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Hey I'm putting together a 78 xs1100 and have found some things that I'm not very familiar with. I confess I'm a total newb when it comes to bike rebuilds but it seemed like a good idea at the time. The electrical is giving me headaches and the fuel system is also posing some challenges. Any comments or suggestions would be great!
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'78 E resto/bobber project -
Very common issues. Take your time, be thorough with repairs, don't cut corners, it will come back to haunt you. If you don't have a manual, get one (download one here: http://www.ringler.us/family/mybike.html). Don't assume all parts are original either, as parts swapping on these is extremely common.
Here's some links to get you going....
Wiring:
http://www.xs11.com/forum/showthread.php?t=35337
http://www.xs11.com/forum/showthread.php?t=35339
Carbs:
http://www.xs11.com/forum/showthread.php?t=35964
http://www.xs11.com/forum/showthread.php?t=36017Fast, Cheap, Reliable... Pick any two
'78E original owner - resto project
'78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
'82 XJ rebuild project
'80SG restified, red SOLD
'79F parts...
'81H more parts...
Other current bikes:
'93 XL1200 Anniversary Sportster 85RWHP
'86 XL883/1200 Chopper
'82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
Cage: '13 Mustang GT/CS with a few 'custom' touches
Yep, can't leave nuthin' alone... -
And welcome by the way! Everything you need to know can be found here, just ask....
Fast, Cheap, Reliable... Pick any two
'78E original owner - resto project
'78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
'82 XJ rebuild project
'80SG restified, red SOLD
'79F parts...
'81H more parts...
Other current bikes:
'93 XL1200 Anniversary Sportster 85RWHP
'86 XL883/1200 Chopper
'82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
Cage: '13 Mustang GT/CS with a few 'custom' touches
Yep, can't leave nuthin' alone...Comment
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Thanks for the info. I already have the carbs apart and rebuilt and am just trying to wrap my head around re-instaling. As for the elctrical I'm gonna have to sit and stare at this stuff for a while... the diagrams may as well be greek in my eyes haha.'78 E resto/bobber projectComment
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The 'full' wiring diagrams are hard to follow (and worse yet, aren't always right). Best bet is to look in the 'electrical' section of the factory manual and look at the circuit diagrams. These are accurate and much easier to read.
The big thing on these is poor connections; just because you see continuity through the wiring doesn't mean it's good. The quality of the connections is critical, you can't get them too clean. If you still have the OEM fusebox, give serious thought to replacing that as it's a known trouble point, and overheated/melted connections in the charging system and ignition switch are also very common. The factory wiring was only adequate when new, any degrading of the connections quickly translates into 'stuff don't work'...
Fast, Cheap, Reliable... Pick any two
'78E original owner - resto project
'78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
'82 XJ rebuild project
'80SG restified, red SOLD
'79F parts...
'81H more parts...
Other current bikes:
'93 XL1200 Anniversary Sportster 85RWHP
'86 XL883/1200 Chopper
'82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
Cage: '13 Mustang GT/CS with a few 'custom' touches
Yep, can't leave nuthin' alone...Comment
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ya the original fuse box was cooked. I already put in a new panel that takes spade fuses and wired that up. Now its more about making sure that everything that requires a connection has a part to go to and cutting out whats unneeded. I have an original manual(sadly like you say its not always easyto read) and itsjust a matter of tracking everything. who ever had this bike before already tried to mod some of the electrical by the look of it so that may pose some problems for me going forward.'78 E resto/bobber projectComment
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And installing the carbs isn't bad if you do it right; the stock airbox (if used) goes in first, then the carbs. Here a link...
http://www.xs11.com/forum/showthread.php?t=35349Fast, Cheap, Reliable... Pick any two
'78E original owner - resto project
'78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
'82 XJ rebuild project
'80SG restified, red SOLD
'79F parts...
'81H more parts...
Other current bikes:
'93 XL1200 Anniversary Sportster 85RWHP
'86 XL883/1200 Chopper
'82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
Cage: '13 Mustang GT/CS with a few 'custom' touches
Yep, can't leave nuthin' alone...Comment
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Be careful about removing 'unneeded' wiring; a lot of those wires have multiple uses and there's not really that much that can be taken out if you're retaining all required equipment (turns, horn, etc). You won't save any weight worth talking about, or reduce the complexity of the harness.
Yeah, if a PO has been at the harness it can be a mess to fix....
Fast, Cheap, Reliable... Pick any two
'78E original owner - resto project
'78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
'82 XJ rebuild project
'80SG restified, red SOLD
'79F parts...
'81H more parts...
Other current bikes:
'93 XL1200 Anniversary Sportster 85RWHP
'86 XL883/1200 Chopper
'82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
Cage: '13 Mustang GT/CS with a few 'custom' touches
Yep, can't leave nuthin' alone...Comment
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good advice. perhaps then i'll leave everything intact and just not hook in what i'm not installing.'78 E resto/bobber projectComment
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