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Author Topic: Just picked up a K75 - need input on the plan of attack  (Read 72159 times)

Offline Laitch

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #100 on: December 06, 2018, 05:54:44 PM »
Quote from: oneplustwo on December 06, 2018, 04:56:08 PM
Anyone have a favorite resource for rewiring?  Already have the schematics, just thinking about the bigger picture...
What is meant by the bigger picture? M-units have been deployed during several modifications found in the Custom section. If you find a thread with a successful outcome, try personal messaging the moto's owner.
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Offline oneplustwo

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #101 on: December 06, 2018, 06:28:23 PM »
I guess I was thinking more along the lines of tips and tricks in making looms, wire routing, stuff like that.  First time rewiring a motorcycle so this is new territory for me!  Might be overthinking it.

Another question... any advice on custom front brake line and clutch cable?  Since I have new controls, I need to redo those two items.  And I think I'll have to go custom so as to make sure they're not weird lengths since the bars are now much closer to the triple clamps.
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Offline Laitch

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #102 on: December 06, 2018, 07:46:30 PM »
Quote from: oneplustwo on December 06, 2018, 06:28:23 PM
I guess I was thinking more along the lines of tips and tricks in making looms, wire routing, stuff like that.  First time rewiring a motorcycle so this is new territory for me!  Might be overthinking it.
You've been working with that Motogadget since June so it doesn't seem like you're underthinking it anyway. You had many questions and responses back then. What's hanging you up?
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Offline johnny

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #103 on: December 06, 2018, 08:06:54 PM »
greetings...

dont use solid copper wior or any solid wior for that matter... use only stranded copper wior...

j o
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Offline oneplustwo

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #104 on: December 06, 2018, 08:34:42 PM »
Quote from: Laitch on December 06, 2018, 07:46:30 PM
You've been working with that Motogadget since June so it doesn't seem like you're underthinking it anyway. You had many questions and responses back then. What's hanging you up?

I bought it in June and started looking into the basics and what my general plan would be in terms of how much of the original I would replace.  Having now decided I'll likely replace most all of the existing wiring, I'm now at the point where I actually need to do stuff practically.  So yah, maybe I just need to get started.
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Offline Laitch

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #105 on: December 06, 2018, 09:26:29 PM »
Quote from: oneplustwo on December 06, 2018, 08:34:42 PM
Having now decided I'll likely replace most all of the existing wiring, I'm now at the point where I actually need to do stuff practically.  So yah, maybe I just need to get started.
There are some observations in this thread which might interest you.
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Offline oneplustwo

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #106 on: December 06, 2018, 11:46:44 PM »
Ooh, good stuff there that led to other threads still!  Deconstructing the stock harness sounds like a bear but also would be nice and clean.  I worry I might mess something up along the way though.  Will have to think on it further.
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Offline natalena

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #107 on: December 09, 2018, 01:13:38 PM »
Quote from: oneplustwo on December 06, 2018, 11:46:44 PM
Deconstructing the stock harness sounds like a bear but also would be nice and clean.

Reconstructed a harness once, because I figured it'd be easy to save big bucks and any monkey could do it. Well, THIS monkey should've stayed in the tree playing with himself, as it took a longtime spread out on the garage floor. I used to live off 21st and California, with those super narrow, 9ft wide 3 car garages. I'll never do it again!

A take away is this; use a 4x8 sheet of plywood to tack up the old harness to methodically label end components, unpeel and see the wire gauge, terminal ends, junctions, and colors easier. Rebuild the new harness following the physical schematic that's now tacked on the board...easy-peasy, any monkey could do this! Cheers
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Offline oneplustwo

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #108 on: December 10, 2018, 07:05:10 PM »
Thanks for the tip!  Maybe this monkey following another monkey's advice will be have less headaches!
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Offline oneplustwo

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #109 on: February 02, 2019, 07:22:43 PM »
Hi folks!  Finally got some time to tackle some wiring and have made some progress.  I decided to take a break from it and tackle some of the other items.

