XS1100 Standard for $1.00

[TheRev]

Thank you Wayne.

[TheRev]

Ok, now for the headlight mod. Here is what I did to mount a new LED Truck Lite Headlight. First I read Crazy Steve's Post titled:

"Install an Off-The-Shelf Headlight in a Standard"

His post was excellent. So I purchased a truck headlight bucket. Mine was actually a Toyota 4Runner.

1: purchase a used truck headlight bucket on ebay. I couldn't find a s10 so I bought a Toyota 4Runner. It doesn't really matter as long as it is the 5x7 type.




2: I cut the mounting tabs off of the original headlight. In my case I used the sealed beam light. I chose to cut the original tabs rather than fab new ones. It was much easier, trust me. I took a dremel with a cutting wheel and went to town. There are three tabs on the original light.














3: Then I drilled two holes in each of the tabs so that I could use rivets to attach the tabs to the 4Runner bucket.

4: Then I cut off all the "ears" off of the 4Runner bucket because they were unnecessary. I used a dremel to do the cutting.







I then bent down one of the tabs so that I can mount the brackets onto the 4Runner bucket.





5: I then placed the xs1100 headlight ring on the 4runner bucket to see if there was clearance for the mounting tabs. Then I used a marker and marked where the tabs should go on the 4Runner bucket.

6: The next step will be different for you depending on what truck bucket you purchased. What i did was manipulate the 4runner bucket in order to mount the xs1100 tabs. This included some cutting, bending and flattening the raised parts of the 4Runner bucket so the xs1100 tabs would sit correctly.

7: Next I repeated step 5 until I was confident that everything lined up well. When I was satisfied I marked where the "rivet" holes would need to be to mount the brackets.

8: I then drilled the rivet holes into the 4Runner bucket.

9: Next I mounted the brackets onto the 4runner bucket using rivets. Make sure you rivet the brackets from the inside out. What I mean is make the head of the rivet on the inside of the bucket and the "tab" side of the rivet on the outside of the bucket. This will give you more clearance for the headlight. I originally did not due this and it was a tight fit.





Notice the head of the rivet is on the outside of the bucket. I am going to fix this. Next time I do it the head of the rivet should be on the inside and the tab on the outside. Lesson learned.








10: Attach the xs1100 headlight ring onto the 4runner bucket using the original screws and nylon nuts. You are going to need to make some fine adjustments to the 4Runner mounting tabs so everything fits correctly. Just work slowly, measure often and use your grinder lightly.





11: Finally, trim everything up so it doesn't look like my hack job. Grind down any sharp edges, etc. I then sandblasted everything an am planing on painting it all black. How you finish yours is up to you. However, know that when the headlight is installed into the xs1100 bucket you won't be able to see the hacked up truck bucket. Hope this helps.

[IanDMacDonald]

Great follow-up Rev. Thank you for the post.

[TheRev]

I finished the bike this week. I am only concerned about the about the cam chain. I can hear the cam chain when I ride the bike. It's not a knocking sound, rather it is a consistent whine. I added a automatic cam chain tensioner when I did the build so I think the cam chain is tight. Please let me know if it is normal for the cam chain to make noise. Anyhow, here are some pics.

[jjz28]

That is one BEAUTIFUL XS Rev! I absolutely would ride that with pride! You have resurrected an old muscle bike into a modern monster. I believe I have a new favorite bike here on channel 11.

[3Phase]

I finished the bike this week. I am only concerned about the about the cam chain. I can hear the cam chain when I ride the bike. It's not a knocking sound, rather it is a consistent whine. I added a automatic cam chain tensioner when I did the build so I think the cam chain is tight. Please let me know if it is normal for the cam chain to make noise. Anyhow, here are some pics.

Nice work, Rev!

Yes, the cam chain does make some noise with the Automatic Tensioner. I like to think of it as my bike singing happily to me while I'm riding instead of fooling around with the stock tensioner.

I can't hear your engine so do you think the noise just an artifact of the new steel tensioner tip touching the chain guide with no rubber silencer so you hear the cam chain now or is the chain noise really loud and annoying like a chainsaw chain?

