Hi
As many of us know smoe old K-engines have one common ailment - noisy work when they are cold.
I bought my brick in October 2009. She was little bit noisy when she isn't warmed up.
And the noise intensified lately so I decided to repair it.








I paste more photos and I describe the repair more detail ... soon

I found the culprit of noise:

Sorry for the bad news, but this could be a very expensive repair.
But wait....
First, say a big "Thank You Bert"!
Now, check this. This part is very difficult to find, but this one is the cheapest that I ever seen.

Nice work Lifeguard! This is the type of stuff I've been looking for on the motor. Hopefully this will encourage more folks to post their engine work

OG

Wow, Nice find Bert! That's a crazy price if it a clean unit.

OG

Crazy Frog wrote:Sorry for the bad news, but this could be a very expensive repair.
But wait....
First, say a big "Thank You Bert"!
Now, check this. This part is very difficult to find, but this one is the cheapest that I ever seen.

Thanks Crazy Frog.
I am aware of the fact that normally it would cost a lot of money to change output shaft.
I bought 12 rivets version of output shaft from K1200. I hope that it will fit.

(12 rivets) output shaft
K1200 - 11211464947
K100 - 11211461499

http://www.bmwmcchattanooga.com/showassembly.aspx?ukey_assembly=188693

Their web site is very good. They have the ETK online like RealOEM.com

In water pump I have an old type of rotator



BMW recommends replacing this when rebuilding any "old" style but servicable K bike pump.

Is it necessary?

The 'old' parts of the water pump will not retrofit to the 'new' type. Replace the mechanical seal kit and the impeller as a set.

Hope I can jump in on this thread. I've got my bike apart and I noticed that I have the old impeller. I know I have to replace the seals w a new impeller, can I reuse the nut or do I have to change it to use the bolt? If so, what else will I need to order. I'm looking at the Motobins site and they have the kit and impeller and would like to make just one order. Thanks to all for the input on this site, I would never have attempted taking this bike apart without knowing this invaluable resource was here.

Just buy that kit from the 'Bins. It's complete.

Thanks TWB, done and ordered!

progress! I bought the absorber version 12 and 6 rivets
of course I will mount 12-rivets version

some photos of the restoration


the pump after disassembling:



renovated and cleaned "new" output shaft:







starter cleaning:



exhaust elements ready for polishing:



purchased items:



adhesives:



pump after renovation (cleaning, sandblasting, powder cating)







stainless screw plug:



clutch centering tool



differences between old and new timing chain
(new - bottom, old - top):


new - left, old - right:



bon appetit

Nice work, Lifeguard! It's good to see the photos of a job done thoroughly.

You are the MAN!,
Excellent work,
Regards,
K-BIKE

this is just the beginning

more pictures soon...

I start to make the engine at the weekend

Very well done LifeGuard,
first class pictures look forward to the next installment.

BIG D

Outstanding work so far Lifeguard. Keep it coming!

OG

another set of photos from weekend:

I started assemble a water pump
my inspiration:
http://hrsbstaff.ednet.ns.ca/bvogel/K100/oil_pump/oil-pump-seals-replacement.htm







cleaning the engine:






setting timing chain:







setting housing with sealant:

















replacement alternator carbon brush:













differences between old and new alternator clutch rubber:





I destroyed output shaft seal at the end of today work. I have to order new one... f#ck :/
$ 30 USD I'm in the back



enjoy photos, more soon

Just outstanding Lifeguard! Keep up the excellent work!!

OG

We love photos!

Brilliant LifeGuard!

next photos...

I made special tool for embedding sealer:








BMW has developed a new type of sealant, I hope that a more persistent.
It seems that these new sealers hurt less shafts, because they are delicate.







cluth mounting:







old contact spring:



new one:



pump:







polishing exhaust:





















enjoy photos, more soon

I look forward greatly to the next installment

fantastic work lifeguard ......im impressed !!!


how did you polish the exhaust up ? ive never done it before ....have seen the results ...but would love to find out how ...

cheers

charlie99 wrote:fantastic work lifeguard ......im impressed !!!


how did you polish the exhaust up ? ive never done it before ....have seen the results ...but would love to find out how ...

cheers

In the photo you can see the brown "abrasive wiper" this serves to remove major contaminants. Then I used sandpaper (400-600) dipped in oil. When I reached the clear matte metal the next step was polishing with paste. I used drill with felt tip...
Stainless steel polishes very nicely because it contains more than 13% chromium

lifeguard ...i had imagined something simillar ....working my way carefully to remove layers of "crud" to clean layers of metal.

i guess ill have to get some of that paste and a good felt pad for the drill .....thanks for replying ....

Great stuff lifeguard, brilliant work,

BIG D

How humbling...

I'm pretty chuffed if I change the spark plugs without cross threading them!

Excellent work LifeGuard!

I finaly made bike, there was a leak near the pump, I unscrewed and sealed better and screwed stronger.
There is no noise around clutch. mission acomplished

Photos in one place

Really great work LifeGuard! What did you paint your oil sump with if I may ask?
Thanks,

OG

This is powder coating. As the car alloy rims are painted. Paint is chemically resistant and durable

I had a feeling you were going to say powder. It looks fantastic! I've been trying to resist calling the shop here, but results like this make it hard to resist, lol!

OG

What great work you are doing, Lifegaurd. I hope my exhaust will shine like yours.
I also have a 1987 K100rs and I'm going to begin posting the whole experiance here for all of you see and comment on. I know there in much work to do but I think I've to the right place for this new project.
Ed