K100 CAFE FIGHTER

[jc55]

Keep the pics coming!

[Boxermann]

Finished the intake manifold. The design was inspired by the Impuls K100 build. I folded the box from a plate of aluminum and glued the tubes (38mm) with epoxy, then metal filler and sanding. Painted flat black.

The weather suddenly allowed for driving this week so I had to scramble together the Harley so I could take it to work. Damn it feels good to sit on a motorcycle again.  :clap:

[Boxermann]

Made a compartment under the tank where I'm planning to put the necessary electrical parts (yes, I know my welds aren't the prettiest..) I couldn't resist ordering the new m.unit blue from motogadget so it will replace the fuses and relays except the starter relay and fuel injection relay. The temp.switch unit and BEP also goes there under the tank.

The m.unit is controlled by Bluetooth; alarm, log, diagnostics and the sexiest part is that I should be able to use the phone as an ignition key. Just walk up to the bike with the phone and it unlocks and lights up automatically. I will put a key switch somewhere just in case though. I was planning to achieve this through a k9 car alarm but this is a lot smoother. 

I got a message from FedEX while writing this telling me that a package from motogadget will be delivered today.   :clap:

Ordered m.switches, m.blaze discs and some other goodies from them at the same time. Also waiting for an YSS shock and a new Shorai battery since I put the one I had in the Harley.


I never seem to be able to remember if its "measure twice, drill once" or the other way around so that's why there are three holes for the fuel tank overflow instead of two...

[nods]

Very cool! I hadn't heard about the new Bluetooth m-unit. Good things come to those who wait!

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[pablooo]

I'm glad I hadn't purchased the M-unit yet then! I'll go ahead and get that now and add it with the m-lock I have now.

[stomatomoto]

I'm so stoked on this thread, this is awesome. Totally inspired to make my own intake manifold now!

[Boxermann]

Very cool! I hadn't heard about the new Bluetooth m-unit. Good things come to those who wait!

I'm glad I hadn't purchased the M-unit yet then! I'll go ahead and get that now and add it with the m-lock I have now.

It's awesome! I just hope they release the mride app for iPhone soon.

I'm so stoked on this thread, this is awesome. Totally inspired to make my own intake manifold now!

Thanks! Go ahead! It was my first try at doing something like this and it was easier than I first thought. Aluminium is easy to work with. And there's always metal filler...




Frame finally primed! 2K epoxy primer/filler. Thinking of doing on one more layer.



Other bits and pieces:
Rear cowl mostly finished, just need a little more sanding. I received the custom Radiantz LED strip for tail/brake/indicators a couple of days ago and it looks great.
Made a bracket to mount the MAF to the frame.
Bought another Shorai battery since I put the first one in the HD.
Bought an YSS shock.
Reinstalled the water/oil pump and added a sensor for oil temperature (from motogadget). I'm actually really looking forward to start the electrical work as soon as I'm finished painting the frame.

[nods]

Do you mean a water temperature sensor? I think the top sensor is the oil pressure switch and the bottom one is the coolant temp sensor. Love this thread!

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[Boxermann]

Do you mean a water temperature sensor? I think the top sensor is the oil pressure switch and the bottom one is the coolant temp sensor. Love this thread!

Yeah, you are right... I didn't think that one through properly. It will act as an optional water temp sensor then. I see now the only option for an oil temp sensor is to replace the filling cap?

[Boxermann]

Finally found time to paint and coat the frame so I can start to reassemble.


Installed the Radiantz LED strip and started placing the electrical components. Also found a place for a coolant overflow tank. I'm using a 500ml car oil catch tank.

[jc55]

It's looking good man. I like the extra long turn signal idea and the clean electrical layout.

[Boxermann]

It started up nice and clean at least... I'm going to tidy it up now that I've got everything working properly.

[MaraudeRS]

I'm lovin what you're doin. Keep the updates coming!


Sent from my iPhone using Tapatalk

[Boxermann]

Thanks!

Mostly finished with the wiring. The red cable on the outside is to a button acting as a temporary ignition switch. I've ordered a small key switch which I'm going to hide somewhere as a backup for the m.unit Bluetooth keyless go.


40 amp main fuse switch under the tank. Very annoying that I cut the cable just a little too short so it's not straight. Will probably fix that soon. 


Made a little compartment under the triple tree for the m.button and cables for the switches.

[Boxermann]

Itsy bitsy tiny backup ignition key switch installed.

