Taking over restoration myself

[JimmyXS11]

Well, an interesting day. Got the carbs and airbox installed. Changed the lube in the middle drive. Then did one of the dumb things I have read warnings about. I removed the final drive drain plug before being sure I could open the filler. I just got too excited.

For two days I had sprayed the plugs with penetrating oil. Now Phil's idea of using vice grips helped me get the middle drive open, but there is not enough showing to get a grip on the final drive filler plug. I also tried heat, heat and ice, vice grips on the hex key and a chisle on the left side of the plug. All I ended up with was a flat side on the plug from the chisle. I guess my next attempt will be cutting off the other side of the plug to fit an open end wrench.

After I change the oil, I will finally try to start it again.

[bikerphil]

I also tried heat, heat and ice, vice grips on the hex key and a chisle on the left side of the plug.

You want to be hitting the right side of the plug with the chisel as to spin it in a counter clockwise rotation to loosen it. Hitting it on the left side would be tightening it, no?

[motoman]

You want to be hitting the right side of the plug with the chisel as to spin it in a counter clockwise rotation to loosen it. Hitting it on the left side would be tightening it, no?

My thoughts exactly...........

[JimmyXS11]

Sorry, don't know why I typed left, I was hitting the right side of the plug.

[CaptonZap]

Sorry, don't know why I typed left, I was hitting the right side of the plug.

Something you might try, although it take 4 hands.
Get a good grip on the plug with vise grips, and put a foot of so of cheater bar on them. While one set of hands puts a strong steady COUNTER CLOCKWISE pressure on the bar, another set of hands takes a drift pin and a hammer, and applies a series of sharp blows around the top of the plug, going in a clockwise direction with the blows.
Applying some heat to the aluminum around the plug may or may not help, depending on your way of thinking. CZ

[Guest]

I am seeing twins almost.

[JimmyXS11]

Very happy - and very frustrated

I went to the shop to get a hex socket for my ratchet. They had individual 7mm and 8mm and 3/8 inch, but I had to buy a set of seven to get a 6mm. At least when I put it to use, the plug popped like a pistol shot and broke free. Now I can refill the FD. While I was at the store, I got a replacement plug with a hex head on it and a plastic washer. So much for the good.

I put the gas tank back in place and turned the petcocks on. Gas ran from the airbox and it looked like every carb was leaking. This is why I took them apart in the first place. (I know, I skipped the bench test of the floats, but it seems it would have done the same thing.) I tried to be so meticulous when I put it all back together. Brand new matched set of needles and seats, floats set to 1.012 inch, trimmed gaskets, set the drop down flange. The only thing I can think of that I did not do was smooth the tang on the float arm, but I just do not see how this should matter. I will take them apart again tomorrow and see what I can find.

[JimmyXS11]

Virstens - they do look very similar. Your chrome is in much better shape, but my trunk matches the color of the bike. And it looks like you have a radio. Wish mine looked as good as yours, but someday... perhaps...

I looked at some lowers for the faring on the net. Still have not decided whether to get them. Does not get as cold here as it does up where you are.

I guess if I said that you have a great looking bike it would sound a little self serving since there so much alike. Hey, we both have good looking bikes.

Ride carefully

[DGXSER]

Jimmy, that same thing happens all across the world when working on these carbs. I will say, the bench test goes in two stages, first with the bowls off, upside down, on the bench. Hook up a fuel source, blip the floats to get the air out of the lines, then clean up any gas and dry well. Now, go to the kitchen and have lunch,diner, breakfast...kill some time, 15-20 minutes or so. Now go back and see if you have any signs of fuel leaking. No leaks, move to test two.

Test two, put bowls on, turn right side up, get them relatively level. Put fuel to the carbs, and watch for a few minutes. No leaks, mount them up.

Now, here is the part that gets infuriating, sometimes, after both test, when you mount them on the bike, they decide to leak. BTDT, made the T-shirt. Often you will find that tapping the bowls with a screw driver handle or the like will stop the leaks.

Or, as in my case, I found I was using normal auto fuel line, with the soft inner rubber lining. That soft inner lining was getting chaffed off by the fuel Ts. And those chaffins were enough to keep my needle valves from seating. replaced the fuel lines with some Briggs and Stratton stuff form the local hardware store, no problems since.

[Guest]

I just got this and this is the first time I have had a bike with a fairing. I noticed today how much heat was kept near the bike and on my legs with the lower part of the fairing. Nice when cool but not sure when it is hot. This is my fuse panel repair. I used mini fuses.

[JimmyXS11]

Well, it has failed test one so far. Just in case, I bought new gas lines and installed them. I have pulled the needle and seats and made sure they were clean. I am still getting seepage through two of them. I have left it for overnight and look forward to seeing how much has leaked during the night.

Got the FD filled. The motor oil waits until I get the carbs right.

I now know that owning an XS1100 is an exercise in patience. I needed that.

Long live the XS11. Oh, and XJs too.

[DGXSER]

If it is failing test one, then you most likely need to replace the needle valves and seats.

[JimmyXS11]

But these are brand new, just out of the package. Got them from georgefix. I have not been out to check them this morning, but I hope for a good surprise.

[DGXSER]

Sorry missed they are new. Should hold for test one then.

[JimmyXS11]

Finally got through test one. I fiddled with it all morning and early in the afternoon they were all dry. I wish I knew what it did that helped.

On to test two. Number three has a slight weeping and number four a little more. Sure beats the "gasolinefalls" from a couple of days ago. Broke a gas filter trying to put together new gas lines. Found one here in town.

Tried to get an oil filter today. The threads talking about them said several companies had them in stock. Well perhaps in the big cities, but not here in the hinterlands. I know my profile says San Antonio, but I actually live about an hour east. I went to 6 auto parts stores (CarQuest, Autozone, NAPA x2, O'Reilly's and Parts Plus) in two towns and no one had it. Ordered one from O'Reilly's and it is supposed to be at the store in the morning.

I think I am going to go ahead and put the oil in and give the carbs a try. The hope being that if they work a little while the remaining bugs might work themselves out as the parts settle in. Let me know if you think this is a bad plan.