Looks like I will be Picking Up a K110LT on Saturday

[Paul_Waterloo]

IT'S ALIVE!!!

First I got all the parts from Mike in Michigan, thanks for sending those at a fantastic deal!



So I finished the rear brake, just needed pads, so that is sorted out now.



Then I went to the fuel system and airbox. I wanted to get the whole airbox back together just like stock before I attempted to start the bike. Man, you have to be in Zen for something like an hour to get it all together and hooked up. I'm sure there are a lot of threads about the design of that thing. What a royal PITA.

New PCV hose replaces the old cracked one.







Just need a fuel supply now:



Used pump from Mike and some new fuel hose.



PC680 battery installed, I actually bought a new one, put it in my K1200GT and put the one from that bike into this bike.



Ready for start up, see my heathkit air fuel ratio meter plugged in? It has a sniffer tube that you put in the exhaust and reads A/F mixture. Worked pretty much as I expected.



She started right up after a few cranks (less than 10 seconds total), had a little white smoke but that burned off and then I let her heat up for a fan cycle, it cooled down, and I secured her. Now she starts right up.

Runs SOOOO smooth! Still on the list:

- Front brake master cylinder repair or replacement, then fill the brakes with fluid and replace the pads.

- New Tires

- Put the bodywork back on

[Laitch]

 

[Paul_Waterloo]

If you want to see a video of the exhaust analyzer:

[Laitch]

Were you able to draw any conclusions from that test?

[Paul_Waterloo]

No conclusion, just that it's running correctly. I just put in on the exhaust to monitor. It appeared the mixture was working as BMW designed.

[mw074]

When using the exhaust gas analyzer bear in mind that the choke does not enrichen the fuel mixture. It just increases the idle speed.

[volador]

Kill them mosquitos. Congrats sounds sweet

K11 Heat Sink Compound

http://www.motobrick.com/index.php/topic,3061.0.html

https://www.k100-forum.com/t12498-most-overlooked-preventative-maintenance-on-early-4vs-k100rs4v-k1-1993-k1100


Does your 2003 K1200GT use heat sink compound?

[Paul_Waterloo]

So I got the front brakes up and running today, had to buy a used master cylinder from eBay and then I bleed the brakes which were breaks before all of this. Got it all working and then went out without a seat on my maiden voyage! Around the parking lot behind my garage!

Then I pulled back in my garage and it DIED! WTF!!!

After doing some troubleshooting, figured out the fuel pump wasn't running, but it had spark. Then I put the side stand up which I had put down right when it died. So now I know that works.

LOL

The ABS light kept flashing when I was riding it, so I will look into that. Now I just need to drop $300 on tires, install them, and put it back together.

I really don't want to spend the $300, was thinking I could find a deal, but haven't found one yet.

[TommyT]

So I got the front brakes up and running today, had to buy a used master cylinder from eBay and then I bleed the brakes which were breaks before all of this. Got it all working and then went out without a seat on my maiden voyage! Around the parking lot behind my garage!

Then I pulled back in my garage and it DIED! WTF!!!

After doing some troubleshooting, figured out the fuel pump wasn't running, but it had spark. Then I put the side stand up which I had put down right when it died. So now I know that works.

LOL

The ABS light kept flashing when I was riding it, so I will look into that. Now I just need to drop $300 on tires, install them, and put it back together.

I really don't want to spend the $300, was thinking I could find a deal, but haven't found one yet.

Bridgestone is offer a $60 rebate on two tires, I think I got 2 for my 91 100 RS that with the $60 brought it below $300, but I have to check that later when I can dig out the order.

[The Mighty Gryphon]

Can you install and balance your own tires?  If so, Chaparral Motor Sports has Bridgestone Battlax BT46 tires, front and rear, for about $210 with free shipping.

https://www.chapmoto.com/touring-tires/bridgestone

I don't know about the $60 rebate, I think it ended on April 30.

[Paul_Waterloo]

Thanks for posting that info. I was thinking of getting radials. I do plan on mounting and balancing myself, or should I say, my friend has the equipment and will be learning.

The Metzler Roadtec Interact ZR8 is about $280 on ebay new, plus I'll have to pay tax, but it includes shipping. I am thinking this is the way I'm going to go. I know a new tire (s) will show up on craigslist or ebay for cheap as soon as I buy them!

[TommyT]

Can you install and balance your own tires?  If so, Chaparral Motor Sports has Bridgestone Battlax BT46 tires, front and rear, for about $210 with free shipping.

https://www.chapmoto.com/touring-tires/bridgestone

I don't know about the $60 rebate, I think it ended on April 30.

