My K75S needs Valve Surgery

[Burnszilla]

My K75S was serviced at Ted Porter's Beemer Shop yesterday. New front tire, valve adjustment and throttle body sync. 117,000 miles on the odometer. Ted found a problem with my exhaust valves...

Valve specs: Intake: .006 - .008 Exhaust: .010 - .012
My K75S: Intake: .007, .007, .006 Exhaust:.005, .008, .014 (before adjustment)
Exhaust shims on #1 and #2 are thin at 2.2mm and 2.1mm.
The previous valve adjustment 15K miles ago, the exhaust valves were way out too.

Something was wrong, so he did a compression test.
#1: 70, #2: 110, #3: 125 ... not good
Also found an air leak on #2 throttle body.

Next week he's going to do a full leak down test to see where the problem lies.
His guess was that I needed a head job with the valves replaced.
Costing around $1100. Ouch.

A while ago I did something stupid. I rode for about 3 days with my high altitude loop switch on, until I noticed it was on. Arrgh! Could the engine running lean have caused all this damage?

After riding my 87 K75C I notice how much better the engine performance is on the C than on the S. The S has a lumpy idle and is not as peppy.

[jdiaz]

My bike also had a problem with the middle exhaust valve. I don't think its from using the altitude plug for a couple days.

I didn't think the rebuild would be that bad, until I got to item 3:

1) $11 apiece for new guides
2) $14 apiece for new lead-free seats
3) $109 each for exhaust valves!! (this part was $38 four years ago)
4) $44 for a new head gasket
5) $200-ish for a repair shop to R&R the parts in the head
6) 3-4 hours to R&R the head on the bike

That's about $400 in parts and $500 in labor right there. I'd start looking for a used head (or entire engine) instead. Spare motors are cheap, and doing the replacement is quite simple.

[Motorman]

Where is the high altitude switch at?? Never knew there was an operator manipulated switch for that.

[Burnszilla]

Where is the high altitude switch at?? Never knew there was an operator manipulated switch for that.
I took the wires from the loop and attached them to a switch I installed under the left fairing.

[Burnszilla]

That's about $400 in parts and $500 in labor right there. I'd start looking for a used head (or entire engine) instead. Spare motors are cheap, and doing the replacement is quite simple.

The labor to install a used engine would be more I was told. Also when you buy a used engine, you don't know what your getting. You could inherit the same problems. :dunno

[BubbaZanetti]

After riding my 87 K75C I notice how much better the engine performance is on the C than on the S. The S has a lumpy idle and is not as peppy.



so does this mean i get the peppy bike this weekend?? :clap


i'm currently facing a possible main rear seal leak and at the end of summer, if i don't stop buring oil, new valve guides and rings, don't ya just wish these things would run forever without breaking..............

[knary]

:cry

It might be easier if you were looking for a reason to rationalize a new(er) bike...

[Burnszilla]

:cry
It might be easier if you were looking for a reason to rationalize a new(er) bike...

Scott.. I tried.. "Hell hath no furry like my wife when she hears the letters GS."

djw just sent me a PM with an 87 engine in Long Beach, CA with 21,000 original miles on it for $500.. I think this is the way to go. Why replace the valves when you can do a whole heart transplant for the same or lower price.

[GSTom]

The labor to install a used engine would be more I was told. Also when you buy a used engine, you don't know what your getting. You could inherit the same problems. :dunno

A quick check of the IBMWR Marketplace found this ad:


1987 K75 S engine
K75S engine from wrecked bike with 21,000 orig. miles. No damage to engine, this whole thing has been sitting in my garage and needs a good home.
Price: $500 obo
Location: Lakewood CA.
Contact XXXXXXXXXXXXXXXXXX
Telephone XXXXXXXXXXXX
Posted Wednesday, April 12, 2006 at 23:10:17 (EDT)

[Burnszilla]

so does this mean i get the peppy bike this weekend?? :clap
I've been contemplating that same question.. I rode the C to work today.. The peppiness is really nice and it's way faster, but there's some kind of K75 class system affecting me. Once you ride an S it's hard to go down a level and ride the C. I don't feel as 'cool' on the C as I do on the S. :dunno Perhaps I have some issues.

