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This thread... http://www.xs11.com/forum/showthread.php?t=37304 ... discussed what was needed for a 'carb set' and possible costs. Well, I did some research and I'll throw this out there for comment...
There's a eBay seller who has both the carb kits and engine kits for about $16 and $40 respectively, including shipping. He is making money....
His kits do offer 'tumble polished' bolts; a bit shinier surface than a 'basic' bolt, but not what I'd call polished. After checking costs at McMaster-Carr, it looks like actual costs are about $5 for the carb kits and $16 for the engine kits. This is pricing the hardware out per each. The fly in the ointment is the quantities these are sold in don't quite match what you need. For example, to replace all the 6mm external cover screws on the motor you need 26 @ 35mm long, 26 @ 25mm long, and 14 @ 20mm long, a total of 66 bolts, plus two flathead screws for the clutch cover. Now, the 20mm and 25mm lengths are no problem as the minimum quantity is more than you need. But the 35mm comes in multiple of 25, so you're one short or 24 over...
But even so, if you buy the minimum (50 35mm, 50 25mm, and 25 20mm), you're still saving a few bucks.
If there's enough interest, I might do a large enough 'buy' to assemble some kits. Actual kit costs will depend on how many are wanted and how many 'leftovers' I have to eat. I probably won't include the two flat head screws for the clutch cover as I'd have to buy 50 of those, so unless there's enough demand (20+ kits), it will cheaper for you to buy those locally or reuse what you have. Same goes for carb kits; while there's a bit better 'break' in terms of how many are needed and how many you need to buy, I still have to eat the leftovers.
If you want to get your own, here's what you need for the engine...
26 - 6mm x 35mm. 20 for the cam cover, 3 each for the alternator and clutch covers.
26 - 6mm x 25mm. Ignition/shifter/clutch/alternator covers, brake lever pinch bolt.
14 - 6mm x 20mm. Bearing cover (in front of the starter), cam chain tensioner, intake boots, shifter pinch bolt.
The carbs...
'78-79 with cast tops: 8 - 6mm x 14mm (carb rail), 32 - 5mm x 15mm (tops and bowls).
'80-82 with steel tops: 8 - 6mm x 14mm (lower rail), 24 - 5mm x 10 mm (tops and upper rail), 16 - 5mm x 15mm (bowls).
A couple last things... First, be sure to use antiseize on any stainless fastener; these will seize at the drop of a hat and break off. Second, stainless isn't as strong as plain steel; maximum torque on the 6mm is 6.4 ft-lbs or 77 in-lbs. The factory spec is 7.2 ft-lbs on all the cover bolts, use the lower number, it'll be fine. If you decide to replace some of the other bolts, do check torque specs. The 8mm stainless is only good for 15.6 ft-lbs.
I'm going to order some stuff from McMaster-Carr soon, so if there's interest don't wait....
There's a eBay seller who has both the carb kits and engine kits for about $16 and $40 respectively, including shipping. He is making money....
His kits do offer 'tumble polished' bolts; a bit shinier surface than a 'basic' bolt, but not what I'd call polished. After checking costs at McMaster-Carr, it looks like actual costs are about $5 for the carb kits and $16 for the engine kits. This is pricing the hardware out per each. The fly in the ointment is the quantities these are sold in don't quite match what you need. For example, to replace all the 6mm external cover screws on the motor you need 26 @ 35mm long, 26 @ 25mm long, and 14 @ 20mm long, a total of 66 bolts, plus two flathead screws for the clutch cover. Now, the 20mm and 25mm lengths are no problem as the minimum quantity is more than you need. But the 35mm comes in multiple of 25, so you're one short or 24 over... But even so, if you buy the minimum (50 35mm, 50 25mm, and 25 20mm), you're still saving a few bucks. If there's enough interest, I might do a large enough 'buy' to assemble some kits. Actual kit costs will depend on how many are wanted and how many 'leftovers' I have to eat. I probably won't include the two flat head screws for the clutch cover as I'd have to buy 50 of those, so unless there's enough demand (20+ kits), it will cheaper for you to buy those locally or reuse what you have. Same goes for carb kits; while there's a bit better 'break' in terms of how many are needed and how many you need to buy, I still have to eat the leftovers.
If you want to get your own, here's what you need for the engine...
26 - 6mm x 35mm. 20 for the cam cover, 3 each for the alternator and clutch covers.
26 - 6mm x 25mm. Ignition/shifter/clutch/alternator covers, brake lever pinch bolt.
14 - 6mm x 20mm. Bearing cover (in front of the starter), cam chain tensioner, intake boots, shifter pinch bolt.
The carbs...
'78-79 with cast tops: 8 - 6mm x 14mm (carb rail), 32 - 5mm x 15mm (tops and bowls).
'80-82 with steel tops: 8 - 6mm x 14mm (lower rail), 24 - 5mm x 10 mm (tops and upper rail), 16 - 5mm x 15mm (bowls).
A couple last things... First, be sure to use antiseize on any stainless fastener; these will seize at the drop of a hat and break off. Second, stainless isn't as strong as plain steel; maximum torque on the 6mm is 6.4 ft-lbs or 77 in-lbs. The factory spec is 7.2 ft-lbs on all the cover bolts, use the lower number, it'll be fine. If you decide to replace some of the other bolts, do check torque specs. The 8mm stainless is only good for 15.6 ft-lbs.
I'm going to order some stuff from McMaster-Carr soon, so if there's interest don't wait....
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