21:03 PM: Thanks Martin - I like your setup. I am going to build one the same. I think I have an old fire extinguisher in the shed that may work as the container.

TH