[BubbaZanetti]

I've been contemplating that same question.. I rode the C to work today.. The peppiness is really nice and it's way faster, but there's some kind of K75 class system affecting me. Once you ride an S it's hard to go down a level and ride the C. I don't feel as 'cool' on the C as I do on the S. :dunno Perhaps I have some issues.



you don't have issues, i'd feel like a dork on an R11/1150R

[Burnszilla]

A quick check of the IBMWR Marketplace found this ad:
1987 K75 S engine
K75S engine from wrecked bike with 21,000 orig. miles. No damage to engine, this whole thing has been sitting in my garage and needs a good home.
Price: $500 obo
Location: Lakewood CA.
Contact XXXXXXXXXXXXXXXXXX
Telephone XXXXXXXXXXXX
Posted Wednesday, April 12, 2006 at 23:10:17 (EDT)
Thanks Tom.. the ball is rolling.

[jdiaz]

The labor to install a used engine would be more I was told.
Don't pay anyone else to install it! Its not that hard. One day, tops.

[Burnszilla]

Don't pay anyone else to install it! Its not that hard. One day, tops.
I could fly you from Chicago to San Jose for $350. :)

[jdiaz]

I could fly you from Chicago to San Jose for $350. :)
Sounds like fun. I'm in!

Let's do it at DarrylRi's house. I think he's got a bike lift. :laugh

[Burnszilla]

I still have to finalize with the seller, and pickup or ship..
Darryl's is a good idea.

I'll let you know of a good time later this month after I get the engine.

[kbasa]

:lurk

[Burnszilla]

Hey Kbasa... didn't something like this happen to your old K75??

[kbasa]

Hey Kbasa... didn't something like this happen to your old K75??

Yeah. It was Tina's, actually. It had a cracked valve in it. Dunno how that happened. She rode it like, well, a girl. :ha


I'm so gonna get my ass kicked for that.

[Burnszilla]

Good news. I got the engine in Lakewood for $400 and I have to pay for shipping. UPS quoted $76 for 100 lbs. to my door and ForwardAir quoted $82 from LAX to SFO.. SFO is 50 miles away.

So how much does this engine weigh so I can get a more accurate quote?

[SheRidesABeemer]

I've been contemplating that same question.. I rode the C to work today.. The peppiness is really nice and it's way faster, but there's some kind of K75 class system affecting me. Once you ride an S it's hard to go down a level and ride the C. I don't feel as 'cool' on the C as I do on the S. :dunno Perhaps I have some issues.

You may have other issues, :stick but there is nothing cool about the C. Get on enjoy the ride, try not to care what a dork you look like. It's good to have a cool bike as back up. (or the other way around) :brow

[kbasa]

You may have other issues, :stick but there is nothing cool about the C. Get on enjoy the ride, try not to care what a dork you look like. It's good to have a cool bike as back up. (or the other way around) :brow

Hey! I loved my C. :bluduh












:ha

[85K100LT]

jdiaz,

I live in Cave Creek AZ now but lived in Big Rock IL for 10 plus years - if you fly out make sure you have some time to "Test Ride" that engine swap!!!

What a great group we have Here!!

[jdiaz]

I live in Cave Creek AZ now but lived in Big Rock IL for 10 plus years - if you fly out make sure you have some time to "Test Ride" that engine swap!!!

I live two miles east of Kaneville, but have an Elburn address. The restaurant in BigRock is one of our favorites.

[wanderer]

:lurk :lurk I just love hangin' out around here. The people are .... well unlike any I meet anywhere else.

[deilenberger]

One suggestion - replace the intake mounts for the throttle-bodies with new ones - even if the "new" engine comes with the TB's.

