after a year, i fiinally get to tear into my bike

[dingman29]

i got this bike last summer and after i was ready to start it, i was laid off. Anyway its been a year and i finnaly get to tear into it. This is an 80 special that sat out for about 5 years. the only reason i am even messing with it is because my buddy i got it from says it couldn't be fixed. The frame is solid but i am going to powder coat it. Needs all new cables and brake lines. The forks are quite rusted and pitted... rusted handlebars.... triples need cleaned polished and repainted... Wheels are going to be powdercoated also. Also plan on braided brake lines.

I removed the engine this weekend. Surprisingly it looks good. The Finish actually held up pretty good, and the only visual "problem" is the oil pan is missing a few fins. Got took off the expensive electrical components since i am not working in a garage The wiring harness is a ****in' wreck... at one time it had bags on it and a vetter fairing from a kawasaki... a very bad rigging job to say the least. the taillight is hacked and taped and the front headlight has these plastic splicing connectors (the blue ones)...



This is my first bike i am taking apart down to bare frame... But I think i am going to replace the whole harness because after just seeing this, i don't think i should trust it... What do you guys think. Ill take any suggestions

btw my digital camera took a **** and wont power up and canon wants 109 dollars to fix it...i might go buy a disposable...

[dbeardslee]

Chris - I just finished going through Betsy's harness. I replaced all of the connectors and several of the plastic housings with parts from Z1 Enterprises. I also purchased a professional crimping tool from Mikes XS - part #35-0008, that does a fast, perfect, factory crimp. You could buy another harness, but you're going to wind up with a new old harness. Chances are the connectors are going to need some attention on a new harness too. Additionally, unless you get one off the exact year for your bike you may run into some issues with connectors. If it was me, I'd repair what you have. In the places where the PO went nuts you can always pull some new wires, or repair the connections with solder. Probably easier than replacing the whole harness. My $.02.

[exquized1]

Chris

I am in Dixon if you need any help or a few parts. I am not good at fixing them but I can had tools out very well. There is a rallie at my place Aug. 22nd if you can get her running if not bring it over and maybe the guys will be willing to help out.

[dingman29]

got to looking at the harness again... i think if i just fix the areas where that stupid ass fairing was wired in i think i will be ok... then i am going to go through the rest of it and probably change out the bad connectors...

also noticed the axle nut is rounded off... does anybody know the exact size, i might have to find the SAE equivalent and beat it on and hope it comes off...

i doubt it will be done by august due to the limited amount i am able to spend... i set a more realistic goal of having it done next spring... i could probably take the kz down there... i actually live in tampico now but it just shows what a small world it is after all...

thanks for the replies...

[Cobia]

axle nut

Hey Chris,
You may want to use a pipe wrench to remove that rounded axle nut. Then you should be able to pick one up at well stocked ACE Hardware store. Maybe even in stainless steel. They have a lot of metric stuff. Or, shoot Andreass a message, I'm sure he'll have one.

Good luck.

[dingman29]

i have the swing arm to remove and the front suspension... the wheels are off, but after reading through the manual the upper and lower adjusting nuts require a pin spanner thats in the xs tool kit (which i don't have). is there a different way to get these out... i will try to get to it after work around 1 in the morning working by my car headlights outside with no garage (landlord wont rent the garage)... i guess it will make me appreciate it more...

thanks for all of your responses...

[dbeardslee]

If you're talking about the funny looking locking bolts on top of the triple tree they can be removed with a ring wrench, or just by tapping them with a flat-bladed screwdriver and a hammer. They're only supposed to have about 5 ft lbs of torque, so they shouldn't be too difficult to remove.

[dingman29]

here are some pics...


This is how ive been working after midnight...

Good Ol' Rust

And More...

[exquized1]

Wow Looks like you got some work on your hands. There is a guy there in town that had/has a 82 Xj11 upside down in his garage. It might be worth looking into. I was going to buy it until I went on layoff.

[dingman29]

yeah but i have it down to bare frame... now its just weather i want to have it powdercoated or paint myself... thought of possibly using tractor enamel but i may just spend the extra money and have it powdercoated... figure its good learning experience... i unfortuanetly couldn't buy another bike if i wanted too...

[Shuriken]

Wow.... that one took a weather beating... if the speedometer is correct, I wonder what transpired to cause it to only make it to ~11k miles?

[dingman29]

i just got a couple questions while im waiting for my frame to get back from powdercoating.
-is there anything i should be cautious about before i get the swingarm blasted and powdercoated.
-steel brake lines are on ebay,search xs11 lines $70ish. think theyre worth it?
-anyone know of a good chrome powdercoat like on the michael waltrip racing nascar teams tires? $75/wheel beats 550 for actual chrome.
-any other suggestions are welcomed and more and likely needed.
btw going for a restore

[DGXSER]

I bought those S/S lines from Coastguard. Have them in the garage right now. The only issue I can see right off is the line from the front MC to the splitter at the trees does not have the 90 degree offset in the line end fittings of the original line for that location. I have not physically tried to bolt it on, but it is not going to be easy to get it on.

When I first got them I sent him a note that I thought this might be an issue, he promised to make good on the lines if I had any problems. Was planning to write it up in the product evaluation area, but wanted to see what comes of this one line issue first.

[dingman29]

well i just visited my freshly powdercoated frame when i dropped the swingarm off... it looks so freakin' amazing as opposed to when i dropped it off... i will have pictures when i get a hold of my brother to borrow his explorer... don't want to just throw it in a pickup... seems the ol' lady or parents don't seem to impressed but im so excited to see this bike when its done...

[kirmit77]

Stick with it man! After you get that frame back you will want it to go back so you can ride that sucker. Good luck to yah