Noob, doesn't really know where to start....

[mikubuilder]

welcome!

hey Ash, looks like you will be busy for a while
to get those bikes running doesn't take much, so it only depends how far you want to take this project....if you want to restore it to it's original state, or just to make it a runner...
there is plenty of original parts here, in "parts for sale" forum, or ebay, to make it all original, and from my experience it's the most rewarding experience, but it's your choice
looks like the compression numbers are fine, so you just need spark and gas...carbs need to be sparkling clean, so take them apart and clean every passage, especially pilot circuit.
that spark plug wire can be trimmed, cut about 3/8 in off, then trim 1/2 in. of just the insulation off and fold wire strands back over the insulation(it will help with screwing the cap back on)
any other questions, you will find answers here by searching, or just keep adding to this post, at least we will know the history of you project, that helps with troubleshooting...

good luck, it's a blast to hear those machines roaring back to life

[ashpave]

Thanks Mikubuilder, I will trim up that spark plug wire, and try to reuse it. Im glad to hear the compression numbers are good, I was a littler nervous about that. I shifted through the gears and they felt pretty good. I started tearing into the carbs, I got the bottom halves taken apart and cleaned them in an ultrasonic cleaner with simple green, it seems to clean them up really well. I need to get the top half apart, but I think im going to have to drill a few of the screws out, a few of them are stripped out, and I think thats going to be the best solution.

I probably need to get a good fuse box, and find out about some of the other parts I need that I might as well replace now.

So, I guess on to the carbs I go.......this may turn out to be a $300 well spent!!!! When I bought it, the guy I bought it from said neither he, or the previous owner could get it to turn over.........im assuming im going to find something in the top halves of the carbs.

[mikubuilder]

well turning over has nothing to do with carbs ...you've already done that by checking compression...what kind of millage you have on the motor, if you can tell? looks like you have only speedo, and it looks aftermarket(but I'm no expert...) also, if you have a F, it's headlight is not correct
you can check what model you have by searching "VIN check" and comparing it to yours...

[mikubuilder]

on frozen screws, try a 50/50 mixture of ATF and acetone, supposed to be better then PB Blaster patience is a key when working on those old bikes, soaking overnight might free up those pesky screws...
as to a fuse box, TC sells them from here, info should be in modification forum(I think)

[ashpave]

Hey Nick, I did the vin check, it came back as an F, the headlight, the apes, the speedo are not original to the bike, the motor and frame are probably all that are original of the bike. Im going to soak the carbs overnight, they are really dirty!

[ashpave]

As far as mileage goes I have no idea, the atf/acetone is a great idea!!!! Thanks so much for taking the time to help me out with this!

[DGXSER]

That thing has been tortured for sure. But it has possibilities fo going stock, the frame looks to be mostly if not completely intact.

The compression numbers look fine. Especially if it sat for much time at all. The FSM recommended 142 is a warmed up engine, yours was cold.

Teh issue with secodn gear and such in the transmission will not show up until you put the gears under power when the bike is running. But, by the time your done with the work you have ahead of you, that will be a simple fix.

As to the stuck screws, the most effective way I have fund to deal with those is use a dremmel tool with a cutting wheel to carve a straight slot through the top of the screw, so it can be turned with a straight blade screw driver. Then go to the hardware store and buy some allen head bolts to install in place of those screws.

You may want to look in the tech tips section and find the thread on carb cleaning. Very informative read with great photos as well.

[ashpave]

Thanks DGXSER, it has been abused for sure, my goal is to have it ready by march, the carbs are frustrating as I need small screws and washers for internal parts, it almost looks like somebody took them apart and robbed pieces from the guts, nothing major, just washers inside, and springs for the idle mixture adjustment screw and the idle mixture screw. I think I should buy a junk set, and make a good set between the two.

I used a larger side drill bit to screw out the majority of the head of the screws, then tapped in a flat head screwdriver, and zipped the screws right out.

[DGXSER]

First thing you may want to do is look over the carb identifier guide to determine if you have the 78-79 style or the 80-81 style carbs. It will also give you a good idea of where to expect to have washers or screws inside the carbs.

Also an idea on proper jetting, but with POD filters and the modified exhaust, stock jetting is probably not going to work well for you. So maybe stick to the jetting that is in there for now, unless you plan to add the factory air box and or a different exhaust..

[fredintoon]

Safety first

Hi Jay,
after you are sure the engine will run, FIX THE BRAKES! before you do anything else.
That way you will at least be able to stop the thing once it fires up and you yield to temptation and try it round the block.
The XS11 forks are pure 1970s flexi-flier, it'll need the brace effect of the front fender to keep the forks honest and the addition of a Tkat fork brace will be the best $100 you'll ever spend.
And man, those apes just gotta go.

[ashpave]

I dont know what I want to do with the look of the bike yet, Ive got several handlebar sets/tanks/fenders laying around to do something with, I just want to get the essentials down, then ill start playing with the look. Good call on the fork brace, and your right, after I go through the carbs, brakes and electric are on the top of the list.

[rs2289]

You have as much work to do as I do. I agree with looking at the engine and electrical as a good starting point. Everyone here as great advise. Use the search function judiciously! Most topics have great walk through s, many with pictorials.

I know someone here posted previously where to download a PDF of the service manual, which IMHO is the first thing you should do before working on the bike.

[thibtyson]

I definitely agree with RS229 that a manual is a great place to start. I would be lost without it. I printed my manual out and put the pages in protective sleeves and put it in a binder. That way my greasy hands don't get the pages all nasty.

[mikubuilder]

to get the manual search for member CatatonicBug and go to his private web page, you will be able to download your year specific manual....a must have IMO

[ashpave]

okay, so last night my daughter accidentally washed my carb gaskets in our washer machine, so they broke up and were ruined, I guess I should have kept a better eye on them, so anyway, probably worked out better, I bought a set of 2002 zrx 1200 carbs off of ebay for $225.00, yeah, more money than I wanted to spend, but im sure it will be worth it, I also ordered some TC bros forward controls! Now the wait so I can put it all together!