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Another XJ Re-born
Well, thanks to a lot of help from this forum, my 82 XJ1100 is finally back on the road after almost 3 years. I discovered this gem in September, 2005. It was last registered by the original owner in 1988, and had been stored in his garden shed since then. It had been dumped on both sides more than once, and definitely needed some TLC. Here's what it looked like when I brought it home:
I tore it down to the bare frame, which was sandblasted and painted, and started to put it back together as the bits were completed. Everything that could be dismantled has been cleaned, inspected and re-built to as-good-as-new condition. Amazingly, the engine was not seized, and the original main and rod bearings and piston rings were still within the Service Manual specs, so they were re-installed. Of course all the rubber seals had to be replaced, and most of the ball bearings in the transmission were rusted, so they had to be changed out as well. It took a while, but I was able to buy everything I needed to keep it original; a few NOS parts and many used parts through EBay. It's amazing how much is available out there for a bike that was only built for one model year (except of course for the extra couple of years up here in Canada). About the only things that I've upgraded from the original Yamaha configuration are the brake lines (stainless steel), the fuse block and the installation of an XS850 final drive. Here's what the finished product looks like (MAXIMAN, if you're still out there, you should be happy to know that your original jet-hot exhaust system found a good home!):
Overall, it's been a very satisfying project. I do have to admit to one screw-up. When I first fired it up, it seemed to run OK, but in no time at all it dropped off the two right-hand cylinders at idle. In fact, those two cylinders were getting so much gas that they wouldn't fire, and the raw gas was filling up the crankcase. After playing around with float levels a number of times and going off on a tangent with the ignition system components, I was embarrassed to discover that all four pilot jets were loose in the carb bodies. In fact, #3 and 4 were almost falling into their respective float bowls. After tightening them up properly and re-installing the carbs, the engine fired right up on all four cylinders and I was easily able to set the idle mixtures and synch the carbs with my Morgan Carbtune.
I've put about 250 km on the bike so far and it's a real pleasure to ride. Everything works as it should, including the self-cancelling turn signals, and the engine runs smooth and pulls like a tractor. Many thanks to all the XS'ives that have helped me with this re-build through their many posts on this forum. I couldn't have done it without you.
I haven't thought up a name for my XJ yet, but "Second Childhood" comes to mind!
I tore it down to the bare frame, which was sandblasted and painted, and started to put it back together as the bits were completed. Everything that could be dismantled has been cleaned, inspected and re-built to as-good-as-new condition. Amazingly, the engine was not seized, and the original main and rod bearings and piston rings were still within the Service Manual specs, so they were re-installed. Of course all the rubber seals had to be replaced, and most of the ball bearings in the transmission were rusted, so they had to be changed out as well. It took a while, but I was able to buy everything I needed to keep it original; a few NOS parts and many used parts through EBay. It's amazing how much is available out there for a bike that was only built for one model year (except of course for the extra couple of years up here in Canada). About the only things that I've upgraded from the original Yamaha configuration are the brake lines (stainless steel), the fuse block and the installation of an XS850 final drive. Here's what the finished product looks like (MAXIMAN, if you're still out there, you should be happy to know that your original jet-hot exhaust system found a good home!):
Overall, it's been a very satisfying project. I do have to admit to one screw-up. When I first fired it up, it seemed to run OK, but in no time at all it dropped off the two right-hand cylinders at idle. In fact, those two cylinders were getting so much gas that they wouldn't fire, and the raw gas was filling up the crankcase. After playing around with float levels a number of times and going off on a tangent with the ignition system components, I was embarrassed to discover that all four pilot jets were loose in the carb bodies. In fact, #3 and 4 were almost falling into their respective float bowls. After tightening them up properly and re-installing the carbs, the engine fired right up on all four cylinders and I was easily able to set the idle mixtures and synch the carbs with my Morgan Carbtune.
I've put about 250 km on the bike so far and it's a real pleasure to ride. Everything works as it should, including the self-cancelling turn signals, and the engine runs smooth and pulls like a tractor. Many thanks to all the XS'ives that have helped me with this re-build through their many posts on this forum. I couldn't have done it without you.
I haven't thought up a name for my XJ yet, but "Second Childhood" comes to mind!
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