These are 20 years old now - and they are likely the cause of your valve problems with your current engine (intake leaks = lean running, combined with the high-altitude switch = extra lean running, = burned exhaust valves.)

Cheapish and easy to do with the engine out, PITA with the engne in. Jon knows how to do it.. :-)

[Burnszilla]

One suggestion - replace the intake mounts for the throttle-bodies with new ones - even if the "new" engine comes with the TB's.

These are 20 years old now - and they are likely the cause of your valve problems with your current engine (intake leaks = lean running, combined with the high-altitude switch = extra lean running, = burned exhaust valves.)

Cheapish and easy to do with the engine out, PITA with the engne in. Jon knows how to do it.. :-)

Thanks Don.. I was going to do that.. I replaced the uppers last year, but should have also done the lowers also.
I have to put together a list of all the parts that i'm going to renew when swapping the engine and place an order.

[jdiaz]

This is an easy time to replace the following:

- Intake rubbers
- Coolant temp sensor
- Cooling system hoses
- O-rings on each fuel injector
- Fuel lines
- New o-ring for the clutch basket (maybe main seal too)
- New wave washers for the clutch assembly
- Starter rebuild kit ($5)
- New alternator rubbers

Do you have a pic of what the motor is coming with? That would help.

[SIBUD]

I took the wires from the loop and attached them to a switch I installed under the left fairing.

I love this place. Didn't even know about this and then looked it up in the book. My question is: Is the high altitude loop just a "jumper wire" or is there something else in the loop? Could one just make their own loop?

[breyfogle]

My question is: Is the high altitude loop just a "jumper wire" or is there something else in the loop? Could one just make their own loop?

It's just a true jumper to the computer. Open circuit for sea level, closed for high altitude.

[knary]

It's just a true jumper to the computer. Open circuit for sea level, closed for high altitude.

:nod

And if you ride in an area with mountains, it's much easier to use if you wire it to a switch as Burnszilla did. IIRC, it only compensates for around 4,000 feet of altitude. It helps, but if you're going over 9,000 ft passes, the bike will still feel anemic.

[SIBUD]

It's just a true jumper to the computer. Open circuit for sea level, closed for high altitude.

Thanks for the info. I hope to ride in CO and this will come in handy.

[jdiaz]

Thanks for the info. I hope to ride in CO and this will come in handy.
I don't think 1100s with Motronic need it. Your bike should have altitude compensation already on-board inside the EFI computer, not to mention an oxygen sensor.

[PHMarvin]

Jon's right. The altitude plug is only for the 2-valve K-bikes, both K75 and K100. The 4-valve bikes have altitude compensation in the computer.

[Motorman]

Can someone post a picture of the loop and or switch you rigged up? I'd sure appreciate it.

[Burnszilla]

Can someone post a picture of the loop and or switch you rigged up? I'd sure appreciate it.
Have you used up all your dash switches? If not, buy a bmw dash switch for $26 and use it.

[jdiaz]

Did the used motor show up yet? What's the plan?

[Burnszilla]

Jon,

I paypaled the the guy today. He's the guy who owns Angel City Cycle in LA, next door to the Parts Haus. Shipping it on Monday or Tuesday. I'll have it next week.

When does Darryl get back from Europe?

You probably want to come up for a weekend to do this?
What's your schedule like?

[Colt03]

When you guys do this engine swap we want plenty of Pics !

Thanks,

[jdiaz]

When you guys do this engine swap we want plenty of Pics !

Why don't you fly out and meet us? You need to get your butt ready for that 8-hour flight to Florence. :clap

[Burnszilla]

I am going to document the engine swap and post it here and on the IBMWR.

[bmwmick]

Jon,

I paypaled the the guy today. He's the guy who owns Angel City Cycle in LA, next door to the Parts Haus. Shipping it on Monday or Tuesday. I'll have it next week.

When does Darryl get back from Europe?

You probably want to come up for a weekend to do this?
What's your schedule like?

