Seconds out, Round Two (K1 fettling):

Spent a few minutes cleaning and polishing the rear of the frame. There are a few scars from where the seat rests on it but it's not too bad:

K1%20BMW%20%28124%29-L.jpg


So with the loom cleaned and re-attached and the cleaned up rear lamp and seat/grab handle mounts in place:

K1%20BMW%20%28127%29-XL.jpg


I added some Helicopter tape to the frame rails to prevent further marking:

K1%20BMW%20%28125%29-L.jpg


My pile of cleaned, fettled and polished bits ready to go back on is growing:

K1%20BMW%20%28123%29-L.jpg


The pivot pins and rear disc mounting screws cleaned of old Loctite:

K1%20BMW%20%28126%29-L.jpg


I'll stir myself into removing the swingarm soon.
 
Before diving into the swingarm removal, I thought that I'd turn my attention to the broken wires in the grips. It's always nice to do a clean job between the grubby ones.

This may be useful for you poor sods who do not own BMW's finest K-Series of all time because the grips are pretty much universal in their design. Chin-up, at least your inferior bike has something in common with a K1. :augie

So, first thing was to bare some of the wire left in the grip itself. There's never much of it because there isn't a great deal of room in there. Don't be tempted to add too much new wire as you'll have difficulty cramming it all inside and you'll risk undoing your work by pinching the wire.

First, roll back the grip itself to expose the wire element under the wrapping material.

Take a sharp knife (without a locking blade, less than 3 inches in length, if you're worried about getting nicked ;)) and cut enough of the wrapping material away:

K1%20BMW%20%28128%29-L.jpg


If you go into the material far enough you will uncover the bare wire element. There shouldn't be any need to do that. Just expose enough of the insulated end to pare the insulation back, solder and heat-shrink the joints (I didn't have the right diameter wire in brown so red has been used instead):

K1%20BMW%20%28129%29-L.jpg


Once that's done, the wires can be fed through the cut-out in the plastic tube of the grip and a wrap of insulating tape (once around, avoid making it bulky) to hold it. At this extreme end of the grip you won't notice any loss of heat caused by the extra insulation:

K1%20BMW%20%28137%29-L.jpg


Then the grip is rolled back over.

I left the wires long at this stage just to make it easier to work with.

From here onwards it helps if you don't have fingers that resemble saveloy sausages. ;)

Gently pull the snapped wire inside the handlebar as far as it goes without snapping off more of it. Then cut away the rubber sleeve enough to expose the two wires. I used a knife to slit it lengthways to avoid snapping or cutting the fine wire inside by over-enthusiastic use of wire strippers.

K1%20BMW%20%28138%29-L.jpg


Then the two wires were extended, soldered and heat-shrink:

K1%20BMW%20%28131%29-L.jpg


Before a larger diameter sleeve of heat-shrink went over them and the original rubber sleeve:

K1%20BMW%20%28132%29-L.jpg


Then it was a case of sliding the end-weight inner (suitably daubed with rubber grease to help the O-Rings slip along nicely) back inside the bars and feeding the extended wires through it at the same time:

K1%20BMW%20%28139%29-L.jpg


The wires have to go through the end at this stage to allow the outer part of the assembly to be re-fitted:

K1%20BMW%20%28133%29-L.jpg


Then once the outer part is going on, the wires have to be pulled back so that they exit in the cut-out. The tiny roll-pin can now be re-inserted to lock the two halves together:

K1%20BMW%20%28140%29-L.jpg


With that done, I cut the wires down, soldered them:

K1%20BMW%20%28141%29-L.jpg


and covered with heat-shrink (remember that the heat-shrink goes over one wire before soldering the joint. God knows how many times I've realised the error after admiring my soldering - I know, it's not that good either :rolleyes:):

K1%20BMW%20%28142%29-L.jpg


The inner assembly can then be pushed carefully back inside the bar, the wires stowed neatly and the grip re-secured with the upper and lower grub-screws:

K1%20BMW%20%28143%29-L.jpg


Just awaiting the refurbished end-weights:

K1%20BMW%20%28136%29-L.jpg


If you are considering changing the original countersunk retaining screw with a nice shiny stainless, make certain that it's no longer than the OE one. If the replacement screw is too long it might cut through the wires where they emerge from the centre of the inner sleeve.
 
I had to do a similar job on the right heated grip but because I snipped the wires myself (for a reason that will become clear). Here the joints to the heating element wires are visible:

K1%20BMW%20%28145%29-L.jpg


The reason I snipped the wires is to fit this:

K1%20BMW%20%28120%29-L.jpg


It's the equivalent of the five quid throttle-stop screw that fits under the right-hand assembly on older models (including Boxers). In the olden days it always seemed a bit naff to call it a cruise control. I mean, whoever heard of bikes with a cruise control?:nenau I came to appreciate the benefits of a positive-close throttle; you can "cruise", you can take your hand off to wave gaily to the proles and see the look of wonderment behind the iridium visored helmets of oiks who have the nerve to nod at a BMW rider and I find the fuel shut-off of the injection to be a little bit abrupt, this thing helps smooth things out.

