The ultimate caferacer EP2 - POWERBRICK BMW K1100RS - Clutch, gearbox & throttle bodies

Welcome back to our second episode of our BMW K1100 RS Cafe Racer build. We're building this bike for the Bike Shed Show in London, where we display our best builds every year. Today we will install the clutch, the gearbox, parts of the intake system and parts of the ignition system. So let's get to work. Before we can start with the clutch, let's collect all the parts that we need. Clutch housing with fresh washer. The wire ring. The spring plate. The pressure plate. The housing cover. A brand new friction plate. All the mounting hardware. And grease. The friction plate and all the mounting hardware are brand new. You don't want to reuse the old hardware because it's been torqued, the bolts lose structural integrity and they may not be able to hold up anymore. So you want to replace all of this. All these new parts come from Kparts Holland. He has everything that you need to rebuild your bike. So if you're looking to replace your clutch, head over to the website of Kparts Holland and get yourself all the new parts that you need. The first thing that we want to do before installing the clutch housing is apply a very light coat of grease to the inside inner surface of this little bushing. We use a little Q-tip because it gets around the places that we need. Then we take the clutch housing and the thrust washer and we install the washer onto the clutch housing and install the clutch housing into the engine. Next up is the o-ring. The thrust ring. And then a new clutch nut. We then need a special tool to fix the clutch housing into place while tightening the center nut. Which is going to be positioned like this. So we need to rotate the clutch housing so the bolt locations line up and we can fix it. The clutch nut is mounted in two steps. First we torque it to 140 Nm just to seat the o-ring and afterwards we completely loosen it and then we tighten it to 100 Nm. Then we remove the bolt. We then install the wiring. And before we can install the spring disc we need to apply a light coat to the outer edge and to the waste parts. Now it's time to assemble the actual clutch. So the clutch housing consists of three parts. We have the pressure plate, we have the clutch cover and we have the clutch housing that's already in the engine. Each of these parts has a certain marking. Straight from the factory. So this is the first marking. And here we have the second marking. What you want to do is you want to position each of these markings 120 degrees from each other. Because this way the clutch is perfectly balanced and you won't run into any issues. We start with the clutch cover upside down and with the factory marking towards us. We then take the friction plate, twist it so this part faces down and then we put it on. We then grease these planks lightly. And then position it face down. The next thing that we want to grease is these pins to prevent corrosion. Just a very light bit of grease. And then it's time to assemble the pressure plate. Make sure to do it evenly. We then position the spring plates. And we install a special tool that we embellish the center of the friction plate. And this is our clutch assembly that goes into the engine. Before we can install the clutch we need to locate the paint mark and the paint mark on the housing. Position those 120 degrees from each other. The center tool can be removed. And it's time for the gearbox. The gearbox has been fully overhauled with new seals and new bearings by Gabart Holland. They have a full kit for the entire gearbox on their website. So if you're looking to do a gearbox restore check them out. We're planning to do a video on the internals of the gearbox soon. But first let's install it on the bike. Before we can install the gearbox we need to apply a very light coat of grease. To these plates that go into the friction plate. And then it's ready to go onto the bike. Now that the ignition is on it's time to do the intakes. These throttle bodies were restored by Didstang in Arizona. He always does our throttle bodies. He's simply the best at what he does. He also restores throttle bodies for other people. So if you're looking for a throttle body restore hit him up. His Instagram handle is Didstang. You probably know him if you're into K-bikes. So we're going to assemble the throttle bodies. Mount them onto the engine. And get the top of the engine pretty much finished up. Now that the bottom side is done it's time for the air intakes. We developed our own kit to run open pot filters. They're directly mounted onto the throttle bodies. And they also hold the air sensor. So I'm going to show you how we install those. We've collaborated with DNA to create the filters that are best for this engine. We're not going to mount the filters yet because they're very fragile. We don't want these to damage by the time that the bike is done. So these go back in the box for now. Thank you for watching another episode of our build. If you want to follow along make sure to subscribe. We're going to showcase this build in two weeks at the Bike Shed Show in London. All the custom parts that we use in these builds are available on our website. We also mention all the suppliers that we use to do these builds. So see you next episode. Thanks for watching.