10,000K Voyage, mechanical advice needed

[YoungEngineer]

The clutch arm only needs to flop down once to tear that boot that is made from unicorn foreskins.  DAMHIK.

Driving off with the disc lock installed? OUCH!!!  You may be in need of first gear dental work.  Have you drained the oil and checked it for metal particles? 

What happens when you rotate the rear wheel with the transmission in gear?  Try it in each of the 5 gears and neutral.  Any binding?  Weird noises?  Can you start the engine on the center stand and run through the gears?

The cable was not removed so the arm has not been left to dangle. But I will bear that in mind when fitting again. Its hard for me to try that as my rear shock is set to the max height plus the extra tread on the tires means that they always touch the ground even when on the center stand. I might try to put a piece of wood under it tomorrow and check again. I will go back and check when the boot and oil arrives hopefully on Monday. If i've managed to strip a gear I will be really upset. I've spent way to much time and money on this bike to let it go so I would replace to gearbox with a low milage one, I decided a long time ago that I'm riding it until it quits!

[Laitch]

You know I just had a thought, this all started right after a tried to drive off whilst forgetting the rear disc lock . . .

That would have been handy to have mentioned with the grinding transmission description. :giggles

It's a singular way of viewing priority, YE.  It might be even more inconvenient if expressed as "I bet nobody is on the other side of this curve. I'll just cut through it to keep up speed."

How many feet did you travel in slow motion?

[YoungEngineer]

The noise I noticed before the disc lock incident. When I pulled away I used no throttle just idle so that should give you an indication of the speed. It was less then 1mph. I heard a thud and stopped. I did not mention it as I thought it would be impossible for damaged to be caused at that speed but I could be wrong. What did happen was that the boot started leaking oil almost immediately after.

[Laitch]

What did happen was that the boot started leaking oil almost immediately after.

How's this sound?

When you failed to remove the disc brake lock and it jerked you to a stop, the excessive amount of gear oil you put in the crankcase because you didn't use a gauge to check its level exited through the rip that you put in the clutch rod boot when you either installed it carelessly or sliced into it when you opened its packaging while trying out the Corona machete you bought for your 10K mile expedition. Once the oil found a path of least resistance, it followed you around London where you had the appearance to onlookers of a public works employee testing a road surface crack repair device. Nobody intervened because the Mad Max color of your bike with its menacing headlight grill was intimidating. Meanwhile, the gearbox started whining from lack of lubrication, eventually growling with resentment and malice.

[Filmcamera]

Uncanny - almost like you were there - or have been there and done that...  :hehehe

[YoungEngineer]

How's this sound?

When you failed to remove the disc brake lock and it jerked you to a stop, the excessive amount of gear oil you put in the crankcase because you didn't use a gauge to check its level exited through the rip that you put in the clutch rod boot when you either installed it carelessly or sliced into it when you opened its packaging while trying out the Corona machete you bought for your 10K mile expedition. Once the oil found a path of least resistance, it followed you around London where you had the appearance to onlookers of a public works employee testing a road surface crack repair device. Nobody intervened because the Mad Max color of your bike with its menacing headlight grill was intimidating. Meanwhile, the gearbox started whining from lack of lubrication, eventually growling with resentment and malice.

Your imagination and choice of words are something to behold. Hehe, no but seriously you should have been on car talk with that kind of investigative imagination.
You know, I was thinking this morning when I saw that huge puddle of oil that it must have been overfilled, I mean surly there should not be a half Liter/Quart of oil above the upper half of boot? Either way I don't actually think that I rode around with it like that otherwise the entire swingarm and wheel would be covered but there is not a drop, hmmm.

[The Dude]

Hmmmm,mechanical advice needed?
When using a forgetful padlock to disable you're bike disc brake also use a reminder that you have done that.I am absent minded enough to warrant a solution for this.A dayglo rubber band around my brake lever to throttle twist grip is good for me.
I once rode off with the stearing lock engaged!That didn't go too well.'Never done that again.

[Rcgreaves]

Starter brushes have surfaced as the the source of all sorts of tertiary electrical glitches in my 105k K75s cleaning and dressing the brushes seems to be a nessessary periodic maintenance chore


Sent from my A573VC using Tapatalk

[MaraudeRS]

They're restricting access and control of clutch arms, too? Lamentable!

California is the UK of the West.

Indeed it is!

We do, we can own pretty much anything that you guys can in Comifornia :) No handguns however that's a big no no. But its pretty easy to get a license you just have to be a member of a shooting club. I have a few friends with M4's, Lee Enfields and other large caliber rifles. No full auto either but as I understand that's pretty heavily restricted in CA also.

"Comifornia" lol! We do get to own handguns but yes, no fully autos


Sent from my iPhone using Tapatalk

[YoungEngineer]

So the new boot arrived yesterday, the swap was trouble free. I adjusted the clutch so that the boot had minimal tension and stretch which should prolong the life. I also topped up the oil using the dip stick so everything seems well.


A second issue has occurred. 


My charging system seems to be damaged, the bike has had problems starting over the past few days. I've not ridden the bike but I noticed that when revving the lights would dim. After 15 minutes idling the lights where so dim that they eventually went off completely including the idiot lights. Eventually the engine also quit, impossible to restart.