It's easier to cut the wires and re-join them than the alternative which is to find and disconnect the plug for the heated grips under the tank, draw the cable through to provide enough slack to slide the grip-assembly off the end of the bars.

I also plugged the top of the mirror mounting screw and sorted the flaking master cylinder cover:

K1%20BMW%20%28144%29-L.jpg


The opportunity to clean the buttons was too good to miss:

K1%20BMW%20%28151%29-L.jpg


Cleaned up the scratches in the mirror and gave it a coat of polish, re-fitted the sprayed-up bar end weights and used a stainless counter-sunk screw on them:

K1%20BMW%20%28148%29-XL.jpg


The new nearside mirror fitted and the assembly cleaned. Somehow the black finished has become pitted. That can be re-coated in due course.

K1%20BMW%20%28147%29-L.jpg


This afternoon I did something I've not done for many a year, I visited a model shop and bought some Humbrol Enamel paints.

K1%20BMW%20%28150%29-XL.jpg


I'm going to mix up and create the best match for the yellow finish.
 
I've just spent half an hour turning this:

K1%20BMW%20%28114%29-L.jpg


into this:

K1%20BMW%20%28153%29-L.jpg


Initially I thought I'd just clean it up, probably fit the new bearing and seal that I have to hand and re-fit it but it seems daft when I have a new unit sat there. All I need to do is pop the UJ off the old one (done that) and pop it into the brand new unit:

K1%20BMW%20%28156%29-L.jpg


It won't hurt to make use of its new bearing and seal plus of course the new Paralever pivot bearings the unit has fitted.

Parts pile continues to grow:

K1%20BMW%20%28154%29-L.jpg


The swing-arm will be the next job and a proper look at the gearbox output shaft seal. I did dip the gearbox earlier today and the level is spot on. I'm hoping that the oil I found in the swing-arm was the result of the owner before Luke thinking that it wouldn't harm to squirt some inside via the top of the gaiter in the belief that it was the way to lubricate the splines. :nenau
 
Someone tell him!
I'm all ears.

Just stopped for a coffee. I began today's play by attending to this:

K1%20BMW%20%28149%29-L.jpg


Some people no doubt have a different way of working but for me, after years of doing this sort of thing to cars and bikes (for the pleasure), I've learned that if I don't sort out things as they come off, there's a tendency to rush things as the re-assembly starts. The desire to see it all back together can be quite powerful. Plus, when the time comes to put things together, this way, it's faster as everything should be ready to just be bolted back on.

Stripped:

K1%20BMW%20%28157%29-L.jpg


Cleaned:

K1%20BMW%20%28159%29-L.jpg


Stainless bits with the ones they'll replace:

K1%20BMW%20%28158%29-L.jpg


Polished and re-assembled:

K1%20BMW%20%28161%29-L.jpg


The "bucket" of parts replaced by stainless is filling up:

K1%20BMW%20%28160%29-L.jpg


As Steptoe has said, the alternator drive rubbers don't seem to suffer as badly in four cylinder models for some reason. I put new ones in anyway:

K1%20BMW%20%28162%29-L.jpg


K1%20BMW%20%28163%29-L.jpg


Right. At last it's off with the swing-arm:

K1%20BMW%20%28164%29-L.jpg


The swing-arm pivots presented less of a problem than either the 'Turd' or Coolcarbon's K1.

Now for a look inside the back of the gearbox casing:

K1%20BMW%20%28165%29-L.jpg


Grubby but no worse than any other I've peered at. It probably looks worse because of the yellow coating.

The gearbox output-shaft seal:

K1%20BMW%20%28166%29-L.jpg


Looks fine to me. :nenau

So where the hell did all that oil come from? The final drive level was fine. After a decent distance from collection back to here there was no sign of oil on the wheel or the brake. The MoT tester didn't spot anything. The gearbox level is fine. While there's some oil residue around the gearbox breather (under the starter motor) suggesting that it's been over-filled at some point, if that was the source there'd be oil over the top of the gearbox case and under the battery tray before it could get down the inside of the swing-arm somehow. :duno

Ho-hum. Unless the bloke who Luke bought the bike from is prepared to cough to squirting oil into the swing-arm via the top of the gaiter, or unless someone here has a better explanation................:confused:

Right, I'm off downstairs, donning my Marigolds and begin cleaning it up.
 
and covered with heat-shrink (remember that the heat-shrink goes over one wire before soldering the joint. God knows how many times I've realised the error after admiring my soldering

:D Made oi laff! Been there, done that :forry

I do like these threads, as winter draws closer and my thoughts turn to a bit of bike fettling. Keep posting :thumb2
 
Mike is that round thing at the top middle with the wire going up, the gear selector indicator bastardthingymebob thing

steve

Now for a look inside the back of the gearbox casing:

K1%20BMW%20%28165%29-L.jpg


Grubby but no worse than any other I've peered at. It probably looks worse because of the yellow coating.
 
