Rebuilding KE100: General Advice

foxkejp · 10-14-2009

New problems:

1. Front brake cable has the metal cable stuck to the outer. Can't seem to loosen it, and the drums on the KE require that the actual cable be seperated from the outer covering to work properly. How to fix or where to buy a new one?
2. Question: will the brake light work without a battery?
3. Where to buy a master link clip for the chain?

All other problems have been (for the moment at least) solved.

Thanks for your help.

Lat 57 · 1 Day Ago

1-- no running without battery wont effect engine, in the generator there are coils that generate electrical power,three of them usually,one powers the engine,one runs the headlight,and the other charges the battery which in turn powers indicaters tail light and instruments.
4---Hard to select neutral can be ridged clutch basket, warped plates,heavy gear oil or incorrect clutch cable/arm adjustment.
5-- use light motorcycle gear oil,bought from a bike shop,ask them.
8--- If your asking the above questions ,don't take the casings apart,without a bit of assistance from an experienced mechanic.
just picked a few of your questions, don't mean to be patronising or disrespectfull , just want to save you some grief
Lee

foxkejp · 1 Day Ago

^ No problem, thanks for the help. The electrical info was particularly useful.

Some of my problems have been fixed and I'll update the thread accordingly.

Someone had used 25W oil in the gearbox, which made it ridiculously hard to shift, flush it with 5W and it works beautifully now.

And I eventually fixed the crankcase screws out with an impact driver- just needed to clean a part (oil pump) that the previous owner said had been "clogged" with dirt.

New problems now, listed in the (updated) first post. Thanks again though.

Lat 57 · 11 Hours Ago

Glad to be of help,hope you have discarded the crap screws holding your cases and replaced with m6 cap screws ( stainless preferably )
Lee

Lat 57 · 4 Hours Ago

Thought you might like to see my daughters 1981 Ke 125,not unlike your 100
it was imported to Scotland from Germany,hence no rust, they don't salt the roads in Germany unlike here.
cheers
Lee

10-14-2009	#1 (permalink)
foxkejp Newbie Join Date: Oct 2009 Location: TX, US Posts: 2	Rebuilding KE100: General Advice New problems: 1. Front brake cable has the metal cable stuck to the outer. Can't seem to loosen it, and the drums on the KE require that the actual cable be seperated from the outer covering to work properly. How to fix or where to buy a new one? 2. Question: will the brake light work without a battery? 3. Where to buy a master link clip for the chain? All other problems have been (for the moment at least) solved. Thanks for your help. Last edited by foxkejp : 1 Day Ago at 05:10 PM.

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1 Day Ago	#2 (permalink)
Lat 57 Newbie Join Date: Nov 2009 Location: North East Scotland Posts: 8	1-- no running without battery wont effect engine, in the generator there are coils that generate electrical power,three of them usually,one powers the engine,one runs the headlight,and the other charges the battery which in turn powers indicaters tail light and instruments. 4---Hard to select neutral can be ridged clutch basket, warped plates,heavy gear oil or incorrect clutch cable/arm adjustment. 5-- use light motorcycle gear oil,bought from a bike shop,ask them. 8--- If your asking the above questions ,don't take the casings apart,without a bit of assistance from an experienced mechanic. just picked a few of your questions, don't mean to be patronising or disrespectfull , just want to save you some grief Lee

1 Day Ago	#3 (permalink)
foxkejp Newbie Join Date: Oct 2009 Location: TX, US Posts: 2	^ No problem, thanks for the help. The electrical info was particularly useful. Some of my problems have been fixed and I'll update the thread accordingly. Someone had used 25W oil in the gearbox, which made it ridiculously hard to shift, flush it with 5W and it works beautifully now. And I eventually fixed the crankcase screws out with an impact driver- just needed to clean a part (oil pump) that the previous owner said had been "clogged" with dirt. New problems now, listed in the (updated) first post. Thanks again though.

11 Hours Ago	#4 (permalink)
Lat 57 Newbie Join Date: Nov 2009 Location: North East Scotland Posts: 8	Glad to be of help,hope you have discarded the crap screws holding your cases and replaced with m6 cap screws ( stainless preferably ) Lee

4 Hours Ago	#5 (permalink)
Lat 57 Newbie Join Date: Nov 2009 Location: North East Scotland Posts: 8	Thought you might like to see my daughters 1981 Ke 125,not unlike your 100 it was imported to Scotland from Germany,hence no rust, they don't salt the roads in Germany unlike here. cheers Lee

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