1981 Rebuild Project

[gene]

Well, after almost 3 years and moving from Cali to South Florida I finally got back to rebuilding my XS 1100. I bought another stand from Harbor Freight because the old stand did not do well during the relocation. My daughter and I started yesterday again. I will post pics this weekend.

I may another set of wheels since the guy powder coating mine in Cali is not responding.

[Tat2demon]

Looking forward to the updates. I love build threads.

[DGXSER]

Excellent, is this the Special or Standard model?? I do enjoy a good build. Just finished one myself and am now in withdrawal!!

[gene]

It is an 1981 Special. Just a classic bike shape even after all these years. I almost got rid of it. I had to fight the wife tooth and nail to stay away from my boxes of parts. Glad I didn't give in. My 20 year old daughter was pretty excited to start working on it again. She helped me take it apart. Now the fun begins.

[DGXSER]

Awesome. I've had three, all specials, two 81s. Now I need a Standard just to switch it up.

[gene]

1981 XS1100 Special Rebuild

Back on the rebuild. Thought I would pull the oil pan and see how it looks. Surprise surprise....

Oil sump was just sitting on the bottom. Looks like it was never screwed on. Shifting fork #1 is missing half the fork. I have photos but I have to re figure how to post them.

[DGXSER]

Wow Gene, you have a handful of fun there! I do not have any spare shift forks, I have plenty of bolts, but they are nothing overly special anyway so you can get them at your local DIY store. You will need the positioning sleeves if they are not there.

As to posting pics, you have to load them to a hosting site, a lot of folks here use Photobucket. After you upload the pics to the hosting site, there will be an IMG code for the pic location. Simply copy the code and paste it in a blank line of your reply / post.

[gene]

[gene]

Im getting to a cross road. Is it worth using the block I have that is bored out .060 over or should I just get a stand used and use the regular piston I have. Going to cost me $500 for the wiseco big bore kit.

Not sure if its worth it.

[Gallaecus]

http://www.ebay.com/itm/80-81-Yamaha...7486d7&vxp=mtr

[gene]

Has anyone on this forum tried these kits from this manufacturer?

[MaximPhil]

Hi gene,
try doing a search of the forum. I recall some discussion about a low cost big bore kit. What I remember is it has cast pistons not forged which led to a discussion. I do not recall the conclusion.
Phil

[Gallaecus]

they also debated whether the original pistons were cast or forged.
for 500 hundred, you could buy another bike.
most claim the big bore kit does not offer much gain in power.
there is still the cost of machining.

[motoman]

they also debated whether the original pistons were cast or forged.
for 500 hundred, you could buy another bike.
most claim the big bore kit does not offer much gain in power.
there is still the cost of machining.

FWIW, original pistons WERE forged, shot-peened and chamfered rods and forged one piece crankshaft.

[gene]

Well, I split the engine case. Surprisingly it looks pretty clean.I don't see any wear on the main bearings and I am considering keeping the stock pistons and just buying a stock cylinder block.

I made a major mistake though. I split the cases and forgot to remove the alternator rotor. Any know a trick to remove this without messing up the crank.