DAMN,
I'm tempted to ride over just to view this epic event first hand. :) I'm sure Darryl wouldn't mind a few uninvited house guests at his place in SC. :clap
I haven't seen Jon in YEARS.

:)

[jdiaz]

Plans are being made for the second weekend of June.....it would be great if you could come over Mick!

[bmwmick]

Hmmmmmm,
Planning on going to Boise for the RA in July, tagging along from there to Frisco, CO for the Valkeyrie rally........I guess a 2,500 mile round trip in June to get me in the mood would be good. :dance
I'll let you know if I can swing it.

[kbasa]

I might have to come down there to um, er, lend support. Yeah, that's it! Lend support! :ha

[Burnszilla]

Bring some beers. :D

[jdiaz]

I might have to come down there to um, er, lend support. Yeah, that's it! Lend support! :ha
And bring donuts from that bakery you like as well. :laugh

[Dick]

Second week in June? I may be gainfully unemployed by then but all my weekends in June are shot.

On a related topic - my K75s smokes on deceleration, maybe you could do my valve guides while you are in town. :laugh

[jdiaz]

One a related topic - my K75s smokes on deceleration, maybe you could do my valve guides while you are in town. :laugh
Smokes? Doesn't it only have 75K miles on it? Shoot, that's brand new still. :stick

[Dick]

Smokes? Doesn't it only have 75K miles on it? Shoot, that's brand new still. :stick

83,700 :fitz ooops I meant http://www.advrider.com/forums/images/smilies/fitz.gif

[Burnszilla]

It's here. I was working from home today. Opened the front door and there was coolant running down my driveway out of the plastic wrapped engine. I unwrapped it and oil spilled all over. So, I put some kitty litter on the spill.

Over all it looks about 21,000 miles old. Injectors included with the engine. There's still about 3 quarts of oil in the thing. Packaging could have been better.

http://static.flickr.com/46/148304715_4edc3bdbfb.jpg

http://static.flickr.com/50/148303703_6d1bc8f6ae.jpg

http://static.flickr.com/44/148302704_b1251cc538.jpg

[jdiaz]

Right on! That doesn't look bad at all. After a little degreasing it should look new.

Throwing in the water pump, injectors, and (most important) Hall sensor plate makes this a pretty darn good deal.

[Dick]

Right on! That doesn't look bad at all. After a little degreasing it should look new.

That's what Sue said about you and look what happened. :bolt

[kbasa]

So this is happening on the 10th/11th?

Is Darryl going to be home by then?

[Burnszilla]

This is happening on Friday June 9th and if we don't finish, Saturday June 10th too. Darryl gets back on May 24th and he approved the use of his garage.

[PHMarvin]

Hi, Steve,
Is this going to be a K-bike Tech Day? Can we watch/help/kibbitz/drink beer (not necessarily in that order)?

[Burnszilla]

Hi, Steve,
Is this going to be a K-bike Tech Day? Can we watch/help/kibbitz/drink beer (not necessarily in that order)?
I would wait until Darryl gets back and ask him.

[Burnszilla]

Jon Diaz (the Doctor) is on the plane right now, on his way here. The operation starts early Friday morning.

I completed the K75S' pre-op and stripped it down..
http://static.flickr.com/70/163283830_94b37dfa57.jpg

http://static.flickr.com/58/163283802_614422b006.jpg

The donor engine (heart) is ready for the transplant..
http://static.flickr.com/60/163283896_b45ab29acd.jpg


DarrylRi (the hospital administrator) looks like he has some other basket case operations in the line up. But it's going to take a while...
http://static.flickr.com/69/163283952_cb1e67fe34.jpg

Because he's too busy riding his new 1928 R52...
http://static.flickr.com/61/161337410_1d41d21737.jpg

[Colt03]

Make sure you take plenty of pictures.

It looks like the left hand frina-france is out of place. The Wally Walkershankel muffler bearings are toast, and the drive belt for the dual expanding rubber cams is dry rotted, other than that you guys are in good shape !