Gas tank fuel pump wires: I don't plan to use the fuel level sensor, but obviously need to get power to the fuel pump.  The sender assembly is quite corroded and I would like to find a way to modify the stamped metal plate to get power to the fuel pump.  Anyone know of an appropriate connector that could work for such an application?

Clutch cable: The aftermarket clutch lever I have doesn't work with the stock cable.  Do I need a custom cable or are there generic cables that will work?  Here's a photo of the lever assembly.

And here's the difference between the ends that thread into the lever assembly:


Throttle cable: The throttle assembly I have has a different end for the throttle body side.  Is there a way for me to modify to fit?  Here's a photo of the cable I have:



Thanks for the help!
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Offline Laitch

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #110 on: February 02, 2019, 08:34:33 PM »
Quote from: oneplustwo on February 02, 2019, 07:22:43 PM
Gas tank fuel pump wires: I don't plan to use the fuel level sensor, but obviously need to get power to the fuel pump.
What stops you from using the existing wiring to the pump but cutting away the sensor hardware and sending it to recycling?
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Offline oneplustwo

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #111 on: February 02, 2019, 08:49:31 PM »
It's all just super corroded.  So I was thinking I would cut a hole in the plate and replace with a small bulkhead connector.  Kinda like this but this seems too big.


Another (ghetto) option that might not even work is to just route the wires through with a connector on the outside, and then seal it up somehow with some epoxy or other recommended sealer that is fuel/solvent resistant.
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Offline Laitch

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #112 on: February 02, 2019, 08:54:16 PM »
Quote from: oneplustwo on February 02, 2019, 08:49:31 PM
It's all just super corroded.
How about posting some photos of this tragic situation? The simplest solution isn't ghetto; it's simple. If it looks like hell when it's finished, that's on you.
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Offline oneplustwo

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #113 on: February 02, 2019, 09:05:02 PM »
Here's another option:
https://www.summitracing.com/parts/abt-cfd-504



They claim you can just have the right gauge wire through the two holes and it seals up ok.  I guess there's not a lot of pressure in the fuel tank so maybe that works?

Here's a photo of the corrosion.  As you can see, I already cut off the fuel level bits.

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Offline Laitch

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #114 on: February 02, 2019, 09:50:53 PM »
Quote from: oneplustwo on February 02, 2019, 09:05:02 PM
Here's a photo of the corrosion.  As you can see, I already cut off the fuel level bits. . . .
I guess there's not a lot of pressure in the fuel tank so maybe that works?
The first step is to determine the depth of the corrosion. Corrosion must be thoroughly removed. If the panel is usable then quite a few bulkhead connectors are available that only need 15mm or less hole diameter. Many require a minimum panel thickness so that will need to be established.

Whether the connector you've indicated will not leak fuel when properly mounted must be established in writing by the manufacturer. Proceeding with a maybe based on assumptions is a poor strategy to adopt.
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Offline The Mighty Gryphon

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #115 on: February 02, 2019, 09:59:40 PM »
I've had some experience with bulkhead connectors many years ago.  Most are designed for weatherproof sealing and not for continuous submersion.  From my experience, most of them aren't intended for use in solvents like fuel with ethanol. 

Whatever you use make very sure the sealing materials are compatible with the stuff in your tank.
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Offline oneplustwo

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #116 on: February 02, 2019, 10:41:24 PM »
I don't think those other two items will work.  I might just try Evaporust-ing the corrosion away to see if I can get wire soldered to the remaining lugs.  Here's another idea but it may take up more space than I would like.

https://www.efihardware.com/products/1593/submersible-pump-bulk-head-terminals


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Offline oneplustwo

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #117 on: February 03, 2019, 02:27:36 PM »
Looks much better after the evaporust although the lugs have some stuff on them. Might try to heat them up with the solder gun to see if I can get a good connection to new wires.