I cannot remember if the battery light was on whilst it was running but if i turn on the ignition (Without starting the engine) all the other idiot lights are on except the battery light.
This all occurred after I fitted a phone charger outlet which involved fitting new terminals to the battery posts so my first thought was that I forgot to reinstall one of the cables. I checked this first and all seems to be in place. Two cables connected to ground and one to positive?


I would also like to mention that in my great wisdom I remember that I stupidly managed to short out the positive battery post to the frame when using a socket to undo the positive battery post. Yes I disconnected ground first and moved it away from the frame but just as I was working on the positive terminal it swung back and touched the frame causing a split second short/spark!


Oh dear, what damaged might have I caused? I've not had much luck and I'm due to leave for France in a few days. I'm hoping its something simple but again the fear has got a hold of me.

[YoungEngineer]

I've just conducted a little background research and it looks like the battery/charge lightbulb is needed to excite the alternator into producing power.
In that case the first step should be to replace the lightbulb as it is clearly no longer working. I will do this now and hopefully that will resolve the issue, fingers crossed.

[Laitch]

Two cables connected to ground and one to positive?. . . just as I was working on the positive terminal it swung back and touched the frame causing a split second short/spark!
Oh dear, what damaged might have I caused?

A photo of your battery connections might clarify things.  When adding connections to either terminal it is cautious to have both terminals disconnected. Check all your fuses for function.

Replacing the light might get charging back—a valid observation. Cleaning the Motometer plug connections before reinstalling the plug will help insure function. Replacing fear with mindfulness will help you check all systems when you're back in action.

Sparks happen. Sometimes they are warnings; sometimes they are judgements. This one might only have been a warning—no smoke, no blast.

[The Mighty Gryphon]

Is your phone charger on all the time?  If so, it will drain your battery over a couple day period.  You want to connect it to a supply that is only live when the ignition is on.

When you disconnected the battery did you disconnect the negative wire at the battery terminal or at the frame.  The proper place is at the terminal.  Then there is no way you could get a spark off the positive terminal if the negative terminal is not connected.  If you got a spark with the negative disconnected at the battery there may be something else going on with your electrical system.

You need the battery indicator bulb working to get the alternator to excite.  It is possible to have the alternator self-excite with residual magnetism in the rotor, but you need to revthe engine to more than 2500 rpm, possibly as high as 4000 rpm. 

How old is your battery?  Your problems seem to indicate that it may be a bit past it's prime, especially with the recent charging issue,  and it would be a good idea to replace it before going on such a long trip.   If it has sat for a week or two with no charge on it, there is the danger that it has lost a significant portion of it's storage capacity.  Batteries do not like to sit with less than a full charge.

[kris]

Once you get this sorted out, and have replaced the battery, get yourself a battery tender.....and use it. Never hurts to keep it juiced up.  Or ride more often!

[Laitch]

get yourself a battery tender.....

That isn't going to help because where he's going he will be eating goat meat from a walnut burl bowl deep in the mountains far from the comfort of electricity. Right, YE?  :giggles

[The Mighty Gryphon]

He's going to Vermont???

[Laitch]

He's going to Vermont???

How did you get that impression, Gryph. I didn't mention double lattes with that. :giggles

[The Mighty Gryphon]

I guess I got thrown off by the goat meat in mountains far from the grid.  Never saw a wood-fired espresso machine.

[Laitch]

I guess I got thrown off by the goat meat in mountains far from the grid.  Never saw a wood-fired espresso machine.

Come on up when the road is dry in spring. They're part of the scenic vistas.

[The Mighty Gryphon]

It's on my to do list. 

Next time I want to do the 100 when it isn't snowing.  A very fun road.

[YoungEngineer]

Ok so some good news and bad. I changed the bulb and it made no difference, bulb was fine. I went to check the output directly from the alternator and noticed that the single blue wire was disconnected, once connected the battery light came back on and voltage started being produced once again! 13.80v at idle, no noticeable drop with all lights and accessories on, good news. I took the battery out and fully charged also. The other news which could be good or bad depending on your view is that I believe that the bag of bolts noise i heard from the gearbox is in fact from the alternator. It defianatly sounds like a bearing on its way out, I suppose this is better then the gearbox.

[The Mighty Gryphon]

Pull the alternator.  You should be able to get it out after removing the battery.  There are rubber cushions in the cup on the drive end.  These are the infamous monkey knutz that are often found to be worn out and cause quite a clatter.  A set will cost about 15 pounds. 

When reinstalling I have found that putting soap on the knutz and using a pair of M8x75mm bolts with the heads cut off makes getting things together infinitely easier.  Use a lube on the threads of the bolts and don't tighten them so they are easy to remove after you have the alternator in place.  A black mark from a Sharpie pen to show where the slot in the knutz is helps line things up with the drive dog.

Hang on, you're getting there.

[YoungEngineer]

Thanks Gryphon. I shall do that.


No one told me that buying a K would mean becoming a full time mechanic :)


I suppose i've learnt allot :)

[Martin]

Once you have it sorted they are incredibly reliable. In 19 years it has never left me stranded, even some of the Japanese bikes have done so. Stick with it and you will be rewarded.  :2thumbup:
Regards Martin

[Laitch]

. . . No one told me that buying a K would mean becoming a full time mechanic :)

OK, YoungEngineer. Here is a quick quiz for you.

Identify the person who wrote the following:
I would think pretty much every K owner out there is a semi professional mechanic by now . . .
The correct answer wins you a free counseling session at MOTOBRICK.COM!  :hehehe