Best

[Dick]

Jon Diaz (the Doctor) is on the plane right now, on his way here. The operation starts early Friday morning.

I thought I felt a disturbance in the force - we will honk when we go by on 17 in a couple of hours. I will see if I can talk Kate into sending him a salute. :brow

Good luck with the transplant.

[Burnszilla]

Engine, tranny and driveline are in place. The rest of the bike has to go back together Saturday morning starting at 9am. Just got back from a wonderful dinner at Cafe Cruz with Ned & Sarah, Dave Brick, Conrad, Jon, and Darryl.

Let's hope the engine starts.

[kbasa]

Engine, tranny and driveline are in place. The rest of the bike has to go back together Saturday morning starting at 9am. Just got back from a wonderful dinner at Cafe Cruz with Ned & Sarah, Dave Brick, Conrad, Jon, and Darryl.

Let's hope the engine starts.

Arrrrrrrrgggghhhhh!

[Burnszilla]

Operation successful. The new engine started after 2 cranks. I will post photos tomorrow.

Only problem now is that my radiator is leaking along the seam on the right side. I took it apart and put RTV on the gasket and resealed it. We'll see if that fixes it.

It just never stops.

[username]

It just never stops.

of course, the other choice is to buy a new bike and then complain about how all the electronic doo-dads make it impossible to work on. :D

aren't there more photos?

[jdiaz]

of course, the other choice is to buy a new bike and then complain about how all the electronic doo-dads make it impossible to work on. :D

aren't there more photos?
There are WAY more photos. Be prepared for modem meltdown later. :p

[Burnszilla]

All I've got to say is thanks to DarrylRi and Jon Diaz for helping me replace
my engine. These guys are great! We had a lot of fun doing this job.

DarrylRi. Removing the old engine...
http://static.flickr.com/53/165929319_65cb1d71d9.jpg

Jon Diaz...
http://static.flickr.com/50/165929447_948d595a1f.jpg

Before Room Temperature Vulcanization-izing the oil pan...
http://static.flickr.com/51/165930018_dddff559e3.jpg

Crank case cover gasket installation..
http://static.flickr.com/55/165929936_0c2fe27b73.jpg

http://static.flickr.com/54/165929905_3af03c8225.jpg

Jon getting high off of all the carb cleaner fumes...
http://static.flickr.com/71/165930200_183affbcfa.jpg

New engine in place..
http://static.flickr.com/69/165930317_bd5884fa81.jpg

Day 2..
It started up after 2 cranks.
http://static.flickr.com/55/165930454_226189164c.jpg

All the Photos Here (http://www.flickr.com/photos/burnszilla/sets/72157594160034205/)

[knary]

Jon's belly kinda looks like a K75 tank in profile... :hug

[BubbaZanetti]

nice work man!

[jdiaz]

I had a lot of fun flying out for this. Burnszilla definitely knows his way around his motorcycle (I was mostly shop decoration, as you can see from the pics) and dealt with all the the parts we broke/stripped with a smile. :D

And thanks to Darryl for the hospitality and the Flinstones-style rib feed on Saturday!

[Warthog]

It's just a true jumper to the computer. Open circuit for sea level, closed for high altitude.

God, I love this place ....it's better than the Discovery Channel.

I live in Colo Springs (approx 6500' above sea level) and did not know that.

Assume that the 91 K100 could be modified as well?

[PHMarvin]

Hi, Don,
The 2-valve bikes (K75 and K100/8valve) can use the high altitude plug. The 4-valve bikes (Motronic engine management system) do NOT use the high altitude plug. I believe a '91 K100LT still has the 2-valve engine so, yes, at your altitude you should have the plug. If you don't, your dealer will be happy to sell you one. They aren't too expensive. The last one I bought was under $10, but that was almost 3 years ago. Your wiring harness has a cap on the connection. Your local dealer should be familiar with these and can show you where the plug is installed in the wiring harness.
Ride Safe,