How to butcher a 1993 K1100RS

Discussion in 'Road Warriors' started by Shoganai, Nov 24, 2013.

  1. johnwoodsrides

    johnwoodsrides Been here awhile

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    And most of the factory folks couldn't put a whole bike back together, they assemble one or two parts at their station. Sure, they rotate stations, but I doubt they could do a bike start to finish. A buddy of mine works on the floor at HD, even the torque settings are pre-programmed into the computer for the part he installs. He has only 90 seconds to install his part, get it torqued and pick up the next part for the bike that is coming. Doesn't take any mechanical knowledge, at least at HD, not sure how they do it at BMW or Honda or.......
    #61
  2. Shoganai

    Shoganai Let's do some livin'

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    The first is the Official BMW tools.
    The second where I found them WAY Cheaper


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    Stahlwille 1501+1511
    For contact size of 1.5mm. Bushing size 2.9mm inside, 3.3mm outside. $73.55
    http://www.toolsource.com/15011511-kabelex-ejectiontool-p-104402.html

    Stahlwille 1504+1514
    For contact size 2.5mm, Bushing size 4.0mm inside, 4.4mm outside. $84.31


    Stahlwille 1502+1512
    For contact size 3.5mm, Bushing size 4.4mm inside, 5.0mm outside. $79.99

    ************************************************************

    contact size of 1.5mm.
    http://www.mytoolsforyou.com/automotive-tools/JSP-95929-07.html
    Sale Price: $11.19

    contact size 2.5mm,
    http://www.mytoolsforyou.com/automotive-tools/JSP-95929-06.html
    Sale Price: $11.19

    contact size 3.5mm,
    http://www.mytoolsforyou.com/automotive-tools/JSP-95929-02.html
    Sale Price: $8.39

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    #62
  3. AntonLargiader

    AntonLargiader Long timer

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    I have the BMW 61 1 132 tool; 4mm ID.
    #63
  4. Shoganai

    Shoganai Let's do some livin'

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    Thanks Anton. :D
    #64
  5. Waco

    Waco Renegade Sickle Hound

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    I've talked to assembly guys at one of the Cat plants. "Is there a procedure for free-wheeling the final drives in case the engine is down?" Silence.
    #65
  6. Shoganai

    Shoganai Let's do some livin'

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    Today I finally get the wiring harness board put together and hung.

    This is the original 1993 fuel injection harness. I found a couple of holes and a cluster of cut wires.

    I don't have a clue what those cut wires went to, but I'm sure I can find out. Clearly the bike run fine without them because these were not cut by me and I've had it since 1999.

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    #66
  7. Shoganai

    Shoganai Let's do some livin'

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    The following posts represent the deconstruction of the fuel injection wiring harness.

    Some of the pics will have notes. All of the pics are intended to help me remember of what it looked like. After I make this post I'll take it off the board and set it aside for now. I'll leave all the zip ties holding the wires together to keep each cluster together for now.

    Then I'll start on the main harness.

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    I did this to avoid cutting any wires while removing the covering.

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    Steve reminding me I cut this off while trying to scavenge parts for another project. I still have to connector.

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    #67
  8. Shoganai

    Shoganai Let's do some livin'

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    .

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    As far as I can tell, the joining of the green/white wires and the yellow/brown wires must have been done this way due to assemble needs, not function needs.

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    I have a couple of observations.

    One: If stupid is as stupid dose then I'm fairly stupid.

    Two: Anything that hurts that bad should look worse.

    Three: 18 year old electrical tape feels like baby snot mixed with contact cement.

    Four: #11 Exacto blades rammed under thumb nails when Stupid forgot about not cutting towards one's self SUX!

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    #68
  9. doc4216

    doc4216 Chronic High Fiver

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    Note-bloody hand needs repaired!
    #69
  10. Shoganai

    Shoganai Let's do some livin'

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    <iframe width="420" height="315" src="//www.youtube.com/embed/zKhEw7nD9C4" frameborder="0" allowfullscreen></iframe>


    #70
  11. doc4216

    doc4216 Chronic High Fiver

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    Totally made my day!!! lol, "just a flesh wound" :wink:
    #71
  12. Shoganai

    Shoganai Let's do some livin'

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    Main wiring harness mounted on the board. Due to the large number of connections, I'm going to identify and tag each one before
    cutting it open.

    At least it can't hurt, might help and looks good on paper.


    I keep thinking this is one of those times where you might hear, "Hold my beer and watch this".
    #72
  13. Bonsai Elephant

    Bonsai Elephant Banned

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    Impressive stuff Shogs, but a quick question, as someone else who has never done this I could only approach this by building the new loom over the existing loom, I figured that was the object of it.

    Photos, notes, tags, none of that would help, and memory sure as hell wouldn't!

    Is there any particular reason why you didn't choose to do that?
    #73
  14. Shoganai

    Shoganai Let's do some livin'

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    When I'm ready to build the new ones that's what I'll be doing. Right now all I'm doing is inspecting and dissecting. I'm learning how it's put together by taking it apart. Today all I did was learn to read schematics, compared Clymer to original German versions, translate stuff to English and print large format schematics and label them.
    #74
  15. Shoganai

    Shoganai Let's do some livin'

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    Posting on phone difficult.
    Only gonna put up a couple of pictures.

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    #75
  16. Bonsai Elephant

    Bonsai Elephant Banned

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    Ah, okay. That makes sense.

    I misunderstood from your post.
    #76
  17. knybanjo

    knybanjo kinda slow

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    Looks like the dissection of an alien monster to me! :patch

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    Great work Shogs! :thumb
    #77
  18. damurph

    damurph Cold Adventurer

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    As a K-Bike owner and an electrical illiterate I want to thank you for taking the time to pic and post this. :clap
    I recognize a lot but know so little.
    #78