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Old 12-04-2013, 05:27 AM   #16
Shoganai OP
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Location: Out riding with joy and breaking bikes
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I know I set HM VII (May 2014) as the dead line but Steve and I talked about the reality and the depth of this project last night.

If I only had $200 a month, that's only $2400.
The truth of the matter it will cost several thousand dollars.
Steve estimates $6000

Let me break it out as far as I understand this process.
(just off the top of my head)

1. Powder coat frame - Cobalt blue

2. Powder coat all of the following black.
Final Drive
Drive shaft housing
Intermediate housing
Exhaust protection plate
Exhaust bracket left
Both foot peg brackets (black with cobalt blue raised areas)
Transmission housing
shift lever
Triple clamp
fork tubes
handle bar (minus where the controls attach)
Clutch and brake handles
rear brake lever
brake caliper housings
"H" bracket
Rims with cobalt blue pin stripe
Center and side stands
alternator housing cover

Satin Black Velvet Ceramic coated exhaust headers

ChromeX bright polished aluminum ceramic coating exhaust can

Black Gloss Ceramic coating the following
Engine block
Oil sump
Oil pan cover
Timing chain cover
Crack case cover
Cylinder head cover with cobalt blue stripe


Assess every nut, bolt, washer and screw for stainless steel replacement

New wiring harness (I'll make this from scratch)

Rebuild the water/oil pump

Rebuild the top end

Rings and assess cam tolerances

Create functional crash/drop bars for front fairing

Create functional crash/drop bar for panniers

Replace panniers with NEW ones

Repaint the entire bike (color yet to be chosen)




Keep in mind to paint power train (front to rear) they will have to opened and gutted so there'll be a mess of one time use things that'll need to be bought.


Anton said he would help me with the deep engine work.
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Old 12-04-2013, 04:27 PM   #17
AntonLargiader
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There are different blacks. For instance, I use what PCS calls 'frame black' for most stuff. It's a satin; I think it's 80% but they can tell you for sure. I have also used their gloss black which is 100%. Each has its place; don't assume you want all of it to be the same black; it might not give enough variation.

Unless you want to radically change the functionality of the wiring, I can't see any advantage to building your own harness.

As for the tools, remember you already bought the transmission seal installers. It doesn't make sense to buy the BMW tools that I have for just one use.
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Old 12-04-2013, 04:52 PM   #18
Shoganai OP
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Thanks Anton. I agree with you on using slightly different blacks on those parts.
How to break it up will be a little challenging.
Any POV's about that, I'm always listening.

The wiring harness rebuild is for personal growth and the upside will be new wires VS 18 year old wires.
Heat and time degrade wire.

I just need a good pin remover tool.
I'm going to get this one.

NAPA, Advance Auto Parts, Auto Zone and Morton's BMW were no help even with me bringing in a connector.

http://www.toolking.com/eclipse-ce-0...FUgS7AodAQwAPw

One more thing, I've learned that ceramic coating the engine block would not be advised so I'm going with either powder coating or paint.


Quote:
Originally Posted by AntonLargiader View Post
There are different blacks. For instance, I use what PCS calls 'frame black' for most stuff. It's a satin; I think it's 80% but they can tell you for sure. I have also used their gloss black which is 100%. Each has its place; don't assume you want all of it to be the same black; it might not give enough variation.

Unless you want to radically change the functionality of the wiring, I can't see any advantage to building your own harness.

As for the tools, remember you already bought the transmission seal installers. It doesn't make sense to buy the BMW tools that I have for just one use.
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Old 12-05-2013, 09:32 AM   #19
Shoganai OP
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Making one from scratch would be madness.
I'll making something like this, but not as fancy.





I like this guys pegboard idea a LOT!

http://www.motoiq.com/MagazineArticl...From-Heck.aspx


All I'll be doing is making a mirror image of the busted one I have minus messed up parts.

.
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Shoganai screwed with this post 12-05-2013 at 02:11 PM
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Old 12-05-2013, 01:38 PM   #20
AntonLargiader
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Don't buy that pin remover kit yet. There's a lot of K11 stuff that it won't work on.
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Old 12-05-2013, 02:09 PM   #21
Shoganai OP
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Thanks.
I'll hold off on it.