[Boxermann]

Wheel bearings came out pretty easily at the expense of a small chisel. New ones are in the freezer and are going in today.

[stomatomoto]

Probably a dumb question but am nooblet for sure, but why the freezer exactly? Also awesome work man, always excited to get a notification for this thread's updates! How do you plan on wrangling those wires under the seat, bunch of zip ties or something? Another question I had was, is there any risk of oil blowing up into the air filter given the custom design of the intake manifold? I was always cautioned against similar designs on other bikes because of that for some reason, not exactly sure of how that all works though.

[Laitch]

Probably a dumb question but am nooblet for sure, but why the freezer exactly?

Freezing the bearings reduces their diameter slightly, making easier the installation of them within a tight tolerance. The hub is sometimes heated to expand its diameter slightly. Sometimes they are just driven into place by pounding on them with a wrench socket of appropriate diameter then life moves on.

None of this is as interesting as a cheese-producing crankcase.

[thecableguy]

None of this is as interesting as a cheese-producing crankcase.

:hehehe

[Boxermann]

Probably a dumb question but am nooblet for sure, but why the freezer exactly? Also awesome work man, always excited to get a notification for this thread's updates! How do you plan on wrangling those wires under the seat, bunch of zip ties or something? Another question I had was, is there any risk of oil blowing up into the air filter given the custom design of the intake manifold? I was always cautioned against similar designs on other bikes because of that for some reason, not exactly sure of how that all works though.

Laitch beat me to it.  :2thumbup:

I don't think I need to do so much about the wires under the seat except zip-tying them so they don't move. I'm going to make a fiberglass seat pan that will leave about an inch of space under it.

I can't see how oil could get in the air filter except from the crankcase breather? In the original design there is a hose leading the breather in to the plenum. I've just added a separate filter on the breather outlet now, but I'm thinking of replacing it with a hose leading to under the engine and place the filter there, to avoid mess on the top of the engine.


And thanks!

[Boxermann]

New wheel bearings installed. Went in without a fuss after heating the hub and freezing the bearings.


Also serviced the rear caliper. New seals, pins, pads, bolts, stainless bleeding nipple and cover.

[stomatomoto]

Gooooot it, thanks, crafty! Except I don't understand the cheese-producing crank case thing either... Is this one of those things where any question x of mine results in answers that actually further raise yx additional questions? Because I'm game if you are. cool shades


Yeah that's what it was, the crank case breather thing that was mentioned to me about oil in the filter and such, but sounds like you've got it planned and sorted already, so I'll definitely be wanting some details on how you did that for if/when I try something like this with my brick!

[Markus77]

This project is looking fantastic - looking forward to seeing more pics. Great job:)

[Laitch]

Gooooot it, thanks, crafty! Except I don't understand the cheese-producing crank case thing either... Is this one of those things where any question x of mine results in answers that actually further raise yx additional questions? !

It was a reference to a different thread where a crankcase was first producing mayonnaise then followed with cheese-product.

[Boxermann]

Yeah that's what it was, the crank case breather thing that was mentioned to me about oil in the filter and such, but sounds like you've got it planned and sorted already, so I'll definitely be wanting some details on how you did that for if/when I try something like this with my brick!

As far as I know the reason the crankcase is vented in to the inlet manifold is solely because of emissions. The unburnt gasses that bypass the piston rings go out the breather, in to the intake manifold and back in to engine to be burnt. No performance benefit since it makes the mixture slightly less combustible. Also it messes up the inside of the manifold. Not a big deal on these engines, but on e.g. Harleys the crankcase is vented straight in to the airbox thus dirtying the filter pretty effectively.

You can route the breather to a catch tank that collects the gas, or just a filter and let it go out in to the environment. It's not that much anyway.

I own an electric car so my conscious is clean when it comes to pollution anyways  :eek: (I rarely drive it though, I mostly drive my 4.7 and 4.0 liter Jeeps...)

This project is looking fantastic - looking forward to seeing more pics. Great job:)

Thanks Markus!


I fabricated a bracket and made a coolant expansion tank out of a 500 ml oil catch tank. I'm thinking of replacing the hose connector on the outlet/vent side with a PCV-valve and I'm routing the outlet hose down the right side next to the foot pegs. I'm not sure if this will work properly since the tank is lower than the radiator, but then again the stock expansion tank isn't placed much higher. Ideally maybe the tank should be standing vertical but I couldn't make it look nice. Any input?