Anyone have thoughts about the clutch and throttle cables?
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Offline oneplustwo

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #118 on: February 07, 2019, 02:01:52 AM »
What should have taken 15 min took an hour because of multiple mistakes. But it’s progress.
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Offline Rcgreaves

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #119 on: February 07, 2019, 05:30:47 PM »
One of the greatest riding weeks of my life was attending a friends wedding in LA and then bunking with SF friends and bombing around the bay on a cafe Honda 500.  Ive enjoyed reading your thread.  Keep it up. Post the source for those styling mirrors mounted on the grips.  My son's R6 could use a set of those.
I'll dig for a pic of me thirty years younger in SF.  What a place to ride!!
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Offline oneplustwo

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #120 on: February 07, 2019, 05:59:07 PM »
Yes, the Bay Area is amazing for motorcycle riding and tons of other stuff too.

Here's the link to the mirrors: https://www.amazon.com/gp/product/B01NCLB57U/ref=oh_aui_search_asin_title?ie=UTF8&psc=1

I would love a cafe Honda 500 or similar next.  Maybe something with a kick start.  Need to finish this one first!


Quote from: Rcgreaves on February 07, 2019, 05:30:47 PM
One of the greatest riding weeks of my life was attending a friends wedding in LA and then bunking with SF friends and bombing around the bay on a cafe Honda 500.  Ive enjoyed reading your thread.  Keep it up. Post the source for those styling mirrors mounted on the grips.  My son's R6 could use a set of those.
I'll dig for a pic of me thirty years younger in SF.  What a place to ride!!
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Offline oneplustwo

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #121 on: February 11, 2019, 02:12:21 AM »
I was able to get the throttle cables and clutch cables to work-ish.  Basically, I got a couple universal cable kits from Venhill and repurposed some of the bits from the old cables to work with the new kit.  Throttle cable worked out pretty well.  But the clutch cable has a couple problems.  First, I need to find a replacement for the little rubber boot that goes on the clutch arm end.  The old one is in many pieces.  Second, it seems like the clutch lever doesn't provide enough throw to fully disengage the clutch.  I don't know how much I need and it's possible that I just need to shorten the cable a bit.  I just now read that the measurement of the barrel to the cable housing end should be 75mm at it's longest so I'll check that tomorrow and see.  If anyone has any other advice, would love to hear it.
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Offline Laitch

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #122 on: February 12, 2019, 09:57:26 AM »
Quote from: oneplustwo on February 11, 2019, 02:12:21 AM
I just now read that the measurement of the barrel to the cable housing end should be 75mm at it's longest so I'll check that tomorrow and see.  If anyone has any other advice, would love to hear it.
First, I grease the cable nipples at the hand lever and clutch arm. Then I follow the clutch adjustment steps in the sequence presented in the K75/K100 2V service manual downloadable from this site. When setting free play dimension A, I use one-finger pressure on the lever to verify there is slack of the correct dimension before the cable starts to engage the clutch arm. Out-of-sequence adjustment of these elements is unlikely to provide good results.

Low and medium bar clutch cable length is 1510mm.
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Offline natalena

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #123 on: February 12, 2019, 10:39:53 AM »
Quote from: oneplustwo on February 11, 2019, 02:12:21 AM
it seems like the clutch lever doesn't provide enough throw to fully disengage the clutch.  I don't know how much I need and it's possible that I just need to shorten the cable a bit.

You're probably on top of this, but I've changed cables and had "slack" in the line, due to not fully seating the outer housing snug in the barrel adjuster. Sometimes it's only a few mm, but it makes a big difference in throw.

* The ride up to Stinson Beach and north to Ocean Cove and beyond is amazing. There's really only 2 roads that connect the coast to I-5 above Santa Rosa, and both are spectacular for MCs. Good luck with the build.
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Offline rbm

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Re: Just picked up a K75 - need input on the plan of attack
« Reply #124 on: February 12, 2019, 12:43:09 PM »
Quote from: oneplustwo on December 06, 2018, 11:46:44 PM
Ooh, good stuff there that led to other threads still!  Deconstructing the stock harness sounds like a bear but also would be nice and clean.  I worry I might mess something up along the way though.  Will have to think on it further.
Yes, it would be a bear.  Read about the experiences that Shogs encountered trying the same thing:  http://k11og.org/forum/viewtopic.php?t=12040&highlight=harness
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  • Regards, Robert
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