Resurrection ups and downs...

[BigRed]

Hey, guys.

As promised, here are a few shots of my bike:




Just picked it up on Friday. Can anyone confirm exactly what it is? I was told it was an '80 special. What model designation is that? I'd hate to order a bunch of parts for the wrong bike.

The bike's been parked for a long time, and I'm trying to bring it back to life. I picked it up on Good Friday, freshened the gas and tried to start it with no luck. Saturday morning, I took the carbs off and cleaned them, and then the bike started and proceeded to redline immediately. Didn't have time to check it out until tonight, so I took the carbs off to see what I'd messed up, and I discovered that the throttle cable was way too tight, so it had pulled the throttle lever off the idle screw adjustment. Put it all back together, but didn't hook up the throttle cable, and it started fine, and sounded great until I heard a squeal and pop. Turns out the alan bolt that holds the timing plate on to the end of the crankshaft managed to unscrew itself and crack the timing cover. The bolt won't thread back in; the tip of it's damaged, so I'm going to try to replace it tomorrow, and hopefully find out that my crank shaft isn't pooched.

So long as I can get it to start, I'll be able to get going on the rest of what it needs before hitting the road. Doesn't look like too much yet: just brake pads, tires, fluids, and fork seals... as far as I know.

I'm pretty happy with how it looks so far! Even when the bike would redline as soon it started, I was just happy to find that it would spark. For the brief moment that I ran it today before I heard the squeal of the timng plate cover, it sounded great. Looks like a little TLC might have it back on the road, and then I can get into the rest of what it needs (windshield, timing cover, foot peg rubber, grip heaters, etc).

Here's a question for someone who's had the engine apart: how beefy is the crankshaft where the timing cover allan bolt threads into it? If a new bolt won't thread in easily, how bad an idea would it be to try and drill and tap a new hole for a larger bolt? From what I can see, it looks like all the filings would be on the outside of the engine, so all I'd have to worry about would be snapping the end off the crankshaft.....

Thanks!

[b.walker5]

Looks like it started out in life as an '80SG but has had a few changes. Right side engine (alternator) cover doesnt look right for the model, seat looks like it's been modified and the frame side covers are definately non original. Handle bars are also non original but they look like they'd be comfortable. Check your frame and engine numbers. They should match and begin with something like 3J6 but dont panic if they dont match, the engine may have been changed which may account for the different cover. If they dont match then the frame number is the one to use. Check this link for model info. http://www.xs11.com/forum/showthread.php?t=396

You'd be a very strong man indeed if you could snap the end off the crank on one of these beasts. I've seen 4 pot car engines with smaller cranks than these. They are a one piece forged crank and they are tough. I'd be more worried about snapping the thread tap off in the hole.

Good looking bike by the way. A very good start.

[81xsproject]

Lucky you! Someone already did the XJ stator swap. More amps for you

[DGXSER]

looks like an 80 XS1100 special or SG to me. Change outs look like the seat has been recovered, bars have been swapped, possible engine swap out or perhaps Jessie (81XSproject) is correct and they just changed the alternator out.

Be interested to see what is behind the timing cover. Does it have a mechanical advance and or vacuum advance in it? If you remove the seat and look at the TCI (brain box) what numbers/letters are on it?

Overall, excellent looking bike!! Very nice. I think once you get the carbs cleaned completely and the throttle linkage set right, she will run like a scalded dog.

[Ivan]

I wouldn't recommend chasing the threads with a tap. Get a thread chaser, also called a forming tap. They don't cut the metal but push it back into place. Taps are very very brittle and the crankshaft is hard metal, which would leave you with a broken chunk of tap in the end of the crank. Then you'd be splitting the cases to get the crank to a machine shop.

Snapon will ship individual thread chasers to you, I bought one for the Venture spark plug hole, and it was $4. If you NEED it RIGHT NOW, you can buy a 12.9 hardness bolt and use a dremel tool to cut some V shaped slots in the threads about 120º apart, and that should do an ok job at reforming the threads, but not be so hard as to break off.

Hope you get it running soon.

[BigRed]

I meant to check out serial numbers this morning, but decided to sleep in instead. I know it's got a vacuum advance, but I don't remember what it says on the black box. I'll check it out when I get home.

I managed to use a 12.9 hardness bolt to chase the threads in the crank, and I got the timing assembly back together. It sure seems like there's a lot of slack when positioning the timing plate. It could rotate it about 10 degrees before I tightened the bolt down. Is this normal?

I also found out that my throttle cable was just snagged inside the twistgrip housing, and that problem basically solved itself when I applied copious amounts of cable lube.

I did get it started, but it's got an intermittent spark problem. Before the bike was put away, I had replaced the coils and CDI with "new" used ones that tested good. That only leaves the pick-ups, and I suppose the rest of the wiring harness. I'm thinking that I'm going to replace the whole shebang... pickups, CDI, coils, plugs, and wires with some aftermarket stuff. I bought an Ignitech ignition unit for my Honda CX500, and it's been great. They also sell the rest of what I'm going to be looking for. Any suggestions on this would be great!

Now, I'm off to search for what other people have done with their ignition problems.

Thanks for the replies!

[bikerphil]

I did get it started, but it's got an intermittent spark problem

The pick-up coil wires under that left ignition cover can break inside the insulation causing 2 cylinders to drop out. You won't be able to see the break, but lightly tugging on the wires seeing if they will stretch will usually reveal the problem. Check under the crimp brackets also. You can carefully jiggle the wires around with the bike running to see if there's a change.

Also, you can unscrew each spark plug cap and trim 1/4" of wire off, then screw the caps back on. Common place for corrosion.

[BigRed]

Thanks, I'll try jiggling/stretching the pick-up wires tonight. What's the fix if it's the wires? Do I need to replace the pick-ups, or can they be repaired? If I resolder/shrink tube them, they'll be way stiffer than they are right now. Even if it's only temporary, I'd like to hear the engine run before I start sinking money in to more parts hoping to solve my problem.

I'll also trim the spark plug wires.

[DGXSER]

There are several threads on here about fixing those wires, I think there is a tech tip also. Alot of folks go to the hardware store and buy replacement lead wires for a multimeter and use that to replace the pickup coil wires.

Here is a link to a method a good friend of mine did it. I can tell you he knows his crap and does nothing halfway, so this is definitely a full blown, no holds barred way to do it. He is ALMOST as detail oriented and anal rententive as I am.

[BigRed]

Thanks! That looks like a fantastic fix; I just picked up some jumper leads, so I'll try this when I get home tonight. Can't wait.... I've got a really good feeling that this is my problem.

[gringojason]

I am just learning about the XS and not technically advanced enough to give you any pointers...but that is a sweet looking ride you picked up!! Congrats!! What kind of windshield/fairing is that?

[BigRed]

Success!

Got it running! Turns out the only thing wrong was plugged carb jets, leaky intake boots, and a busted pick-up wire. Still have to replace the intake boots, but it's running!

Checked the numbers, and the frame is a '80 XS11SG, but the engine's from an '82-84 XJ. I guess that's good?

Jason: I don't know what the windshield/faring is. It's not labeled, and it came with the bike.

Thanks everybody for the help! It's not roadworthy yet, but it will be soon. I'm going to place my parts order tomorrow.

[DGXSER]

Awesome, congrats on the fruit of your labor!! It is a great feeling for sure, I know from experience.