Down the rabbit hole: K100/EML Repairs

Discussion in 'Hacks' started by DirtyDR, Oct 30, 2016.

  1. DirtyDR

    DirtyDR Dana

    Joined:
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    3,257
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    I got the transmission sorted out but I did not have any gasket goop and I ran out of time so I will have to seal it up when I get back to Hotchkiss this coming weekend. I went to test fit the grub screw and the threads were all mangled in the housing so I had to pull the shifter out and run a tap through the offending orifice. Had to pull all of this apart to get part number 88 out so I could run a tap through the threads so part number 84, grub screw, would screw back in. Ample red Loctite and we should be good for another 150,000 miles.

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    #41
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  2. ridenfly

    ridenfly Been here awhile

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    Jul 11, 2006
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    SW CO
    Think what that thread repair would cost if paying shop time rates. You are making? money hand over fist.
    Go buy yourself a beer.
    #42
  3. DirtyDR

    DirtyDR Dana

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    :hmmmmmYea, saving money, that's the ticket.
    #43
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  4. bmwhacker

    bmwhacker Still on 3 wheels

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    MONTANA NATIVE from NATIVE MONTANA

    Paul and I crossed paths many times over the past 20 odd years. Always had a great time visiting with him. He will be missed by many.

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    #44
  5. DirtyDR

    DirtyDR Dana

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    Just wanted to check in and let anyone who cares know that I am still alive and kicking and I really am making progress on putting this thing back together. I got the K1200 GT water/oil pump in. New Monkey Nuts and rear main seal taken care of. Full new clutch kit from Bob's BMW installed, check. Repaired transmission bolted up and ready to go. Should have the subframe welded and ready to go when I head to Hotchkiss next week so I may start getting the rear end together. Newer final drive and driveshaft with the good splines all ready to go.

    I still need to figure out how I am going to plumb in the auxiliary fuel tank under the tub but I have a pretty good idea.
    #45
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  6. DRONE

    DRONE Dog Chauffeur

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    Good to hear from you, Dana. It's been a while. :thumb
    #46
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  7. cycleman2

    cycleman2 Long timer

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    Alberta, Canada
    Following along. We are all on the downward side of winter, so it won't be long before we can get back out to riding.
    #47
  8. High Octane

    High Octane Long timer

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    Glad to hear you are alive and kicking, we all care

    I used a small auto fuel pump as a transfer pump. I usually pull over, open the tank cap and pump fuel into the bike tank thru a bulkhead fitting I put into the bike tank. I can also pump as I drive but it takes longer because it doesn’t vent too well.
    #48
  9. DirtyDR

    DirtyDR Dana

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    Avon, Hotchkiss Colorado
    Aux Tank.png

    I plan on using an auxiliary pump and teeing in to the return fuel line. Question though, is a check valve between the aux pump and the return line all I need or is another check valve between the pressure regulator and the tee necessary?
    #49
  10. DirtyDR

    DirtyDR Dana

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    I was working on it last weekend and cleaned up the swing arm to put it back on and decided to check the bearings. Waiting on new bearings now before I can get the swing arm attached.

    Everything I touch seems to need something replaced before I can put it back together, this better be worth it.
    #50
  11. High Octane

    High Octane Long timer

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    Same here! But I do enjoy the process.
    Better to do it now than have to take it all apart again later.
    #51
  12. davebig

    davebig Another Angry Hun !

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    Bobmws would know, but I would bet you'd need to have engine off to pump fuel to main tank.
    #52
  13. DirtyDR

    DirtyDR Dana

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    Yep, that was the plan. The problem is I think I calculated that the aux tank carries 2 more gallons of fuel than the Main.

    As long as the aux tank was low pressure I do not see why you could not refuel on the fly, though that would require a check valve to isolate back feeding the return line. I think.