Quote:
Originally Posted by AntonLargiader View Post
Don't buy that pin remover kit yet. There's a lot of K11 stuff that it won't work on.
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Old 12-06-2013, 02:03 AM   #22
MikeJansen
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Love the peg-board!

I am going to be redoing my harness on my bike at some point but am thinking of picking up a second one to base the work off so I can keep my bike on the road while I work.

In the past I have generally used a dental pick set as my pin remover tools. For the round ones in Molex type connectors I have a pair of Snap-On ones like these:
http://store.snapon.com/Terminal-Too...l-P651269.aspx

At work I have something like this:
http://store.snapon.com/Soft-Grip-Te...--P643130.aspx

Hope those help, and loving the progress so far and the plans!
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Old 12-06-2013, 06:22 AM   #23
A. T. T-W
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I just stripped the old self-amalgamating tape off:



Checked and cleaned the exposed wires:



Then grouped the bundles to suit the layout:



Then rebound it with new amalgamating tape:



As the ABS has been removed from the K1100, rather than chop off bits of the loom, I've just bound all the ABS related stuff into a dummy branch.
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Old 12-06-2013, 02:54 PM   #24
Shoganai OP
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Thank you for that post A.T. T-W.
Very helpful.


Anton, thoughts on this?

http://www.toolsource.com/piece-term...-p-137775.html


.
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Old 12-07-2013, 05:04 AM   #25
celticus
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Have you tried Eastern Beaver as a source for electrical connections?
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Old 12-07-2013, 05:29 AM   #26
kraven
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I had to do something similar to the board layout when I rebuilt my K100's injection harness after it burned.

iirc, I went through the paper catalogs at NAPA and OReilly to find the weathertight connectors I needed because no one really wanted to take the time. Which is fine. It saved me two more trips for wrong parts.

I found a lot of the early K bike parts cross over as automotive parts used on the 3 series or 5 series cars. Connectors were sometimes the same.
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Old 12-07-2013, 08:36 AM   #27
DRGNHTR
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Thumb Looks like a labor of love

Thee sources might be handy:

http://www.delcity.net/

http://www.bmotorsports.com/shop/index.php/cPath/109
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Old 12-08-2013, 12:11 AM   #28
Shoganai OP
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.

Thank you for the links and suggestions.
Since my last post, and taking into consideration what Anton said, Ive done some research.



These are the exact tools I need.
The prices are STUPID insane!


88 88 6 611 131
Stahlwille 1501+1511 Kabelex Round Pin Release Tool, Small. Pin release tool for round receptacles with locking tongue and contact size of 1.5mm. Bushing size 2.9mm inside, 3.3mm outside. This tool has an ingenious feature to protect the tip. A sliding cover is built into the handle. Also used on BMW, Mercedes, Fiat, Opel and VW-Audi. (Note: the factory tool can be marked number 610 301). Special Order
$73.55


88 88 6 611 132
New Number: 83 30 0 495 385
Stahlwille 1504+1514 Kabelex Round Pin Release Tool - Medium. For contact size 2.5mm, Bushing size 4.0mm inside, 4.4mm outside.With sliding cover. Special Order $84.31


88 88 6 611 133
New Number: 83 30 0 492 708
Stahlwille 1502+1512 Kabelex Round Pin Release Tool - Large. For contact size 3.5mm, Bushing size 4.4mm inside, 5.0mm outside. With sliding cover. Special Order
$79.99



http://www.sparks-shop.lv/v3/index.p...emid=7&lang=en


1501+1511 = $45.28
1504+1514 = $51.79
1502+1512 = $49.90


And I found some discussions about this.

http://www.bimmerfest.com/forums/showthread.php?t=48358

http://www.unofficialbmw.com/all/ele...wire_size.html

http://www.unofficialbmw.com/all/ele...tact_pins.html

Im currently working back to back 13 hour night shifts and when Im off again Ill read those threads for the details and look more closely at the links offered.


.
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Old 12-08-2013, 01:32 AM   #29
Shoganai OP
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This is a VERY cool site!

http://cablesandconnectors.com/260001.HTM
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Old 12-08-2013, 08:35 AM   #30
RaY YreKa
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All the very very best with this Shogs

Ray

(formerly ray_rev)
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