1980 XS11 Special - Ugly Duckling Rebuild

[Bergman16]

Steve,
I would hope the replacement line is a single piece from master to the caliper. Personally, I'd be much happier (and feel safer) with a single line. That little chunk of solid isn't any more resistant to damage than a SS line in my opinion. Also, using a one-piece lines eliminates two(2) potential leak points/unions.

I looked at the offering from Chachal/Len (?sp) over on XJBikes.com and I'm not sure if it replaces all with one piece or not. If it does not replace the whole soft/hard/soft assembly with a one-piece hose I'll have it made locally by Pirtek.

Thanks for the question....not off-topic at all.

Sincerely,
Kurt

My rear is rock solid with that one-piece line, good to know that you think it's just as safe.

[3Phase]

Chacal has both types: single line master-to-brake or O.E.M.-style separate lines master-to-fitting-to-brake with a new middle fitting sold separately.

.

[jetmechmarty]

Those tires didn't really need the date read. They flunked the feel test. They're hard as stone. Replace the front, preferably with one to match the rear.

Does your wife know you're blaming her for lack of parts on a public forum?

[kboehringer]

The Bride.

Does your wife know you're blaming her for lack of parts on a public forum?

Actually, YES. She tends to take the back seat (XS or XJ) or the passenger seat (Trans Am or Camaro) but she's watching the threads a little bit checking out what I post. She's also making sure I respond to help requests from Pontiac forums and such. When we get to XSSE I'm sure she'll get ribbed for shutting down the checkbook...

But, If she didn't give me that funny look once in a while (like when 5 packages show up in one day) we'd have a bunch of really nice toys to play with but no home to keep 'em in.

After 30+ years, I only need to look at her face to know I better not buy anything else for a while!

KURT

[TopCatGr58]

That's why they are called SWMBO's!

If you don't know why we call them that...there's a list of Acronyms we use in the MISC forum. I don't know IF the Pontiac guys/girls use it or not?

It stands for She Who Must Be Obeyed.

T.C.

[kboehringer]

Yama-Harley?

XS Folks,

OK... go grab a trash can or maybe something else to catch with in case you quickly get an upset stomach..... I posted in the "Product Evaluation Thread" my severe disappointment with the EMGO mufflers.... won't continue that here.

Get ready.....Here goes.....



Marty mentioned I should do a little "dumpster diving" at the local Harley dealer as one of the first things a new Harley owner does is buy an aftermarket exhaust. Their OEM pipes are actually top quality and just get tossed in the trash.

I mentioned my need for REAL mufflers at work and the following day a guy showed up with a pair of freebies from his dad's Harley. They have a couple scratches on them but nothing big and apparently were used for a very short time before being replaced for drag pipes.

At first glance I thought these things are far too big. But I took them home anyway. Now that they are next to the bike they may not be too big after all? The inlet is 1-3/4" like the Yamaha Head Pipes, they are rated to perform below 80db and might actually work.

Unfortunately, I don't have a tire & rim to get the real look as they are both at the Yamaha dealer (pick-up tomorrow). The rear hub is getting a fresh shot of paint.

These Mufflers COULD actually work with a little modification...... I have some pretty darn good TIG skills so I could shorten 'em a little near the lower taper and NO ONE would be able to tell they were shortened.

If anyone got an upset stomach from seeing Harley parts near a Yamaha I apologize for making you sick....

Sincerely,
KURT

[madmax-im]

Kurt thats a good alternative and you arent the first one to use HD mufflers...they'll be fine and so will we... If anything those Emgos look like crap compared to the HDs'

[jetmechmarty]

Good move!

[kboehringer]

Big Improvements Today....Ugly Duckling Update

XS Folks,
I got the Yamaha dealer to mount my new Pirelli Route as getting the old ones off the old XS rims was so hard I had to cut 'em off. Figured it was worth the money to let them do it with a machine designed for the job than screw up the rims with nicks & dings.




In addition to the nice new Pirelli, the following overdue PM work was completed:

• New Rear Wheel Bearings, Packed with high performance grease.
• Cleaned and properly lubricated final drive to shaft coupling gears.
• Cleaned, flushed, and polished rear master cylinder.
• Cleaned and lubricated wheel hub to final drive gears.
• Torqued all fasteners to spec.

I couldn't help the urge and took 'er for a little night time ride around the block. Feels MUCH better and vibration is clearly down from previous. There is still a little bit of vibration which will probably disappear with the new front bearings and tire. I'll be ordering a matching front Pirelli on 8/1!

Kurt

[madmax-im]

Awesome job...its a pleasure to follow your progress...

[kboehringer]

The cost of repairing a POS

XS Folks,
Thought you'd get a kick out of how much this dummy has spent on this bike.

Within a day or two of purchasing this SG I had an estimated cost and a parts list that was at/about $1500 (TOTAL). In some cases I had no estimated cost as those parts were things I had not seen or were discovered later. I've kinda stopped putting in estimates as that was part of the initial planning and is irrelevant at this point except for parts still needed. You will note that in SOME cases I got a really good deal vs. my estimate(s). In other cases my estimates were far from realistic.



It's in a pretty decent condition now, but has clearly gotten out of hand.

This post may have some value to others (especially those just starting a rebuild) as it shows how quickly the repair costs escalate. Also, all of this work, other than the actual mounting of the rear tire to the rim was performed by me. If I had needed a technician to perform ANY of this work the costs could easily be double.

I keep thinking of that SG I've seen for sale in Atlanta for $2500. Although every conceivable broken part will be repaired or replaced during this rebuild I'm pretty sure that bike for sale at $2500 will still be a better looking and performing example of the Classic XS11.

Have a laugh on me...

Respectfully,
KURT

[madmax-im]

No Sir ...no laughing here...I bought my XJ1100 maxim brand spankin new back in early '83 and paid full retail...which at that time in NJ was about $3500...I kept it 30 yrs too...and in that time joining here i have seen many folks get theirs for dirt cheap and in decent condition...always felt like a kick in the gut...
Your ugly duckling isnt ugly anymore...and folks have been known to spend even more...so you have done quite well I applaud your efforts and Thanks for saving another fine example of what we so love to see on the road again... BTW we have yet to see those HD pipes installed so if you have done that please by all means post up some more pics...

[MaximPhil]

Ku rt,
That lovely new tire, in the picture , is covered in mold release from the manufacturing process.
BE VERY CAREFUL for the first 100 miles as it is slippery
I always scrub my new tires tread with a scrubbing brush and dish detergent
Phil

[MPittma100]

Value

Kurt, the value of these bikes increases every year. That is a fact. You've just increased the value of yours.

Two ways to realize value:

One is a bike priced at $500 that needs $4000+ worth of work to get it decent.

The other is a bike priced at $4000-$5000 that is cosmetically and mechanically sound that needs nothing.

There is a market/demand for both.

[bikerphil]

That lovely new tire, in the picture , is covered in mold release from the manufacturing process.
BE VERY CAREFUL for the first 100 miles as it is slippery
I always scrub my new tires tread with a scrubbing brush and dish detergent
Phil

Mineral spirits on a shop rag works well too.