New project: XS1100 endurance racer

[DEEBS11]

Mathh, incredible build. I love the tail piece and tail lights. I am a big fan of Dzus fasteners also. I used them on my KZ1000 MKII Alaska bike to attach the diamond plate bags. They have not fallen off in the 90,000 miles I put on that bike since 1999. They quick release with no tool so you can work on the bike when needed.

[DEEBS11]

The DZUS fastener bases welded to the bag rails.

[Mathh]

Thanks! And I agree!

[Mathh]

Electrics and its hardware …yeah ... Its because all my projects eventually arrive at this stage: I have been moving this job forward and forward but eventually I have to dive in , so I might as well do it now.

Starting with the coils. Up front under the tank in the air flow. Only two coils as I gave up on the 8 plug cylinder head. This is one of 8 famous factory race cylinder heads that I wanted to replicate. Here is a picture of it..



I got the advice from a racer that welding and drilling the new (vertical) plug holes could lead to distortion of the head. So that turned into a no-no.
And here is the new location of the coils, not in the space inside the tank as was planned. Simply because there is room and cool air available in the new location.. And as always I use used coils from the earlier Fireblades. They are several generations later than the stock coils, cost next to nothing as they never fail and have screw-on plug cables. Just ditch the ballast resistor.



The speedo/tacho unit until now was this Motogadget unit which also found a place on the fairing bracket.



And here is the location for its speedo drive, the sensor picks up the magnet in one of the rear brake disc bolts.



However as it is no longer to my taste I will swap it later with this electronic tach from a Honda VTR1000 SP1. Still modern but less bling bling. It comes from the turbo bike which I have been dismantling. It was a bitch to get it working as the electronics resemble those inside a last generation smart TV.

[Mathh]

So a new tacho pickup is needed for the NPN proximity sensor that picks up the negative pulses from the new bracket from the crank… like this one on my Triump 1200 which has another one of these.



Same for the speedo pickup, same sensor but it will be getting its negative pulses from a mini sprocket that will be attached to the front sprocket. Number of teeth (17) is calculated back from rear tire circumference and gearing ratio.



Next.. as we were trial fitting the fairing at least three times per day we might as well start with the head lamps. After losing heaps of time searching for a good looking position I decided to go with two 100mm head lamps in a low position, looking like one of the Italian Bimota’s. They are fitted on the fairing bracket together with other electrical stuff that I need.



Without the fairing they look very high because of the ultra low headstock, but once the fairing is on it looks already better:



Here a pic from the inside of the fairing:

[Mathh]

The TCI will also find a place on the fairing bracket, maybe two on top of each other (one spare). The grey covers on the lamps in the picture will close the gap to the fairing.



The Ignition switch, starter button and light switch are bult in the front of the dashboard



The front brake switch is hydraulic and inline between mc and brake line. The rear lights …already on the seat but they need just a connector under the seat.
Then the relais for the lights, horn and starter which found a place below the dash inside the fairing and on the left side of the dashboard come a couple of auxiliary switches. The handlebar has coloured push button switches for high beam, kill switch and horn. The actual horn is mounted in front of the coils in the front triangle. Out of sight. Picture shows the push buttons.



The battery got a place under the seat at the rear of the frame (starter relais at the back of it and close to the starter motor). Using quick connect connectors with very short connections.



This ’98 Kawasaki ZX9R regulator/rectifier now fits behind the cylinder on top of the clutch cover. i Chose it because of the large cooling area. As there is very little room on the bike this is the only place I could think of, close between the alternator, ignition and battery.

[Mathh]

A modern spade type fuse box with a lot more fuses than stock is bolted out of sight with one bolt to the right headlamp and one DZUS fastener to unclamp it from its position in case of a broken fuse.



Last (I hope...) the wiring harness.... but that will be done right before painting the frame.

some more pics ..





I made some brackets on the valve cover to bolt the fairing in its place (with 5 DZUS fasteners, one in the middle below the headlamps) and the screen gets plastic fasteners which are used on modern fairings.



Next on the list will be welding and fitting of the final version of the 4-2-1-2 exhaust...

[DEEBS11]

Very cool Mathh. I worry about the regulator taking heat from the motor fins. Keep an eye on that on a 93° day. Does your display have a volt meter?

[Mathh]

Very cool Mathh. I worry about the regulator taking heat from the motor fins. Keep an eye on that on a 93° day. Does your display have a volt meter?

I agree but there is very little place except when I hang it outside the frame rails and that just does not look right ( I know what you want to say now hahaha). I'll have another look at it , if not ... well I still have some spares lying around Good idea that Volt meter, especially since I have one on all my other bikes... duhhh..

[DEEBS11]

I use these on all my bikes. Really cool part.

https://www.ebay.com/itm/25291889758...Bk9SR9aigNqeYw

[Mathh]

I use these on all my bikes. Really cool part.

https://www.ebay.com/itm/25291889758...Bk9SR9aigNqeYw

Yup! Check, check! With actvating switch.

[oldyam80sg]

Do you have clip ons or is the handle bar clamps whcih model?

[Mathh]

Do you have clip ons or is the handle bar clamps whcih model?

Hi! I now have FZR600 clip ons fitted to the FZR1000 forks (pre Genesis) on the racer but I am still looking for a more comfy seating position. In case of a switch to higher handle bars I would fit separate handlebar clamps. Lots of those available overhere. I normally make them myself like I did on the upper yoke on the Special in the last picture. That one has FZR750R (Japanese FZR1000 model) forks. Also overhere there are several superbike conversion kits available for forks from the racier models with fairings if you don't like the work.
The Standard on the picture above has TRX850 forks with a superbike conversion kit and XS1100 Sport handle bars, see below. . But a lot of other (and or cheaper) stuff is possible, is there anything specific that you are looking for?

[oldyam80sg]

I have seen many clip ons mounted right to where the stock handlebars mount on sport bikes. I like your set up though. I like the stock XS 1100 bars as I have shoulder issues and those bars are just right.

[DEEBS11]

Yup! Check, check! With actvating switch.

I love that spot you picked to mount the volt meter. Brilliant!