    I was also thinking of getting a self regulating pump like new things that do not use return lines and just run the engine off of the aux tank. That would require teeing in to the main line downstream of the regulator and putting a check valve between the Tee and the regulator. That would also require a check valve upstream of the tee between the tee and the aux tank. Come in handy if the main pump decided to die on me also.

    I suppose I could just drill a hole in the tank and insert a bulkhead fitting, then I would not need any check valves and I could refuel any damn time I pleased.

    I think my head is starting to hurt. How did EML do it I wonder?
    #53
  14. norton(kel)

    norton(kel) vintage

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    CO.
    Take 2 aspirin & a nap Dana!
    #54
  15. DirtyDR

    DirtyDR Dana

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    #55
  16. davebig

    davebig Another Angry Hun !

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    Big Blue had a 6 gal aux tank under the sidecar they ran the k1200 off that and ran a large 1.25 line from the main that to the aux and one filled the main and it gravity fed the aux tank.But you had to fill it slowly or it would airlock and all little down the road 3-4 gallons from the top would run into the lower...
    Since you can fill the lower tank from outside the main go ahead. You where a machinist mate you can figure out venting !
    #56
  17. We're Here

    We're Here Been here awhile

    Joined:
    Feb 12, 2007
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    The Ruko rig fills from the main tank that gravity fills the sidecar tank. Vents through the main tank vent.
    Underway an auxiliary fuel pump runs continuously filling the main tank.
    There is a low level switch on the sidecar tank that turns off the auxiliary pump when empty.
    Yes, it took me awhile to figure it out, along with the fuel filters that are part of the system.
    #57
  18. High Octane

    High Octane Long timer

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    That’s all to complicated for me. I just put a bulkhead fitting in the main tank and an electric fuel pump between the two. I pump fuel from the 10 gallon sidecar tank into the main tank when the maini gets low. It’s kinda like having your own c130 tanker flying right beside you.
    I run the pump off an ignition switched circuit. So noone can turn my fuel pump one when the bike is switched off. I also use a light beside the toggle switch so I have a visual reminder when the pump is on. I have a manual ball valve between the main tank and the aux fuel pump to prevent back flow when the pump is off. Likely overkill because the fuel pump is supposed to have its own check valve. I also have a ball valve right under the aux tank so I can shut off the aux tank to change the fuel filter. It’s really pretty simple but does require actively engagement by the operator.
    #58
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  19. Bobmws

    Bobmws Curmudgeon At Large

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    Same trailer, different park, FL
    My system on the K12 was a gravity feed throug a bulkhead fitting in the tank, only a 3 gallon cell so fuelling on the fly was no problem. A friend who rode to Hyder with me had a K12GT and used a 5 gallon cell plumbed into the return line with a pump. Had no problem fueling on the fly but had to watch the volume. If it fills the main tank it will blow out the overflow!
    Dana, the higher pressure of your auxillary pump will just flow into the main tank following the path of least resistance, not back through the fuel rail, no additional check valve needed. In theory your aux pump would keep the fuel from back feeding into the aux tank, but a check valve is good insurance.
    Back when I was researching my system, there were a few on the LDR list who had actually made a gravity feed into the return line work, but I don't recall the details!
    FWIW I used the metal CPC quick disconnects with the integral check valve on both ends of the feed line. Carry a length of hose with the male fitting allows you to easily drain the tank or refuel some else.
    #59
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  20. CCjon

    CCjon Gypsy Rider

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    Apr 29, 2007
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    895
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    Totally agree with Bob's comments, also immediately after the quick disconnect at the aux tank, add a transparent inline fuel filter. I could see debris accumulating in the filter during a trip thru Canada last summer. Was easy enough to disconnect, knock and blow the junk out of the filter, reinstall and ride.

    On a different rig, when trying to transfer fuel via pump on 90 degree days, the small pump could not overcome the pressure build up inside the main tank. Had to pop open the man tank cover so fuel would flow. Just watch the fuel gauge so as not to overfill.
    #60
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