I got a Bridgestone Battlax T31 Radial front tire from them for $114 and a rear one for $154. Yes the rebate ended 4/30. free shipping.

[Paul_Waterloo]

I bought the Metzler Roadtec Z8's.....$282 shipped.

Next question, the handlebars seem to have a lot of movement, I see one of the rubbers is ripped.....but is this movement normal?

[Laitch]

. . . the handlebars seem to have a lot of movement, I see one of the rubbers is ripped.....but is this movement normal?

It could be normal for a handlebar with one of its suspension cushions ripped, especially if the rip is from the perimeter inward.

[Paul_Waterloo]

It could be normal for a handlebar with one of its suspension cushions ripped, especially if the rip is from the perimeter inward.

I can't seem to find the part at all on Max BMW, can you see it? If so, please post the part number. I would like to replace them before I put it back together. Thanks!

[Paul_Waterloo]

I think I found it, called a "hose"

Here is the part from an auction:



Looks like it is round:



Part Number 32 71 2 307 356

[johnny]

greetings...

i takes those suspension cushions out and putts warshers in there for a ridgid mount and firmer bar...

j o

[Paul_Waterloo]

greetings...

i takes those suspension cushions out and putts warshers in there for a ridgid mount and firmer bar...

j o

Johnny-

Having a hard time thinking of how I put in washers, maybe take the plate off, then put the washers around the square shaft and then the plate back on so it sandwiches the washers?

[Laitch]

I think I found it, called a "hose"Part Number 32 71 2 307 356

That looks like it might act as a bumper to provide tension on the dash. The looseness might also be caused by the suspension cushions, which johnny might be indicating could be removed entirely then replaced with washers. What is the condition of the suspension cushions?

[beemuker]

Johnny-

Having a hard time thinking of how I put in washers, maybe take the plate off, then put the washers around the square shaft and then the plate back on so it sandwiches the washers?

Looks like you could use large washers with small holes , so they fit outside , not in.

[Paul_Waterloo]

So she is back together. I even have a non-flashing ABS light, it was "6" for the fault code (relay), just needed a little voodoo (reset completed two times) and it went away.

Last week I washed all the parts again and then used old school HD cleanse and Zymol to clean and wax the parts.



I put the rear end on first so I could test drive it, then the fairing.





It took a while to figure out where the heat shields go on under the gauge covers, I took pictures, but a lot of trail and error before I got it right.





Here is one connector that I cannot figure out what it goes to. It comes from under the tank, anybody know (click on the picture for a larger view)? It took me a while to get all the other connectors hooked up and working. Could it be for the radio? I don't think it is for the radio, when I hooked the radio back up, it did not power up, so still have to troubleshoot that.





Here is a piece left over, haven't figured out where it goes, but I think somewhere near one of the foot pegs, maybe on the left side?



All done, bike came out great, it's super clean. Have about $2,050 all in and I would say 60 hours of labor. Thanks to Mike in Michigan, he kept my budget much lower than I could of otherwise.











I rode my 2003 K1200GT for about 60 miles Saturday morning, and finished this Saturday afternoon and then took her for a ride. Wow, BIG difference. The K1100 has the most easy clutch to work ever, it doesn't have the cam/power band that the K1200 has, and feels like it was tuned for more torque. Love both of them.

The rear brake needs adjustment or bleeding, it basically doesn't work, the rear shock was bottoming out (or felt like it was), I put 30 PSI into it (it's the aftermarket "Works" shock), have to find a manual and adjust it. After charging it with air, worked much better. The Metzlers are great, still breaking in the front brake pads.

I LOVE how the front windshield is like a battle shield when it rises into place, have to take this bike out for more than around the block.

Thanks to everyone here for helping me out, I am a very experienced mechanic, but this and my K1200 is the first bikes I have worked on in a long time, I feel like I could do anything to a K bike now.

[Laitch]

Here is a piece left over, haven't figured out where it goes, but I think somewhere near one of the foot pegs, maybe on the left side?

It's the alternator cover.

[Paul_Waterloo]

Of course it is.....because it's going to be so easy to put on!

Darn.

[Laitch]

Of course it is.....because it's going to be so easy to put on!

Darn.

You can do anything to a K bike now. 

[The Mighty Gryphon]

I think your Works Performance shock needs about 200psi of nitrogen to work properly.  A shop that services the motocross crowd can charge it for you for about $10.