Potential new project

[jetmechmarty]

Hmmmm.... Interesting. There isn't a lot there for a US spec bike. At least, not based upon what I have.

Diablo Cycle has a link to follow and get what you need.

• Need decals that we don't offer yet?

Where you go for these probably depends a lot upon which side of the pond you live.

[James England]

Diablo Cycle has them.

they aren't correct for the XS1100, I believe......

A better set is available http://yambits.co.uk/xs1100-handleba...t-p-19832.html

[jetmechmarty]

Diablo Cycle has them.

[xs650man]

Looking fantastic James. Those decal kits for the switch blocks you mentioned, Ive been trying to find them on Ebay but no luck, can you post a link, cheers

[James England]

And yes, if it was my freshly powdercoated frame, I would definitely "mummify" it before re-installing the engine ... D

The curse of the mummy has begun...

[James England]

Here's a couple of pix of the refurbished front footrests..... Not as good as I'd like, because one of them is missing the rubber flap that goes over the folding joint..But, hopefully, one will become available somewhere......


Rear footrests...

[James England]

Switchgear

Whilst waiting for the valve shim tool, I thought I'd renovate the handlebar switchgear. Although I'd already used Deoxit in the switches, I found on stripping them that they were filthy and full of crud inside. Particularly bad was the engine kill switch which was full of green copper oxide and general filth. I can see how this little switch would cause ignition problems. It can be removed easily from the housing by undoing two screws. The switch then pops out. To get the top part of the switch off, you just remove a small circlip under the switch and the top bit pulls off, revealing the thre position switch and contacts underneath. So I dipped everything in solvent, then removed all the metal bits, derusted them in acid and then...once more...got the trusty zinc plater out again.

I stripped the crusty old paint of the switch housings, pending using PJ1 on them. There are also mini decal kits on eBay for the switches, so I'll post some pix of the finished items once they are done. If the meantime, here's where I've reached....

[James England]

I'm assuming you took the engine out the right side ...

So, to answer your question (using this assumption), I would say yes, lay the engine on it's right (clutch) side, then lift the frame onto it from the left side.

Maybe someone else will chime in with other tips and suggestions ...

And yes, if it was my freshly powdercoated frame, I would definitely "mummify" it before re-installing the engine ...

And by the way, your attention to detail on this build is amazing ... I'm sure the finished product will be stunning!!

I laughed at that.."mummify" the frame. Yes, I took the engine out from the right side of the frame, so I'll put it back I that way by lowering the frame onto the engine. All I need to do is try to make a friend who would then be able to assist me..... (That's the hard part...)

I'll keep posting pix as I go alongl

[James England]

These are the European footrests, Marty. I zinc-plated the ends and used a stainless allen bolt in each.


I put all four footrest grips (I'm reticent to use the word 'rubber' on a US site) in the washing machine and they came out nice and clean.... The reason I want a new one is that one of the front ones is missing a rubber flap which goes over the articulating bit of the peg...



Whilst waiting for the enamel to dry on the footpegs tonight, I PJ1'd the clutch perch and lever. Also zinc-plated the cable adjuster and put on the new neoprene replica lever cover. I'm still looking for the small rubber covet that goes over the cable adjuster....

[Prisoner6]

Yes, it should be much easier to get engine back in but I'll do the bandage treatment first. Am I right in saying I should put the engine lying on the clutch casing side, then lift the frame onto it..ie from the left side of the engine??

Glad you like the pix (they speak a thousand words...) and the updates. I thought maybe they will be of interest to anyone going through the same process..

I'm assuming you took the engine out the right side ...

So, to answer your question (using this assumption), I would say yes, lay the engine on it's right (clutch) side, then lift the frame onto it from the left side.

Maybe someone else will chime in with other tips and suggestions ...

And yes, if it was my freshly powdercoated frame, I would definitely "mummify" it before re-installing the engine ...

And by the way, your attention to detail on this build is amazing ... I'm sure the finished product will be stunning!!

[James England]

Looking good, James. Really good.

Thanks! I've yet to do the tricky bit....getting the crankcases coated in PJ1 without getting it everywhere!

[James England]

Hi, James -

Do you have the middle drive off the engine? That will make putting the engine back in the frame much easier, as will removing the oil pan and oil pump ...

Oh, and of course, the oil filter housing should be removed ...

Looks like things are coming along nicely ... keep those updates and great pics coming!

Onwards and upwards, indeed!

yes, I have the oil filter housing and oil cooler adapter off, the sump off and the middle gearbox out. Also the oil pump off. I also have the starter motor off for taking to bits and cleaning. Yes, it should be much easier to get engine back in but I'll do the bandage treatment first. Am I right in saying I should put the engine lying on the clutch casing side, then lift the frame onto it..ie from the left side of the engine??

Glad you like the pix (they speak a thousand words...) and the updates. I thought maybe they will be of interest to anyone going through the same process..

[James England]

James,

Are your covers supposed to look like this? XS650 covers are still available and cross to 78-79 XS1100 in the US. In a pinch, perhaps you may swap to US footrests? (just the rest, as to maintain Euro position)

No, Marty, they are different. They are not beveled at the end and they are held on with metal plates. I wouldn't want to change types, being a bit nerdy on keeping things original... I did get two new ones last time but I just can't remember where from.....

[MarkD]

Looking good, James. Really good.

[Prisoner6]

I'm somehow dreading trying to get the engine back in the frame! I'm going to wrap the frame with bandages, like an Egyptian mummy, in order to minimise damage to the lovely new powder coating..... Any ideas anyone??

Hi, James -

Do you have the middle drive off the engine? That will make putting the engine back in the frame much easier, as will removing the oil pan and oil pump ...

Oh, and of course, the oil filter housing should be removed ...

Looks like things are coming along nicely ... keep those updates and great pics coming!

Onwards and upwards, indeed!