Topic: K8 Highway Racer - Finished

[seanbarney41]

subscribed, I got a set of Marzochi's that need rebuilding also...kinda pissed that the fellow who sold 'em to me told me that rebuild kits were generally available from vintage Ducati sites.

[JoeCooley]

subscribed, I got a set of Marzochi's that need rebuilding also...kinda pissed that the fellow who sold 'em to me told me that rebuild kits were generally available from vintage Ducati sites.

Here's the link to the seller. Message him, he may have kits still. I paid $100 each. https://m.ebay.com/seller?sid=marzocchimark&nav=ORDER_DETAILS

[JoeCooley]

My shock rebuild parts came in today. So I've been busy with that today. Everything's been cleaned, blasted, and primed. A couple coats of paint and I should be able to throw these Marzocchis back together. I have to remember to take pics as I go. I'll attach a couple for now.

[JoeCooley]

Ok so one shock done one to go!

Here's a couple pics! The disassembled pic has the parts laid in the proper order of assembly. It looks complicated, but these shocks are really pretty simple. Refer to the manual on the site I posted earlier in this thread. I'm using 10wt fork oil in mine but the internet claims you can go as high as 30wt depending on your dampening needs.

The paint turned out pretty good for rattle can. Hopefully my stickers will arrive soon from Europe.

[seanbarney41]

Those look great on your bike!...hope they perform as good

[JoeCooley]

Those look great on your bike!...hope they perform as good

Thanks Sean. It took a while, but they are both finally rebuilt. Well, this was more of a restoration. Haha.

Let me know if you have any questions when you go to rebuild yours.

[RAFster122s]

How do you determine the weight of shock oil you need? A thicker weight is going to be slower to work its way through the shock and result in firmer ride.  I understand you want it to be compliant and maintain contact as well as not giving you a firm ride transferring those bumps into your body but absorbing those.  A motocross or adventure bike would use a very low weight shock oil.

David

[JoeCooley]

For me it will be trial and error. According to my (limited) internet researce on these shocks, ~5wt was used from factory. Most guys complain about them being too soft and switch to 10wt. 10wt also happens to be the same oil I run in my triumph's forks. I need to reseal one of those again. So it made sense to buy a quart of it to use on both bikes.

There isn't much literature on these old Marzocchis and the factory manual is quite vague. In theory, the better designed dampers will require thinner oil than an old shock from the stone age...

[JoeCooley]

Well my stickers came in from France. The shocks look much nicer now. Finally finished with that part of the build.

[JoeCooley]

Tarozzi rear-sets DONE! The brake side was a pita! 😲
If this doesn't work out I'm just going to get a cable setup.

Next up: Clutch replacement and modification as per Mr. Hondaman.

Happy Year everyone!
-Joe

[seanbarney41]

you got that set up really weird...does it work good?  Here is mine, works good...
DSCN0944 by Sean Barney, on Flickr

[JoeCooley]

you got that set up really weird...does it work good?  Here is mine, works good...
DSCN0944 by Sean Barney, on Flickr

Yes it works well. It took a lot of trial and error to make it all fit and work correctly. I have a K8 so the bolt on kits don't work. Also, I can't  go above like you did because the rod will hit the swing-arm nut. Luckily Cognito Moto sells brackets and other bits to make it happen. I may shorten the lever a bit to make packaging easier and clean it up a bit.

[JoeCooley]

New clutch time! I've had these parts for like a year.... Finally get to it...

[JoeCooley]

Some new parts showed up...

[BPellerine]

some good parts,I have one of those cams,havent tried it yet,but it kissed the pistons in a stock engine,maybe contact cyclex about milling the pistons down?

[JoeCooley]

some good parts,I have one of those cams,havent tried it yet,but it kissed the pistons in a stock engine,maybe contact cyclex about milling the pistons down?

Do you know any of the specs for the cam? I can't find anything on Google.
The valve reliefs are huge on these pistons. I doubt I will have any contact.

Yes, I should contact them. Maybe they will know how much I should take off it I want to lower the scr.

[BPellerine]

some guy on here contacted crane cams and got the specs for one of there other cams maybe they can supply you with info,I was not thinking you would have contact with those pistons,just knew it had a little too much lift for stock pistons,hope you can get the cr down.

[JoeCooley]

I contacted Crane's tech line. They said they will research it for me and email if they found anything... A week later and no word... So yeah.

On a positive note, I'm almost done with the rewire and new bar controls. I fired it up on starting fluid! So I know the coils are working and most of the bike is wired correctly. I went to a K1 harness and minimalist early style bar controls. Everything works except the signals. I think it's a simple fix but who knows. I have to probe the switch and check for power and see if it is even functioning. It's a cheap repop.

Also, some of new go fast parts showed up. So far I have the pistons, crane cam, CX Super rods, RC red retainers, and some stock rocker parts. Thinking about sending my gears off to be undercut.

[calj737]

Everything works except the signals. I think it's a simple fix but who knows. I have to probe the switch and check for power and see if it is even functioning. It's a cheap repop.

Check if your harness has the signal power being supplied from the TURN SIGNAL RELAY. On many models (I don't know the K8 well) power comes to the LH pod on GREY.

[JoeCooley]

Everything works except the signals. I think it's a simple fix but who knows. I have to probe the switch and check for power and see if it is even functioning. It's a cheap repop.

Check if your harness has the signal power being supplied from the TURN SIGNAL RELAY. On many models (I don't know the K8 well) power comes to the LH pod on GREY.

I found the problem! It was just a missing spring on the little contact in the switch which I forgot to put in on reassembly. Stupid mistake that cost me an hour of diag to find. Oh well, it's good now. Haha

So Phase ll is nearing an end. The bike is looking much better now and everything seems to work electrically. I can't wait to ride this thing and see how she handles. 👍😎

[SKTP]

Looking good! What Wiseco pistons did you go with (assuming you have a 1978K head)? I am thinking of getting Wiseco 863cc pistons and and trying to figure out if the 78K uses the F style of the 69-76K style...I think F, but I need to do more research

[Stev-o]

Looks fantastic!

[JoeCooley]

Looking good! What Wiseco pistons did you go with (assuming you have a 1978K head)? I am thinking of getting Wiseco 863cc pistons and and trying to figure out if the 78K uses the F style of the 69-76K style...I think F, but I need to do more research

Thank you. My current build is a bit of a mutt. CruzinImage flat top 65mm pistons, 72k cylinders, 72k cam, 75 F1 Head, Kimble white springs. I had 3 angle valve job done and springs & seals replaced.

The 78k Head is supposed to be similar to the F1 head. The F2 got the change in combustion chambers. I have my old 78K head laying around and it looks pretty much like the F1.

Looks fantastic!

Thank you Stev-o! It means a lot coming from you. Your bikes are all very nice. This bike isn't perfect in any way. It does however remind me of a track worn 70s racer with modern updates... That's kinda the look I'm going for....

Cheers Guys!

[SOHC4 Cafe Racer Fan]

Looks good, Joe.  Ride it like you stole it!

[JoeCooley]

Looks good, Joe.  Ride it like you stole it!

Thanks Don! Oh, I plan to ride $hit out it!!!

Seat pan is started. Just taped it up with packing tape and masking tape. I might lay the first layer of glass tonight. Kinda tired tho and I have to be up at 0500...