Mike is that round thing at the top middle with the wire going up, the gear selector indicator bastardthingymebob thing

steve
Steve, I think you mean the Gear Position Indicator?

Yes. It's clearer in the below photo.

K1%20BMW%20%28173%29-L.jpg


It will clean up properly once I strip the front end and have the exhaust off.

More cleaning:

K1%20BMW%20%28169%29-XL.jpg


K1%20BMW%20%28174%29-L.jpg


Then the fun bit starts:

K1%20BMW%20%28175%29-L.jpg


K1%20BMW%20%28176%29-L.jpg


K1%20BMW%20%28177%29-XL.jpg


K1%20BMW%20%28178%29-XL.jpg
 
With it (nearly) all back together, I rolled it out and gave it a rinse and blow-dry:

K1%20BMW%20%28179%29-XL.jpg


Before a coat of polish:

K1%20BMW%20%28180%29-L.jpg


and then pointed it at the way out:

K1%20BMW%20%28182%29-XL.jpg


to watch and wait for the weather to pick up a bit.

Well that's it for now. I'll get the recalls done and hopefully there will be some nice clear days ahead to enjoy it out on the road.

I'm resisting the temptation to tear off the front end and clean it up under the plastic. The exhaust is crying out for a decent clean, the mesh grilles in the side panels would benefit from a re-spray, I have some five inch width helicopter tape to protect the centre panel from stone chips and where the main section of the fairing inner is visible, it needs re-spraying satin black.

There's the top, inner fairing panel needs re-painting where the paint is splitting so I may get the tank and hump re-sprayed at the same time, both have some small marks that won't polish out and it makes sense to get them done soon.

I've managed to get my mini-compressor and tyre repair stuff in the tail under the seat, my enhanced tool-roll and other bits into the offside tail-cubby. The fairing cubby accommodates a wire bike-lock and has space to spare. That leaves the nearside tail-cubby free for stuff that I don't want in my pockets.

In due course I'm going to run another aux-socket to that cubby for recharging phone and ipod etc and I have yet to fit the Nav III.

Now I'm off back down into the garage to sit and look at it. :D
 
Now I'm off back down into the garage to sit and look at it. :D[/QUOTE]

Oh bugger ... what am I guna read now :confused:

was hoping it would take you at least until crimbo
 
Last edited:
its just ............well..............sniff................ beautiful :beer:

we need to get another bike to you ASAP:D:D:D
 
Mike

What is this Helicopter Tape you mention ?

How good how much and where can it be obtained ?

regards Frank
 
Frank,

It's a clear(ish) self adhesive 'rubbery' tape that's apparently used to protect the leading edge of helicopter rotor blades.

It's very like the little clear patches that BMW used to put on the frame rails to protect against the seat chaffing the paint, only thicker.

Just enter "helicopter tape" into ebay search and you'll find plenty of suppliers. The available widths are a bit limited.

It's not invisible but it's better than chipped paint. Here's a couple of strips on the belly-pan of a K75S:

K75S%20%28137%29-XL.jpg
 
Now I'm off back down into the garage to sit and look at it. :D

FFS Mike

You can't stop now, only doing half a job (the rear end) - we need the full monty

Do the front end, so we have something to muse away these long winter evenings - looking, studying, learning, pondering, thinking, dreaming

So come on, don't let us down


Looks fab by the way:thumb2
 
I gave it an airing today and got it muddy.

By heck, it was fun. :bounce1

Apart from a short trip to and from the MoT, I started the work before I had the registration sorted so today was the first proper ride.

The two reasons why I always put off buying one again was the fear that the intervening twenty years would mean that I'd find the riding position a bit difficult and the likelihood that it wasn't as good as my memories would have me believe.

Both fears have proved to be unfounded.

I will be tearing the front-end down soon. Once the recalls have been done, I need to sort the misting fork seal, re-spray the fork lowers, clean the frame and many other bits while some of the paint is sorted.

Forecast is good for tomorrow so I'll probably flash up to Salisbury to see my old dear in hospital (she fell down the stairs ten days ago and broke her hip).

Today, just as I was pulling up to take a few photos, my ipod started to play Bill Withers 'Lovely Day', it couldn't have been more apt. :D

I still can't get my camera to stop the colour looking washed out. :nenau

K1%20BMW%20%28191%29-L.jpg


Ignore the tatty main stand and grubby exhaust, they will be sorted soon ;)

K1%20BMW%20%28189%29-L.jpg


K1%20BMW%20%28190%29-L.jpg
 


Back
Top Bottom