.

[TomB]

Wow that is nice, nice job you did there.

Its a good usable custom job, decent brakes, handling, stylish and practical fairing. Yep I like that.

[jetmechmarty]

If the plastic is no longer bonded to the tensioner assembly, you should get more noise. A loose chain makes noise. If the plastic was gone off the tensioner, you may have found bits of it in the oil. If it is gone, you will find metal in the oil filter. As stated, some noise is normal.

You did a lovely job. Your bike looks great!

[3Phase]

I don't know which tensioner Rev used but the Venture tensioner doesn't have a little rubber foot, it's just a round metal bar with a blunt end and notches for the ratchet.

The cam chain assembly does make a singing sound when the engine's running and after several years and a few ten thousand miles in the engine it's made a very small mark on the steel cam chain guide slipper so now I know that only the lower outer edge of the tensioner bar actually touches the steel slipper.

The other tensioners from different years/models/engines may be similar to the Venture tensioner or they may have little rubber feet. I don't know, I haven't actually seen any of them with my own four eyes so take my one example sample for what it's worth....

.

[jetmechmarty]

Item #9 is the chain damper assembly. It has plastic or rubber bonded to it where the chain rides against it. That is what I was referring to. The foot pressing on it likely is of little consequence, although I expect the OEM one is quieter than the metal on metal ACCT.

[3Phase]

The parts diagram doesn't really show it but the XS1100 cam chain guide is a four piece set: mount base, rear guide, front guide and a steel slipper that doubles as a very effective Yamaha tuning fork.

The slipper provides some leverage for the tensioner foot and a shorter tensioner bar can be used that doesn't have to extend too far into the cam chain gallery to maintain tension on the cam chain.

On the right-hand side of the wear pattern on the steel slipper is a very small mark made by the Venture's tensioner bar because it has no rubber noise damping foot and only the lower outer edge of the bar touches the slipper.

The cam chain assembly is somewhat noisy and makes a singing sound while the engine is running.




Here's a closeup picture of the small mark made by the Venture's automatic tensioner on top of the old wear pattern made by the XS11's original manual cam chain tensioner.

Again, the cam chain assembly is somewhat noisy and makes a singing sound while the engine is running.




.

[natemoen]

I want more info on your brakes!

[TheRev]

Thanks for all the info. It sounds like the noise is normal. It's not clanking or banging it's just a consistent noise. I guess when a chain is moving that fast it's bound to make noise. It's just louder than any other bike I have ridden although I have never ridden a xs before this one. I was going to back the tensioner out and then back in to see if that makes a difference. Thanks for all the great comments.

The parts diagram doesn't really show it but the XS1100 cam chain guide is a four piece set: mount base, rear guide, front guide and a steel slipper that doubles as a very effective Yamaha tuning fork.

The slipper provides some leverage for the tensioner foot and a shorter tensioner bar can be used that doesn't have to extend too far into the cam chain gallery to maintain tension on the cam chain.

On the right-hand side of the wear pattern on the steel slipper is a very small mark made by the Venture's tensioner bar because it has no rubber noise damping foot and only the lower outer edge of the bar touches the slipper.

The cam chain assembly is somewhat noisy and makes a singing sound while the engine is running.




Here's a closeup picture of the small mark made by the Venture's automatic tensioner on top of the old wear pattern made by the XS11's original manual cam chain tensioner.

Again, the cam chain assembly is somewhat noisy and makes a singing sound while the engine is running.




.

[jjz28]

I have never adjusted mine since I have had it (I have put on a couple thousand miles, maybe) but mine makes no noise that I can hear. Mine may need adjusted for all I know, I am scared to touch it.

[TheRev]

Hi Natemoen

The breaks are from a Yamaha R6. They are four piston calipers. I had to make an adapter so they would mount on the original fork. The disks are I believe from a fjr. They are 320mm. Any disk that has the six bolt pattern will work. I needed to use some washers as spacers when mounting the calipers so the disks would be centered. Then I installed stainless lines. Hope that helps.

I want more info on your brakes!