1980 XS11 Special - Ugly Duckling Rebuild

[BillyRok]

Or here is what Mack did when he had that problem --

http://www.xs11.com/forum/showthread.php?t=39867&highlight=motor+mounts

[kboehringer]

TC & Billy,

Thanks for those links. I've dealt with bad bushings and mounts in my older cars and knew I could come up with a viable replacement. I like the sway bushing idea as I probably have a couple sets of those in the attic.

In order to get back out riding today I used the spare set I had with a couple wraps of electrical tape which tightened them up well. I don't expect that temp measure to last long. I took the bike for a ride and there is a TINY improvement.

Since the rear mounts are going to require a significant amount of disassembly I won't address them immediately. They'll have to wait til after XSSE. I think I can get the fronts done beforehand which should help a little.

At least I know/believe the bike is not about to "GRENADE" as I was getting a little scared....

Hope you guys enjoy the rest of the Labor Day Weekend.... I'm about to take the 11 over to a picnic. My youngest son is driving the Maxim

Sincerely,
Kurt

[TopCatGr58]

Hey BillyRok,

Thanks for that! Steve made a bunch of tech tips the last few years, guess I missed that one!

I read it, and have a question for MACK, or anyone. I see that the OEM's have flutes. The aftermarket ones as well as the customized ones(aside from Mack's) are solid. Mack went to the trouble of cutting flutes into them.

My question is why are the flutes required, or are they? I am thinking that they allow a little expansion/compression action as part of the dampening affect as the engine flexes in the frame under varying loads. But then I think this same flexing is what causes the wear of the flutes similar to what happened to Kurt's, and that the solid design might not wear as easily/quickly??

I like the simplicity of Mack's parts he used...but am just wondering if it's really necessary to make the flute cuts, or just install them solid !?

T.C.

[kboehringer]

NO Power - OEM Main Fuse Holder Failed

XS Folks,
The duck is basically done but I'm still dealing with some minor issues. In prep. for the XSSE I'm replacing some stuff that might be serviceable for a good while, or might not. New throttle and clutch cables installed as a precaution as they appeared to be OEM equipment.

I went to take 'er for a test drive and turned the key to find NOTHING. A little wiggle of the main and she came to life. We're not gonna want to deal with this crap hundreds of miles from home at XSSE.



Cooper/Bussman offers this water resistant ATM fuse holder (Part #BP/HHU) rated at 30amps with enough length on the leads (5" #12) to go all the way to the OEM 2-prong connector. The cap provides a mounting tab that will allow for easy mounting NEAR the stock location using the air filter assy. bolt.

One less thing to worry about and one more check mark on the DONE LIST.

Respectfully,
KURT

[MPittma100]

Alternative

XS Folks,
The duck is basically done but I'm still dealing with some minor issues. In prep. for the XSSE I'm replacing some stuff that might be serviceable for a good while, or might not. New throttle and clutch cables installed as a precaution as they appeared to be OEM equipment.

I went to take 'er for a test drive and turned the key to find NOTHING. A little wiggle of the main and she came to life. We're not gonna want to deal with this crap hundreds of miles from home at XSSE.



Cooper/Bussman offers this water resistant ATM fuse holder (Part #BP/HHU) rated at 30amps with enough length on the leads (5" #12) to go all the way to the OEM 2-prong connector. The cap provides a mounting tab that will allow for easy mounting NEAR the stock location using the air filter assy. bolt.

One less thing to worry about and one more check mark on the DONE LIST.

Respectfully,
KURT

Hi Kurt, That is a good replacement.

There is another alternative that also works well. I use them in a lot of equipment. Can be used as a tool for finding shorts.

It is an automatic reset circuit breaker. If a short (permanent or temporary) trips it, it will reset automatically. Item can be found at most auto parts stores in 10-30 amp configurations. The terminals can be trimmed off for better fitment. It can be covered with heat shrink tubing to prevent shorting. They are very reliable. Have had them in applications for many years. Much more productive than a fuse.

[kboehringer]

The DUCK is DONE!



The DUCK is DONE!

I wanted to make a final post to this thread to extend a sincere thank you to all of those that provided help with my XS11 “Ugly Duckling” project.

I attended the XSSE Rally with my wife Nancy and “The Duck”. The bike ran basically flawlessly. “The Duck” accumulated slightly less than 900 miles: to, during, and from the rally in rain and sunshine without any issues.

Although I consider myself a skilled mechanic, I did not have the knowledge or experience to pull of turning this bike into a reliable “fun machine” without your help.


Deal's Gap - THE DRAGON!


FUTURE PLANS:
There are a few minor improvements I would like to accomplish including a big bore kit and maybe even digging into the gearbox to accomplish the 2nd gear mod. I’ll handle any help needed with those items in the normal forum threads.

Now that I have been thoroughly stung by the XS11 bug, I’m scouring the web daily looking for another XS11 restoration candidate!

I also hope to share what I’ve learned with others on the forum whenever possible.

Thanks again for all your guidance!

Very Sincerely,
Kurt

[Prisoner6]

Done!

Kurt,

I have followed this thread from the beginning, and I don't think there's any doubt in anyone's mind that you are indeed a skilled mechanic.

Congratulations on a job well done ... The Duck looks great!

[Stralya]

I wonder if James England got his 100 from here?

If so, the two I bought from him are installed in both my rear wheels and are performing well.

If these are the real deal, I imagine there would be enough of us to order 100 and work out a way to share shipping costs. Just putting this out there as a possible solution to the left rear wheel bearing woes we all have from time to time.

http://www.alibaba.com/product-detail/High-Performance-Na-5904-Needle-Bearing_857287146.html?spm=a2700.7724857.29.48.OMUDz0

Dan.

[trbig]

If so, the two I bought from him are installed in both my rear wheels and are performing well.

If these are the real deal, I imagine there would be enough of us to order 100 and work out a way to share shipping costs. Just putting this out there as a possible solution to the left rear wheel bearing woes we all have from time to time.

http://www.alibaba.com/product-detail/High-Performance-Na-5904-Needle-Bearing_857287146.html?spm=a2700.7724857.29.48.OMUDz0

Dan.

Hey, Dan! Good to hear from you. I'm not on as much, but I was wondering if you fell off the Earth way down under.

[Cyclechrist]

Fuse box

So here's where I moved thins plus i put in a badlands led box.

[kboehringer]

Thought an updated photo of "The Ugly Duckling" would be appropriate for this very old thread.

I drive this bike regularly and it remains my favorite..... These photos taken at the VINTAGE YAMAHA RALLY 2021.

Hard to believe I've had this bike more than eight years!!!!







Been a few minor changes including the Factory Sport Fairing but nothing really big. Bike starts and runs perfectly!

[bajagill]

I just started on the same journey.... but, so far, I have only found some neglect over time issues without any of the electric "customization" issues you had. Still a great looking bike!

[kboehringer]

I just started on the same journey.... but, so far, I have only found some neglect over time issues without any of the electric "customization" issues you had. Still a great looking bike!

Good luck with the rebuilding process. It is a lot of fun to do and especially fun when you can drive the thing regularly.

After this one I've finished two more XS11's and am finishing up my 4th. Without a doubt, this one will remain my favorite XS11. Everything just seemed to work out great with this one and as my first real VINTAGE bike, it holds a special feeling.... Damn thing goes like a bad out of hell too.....

[bajagill]

Thanks... just got in frt n rear tires and (hopefully) my speedo cable by Friday. Getting. So. Close.

[JonnyO]

Well, you've got your hands full, I'll grant you that.
Good to be young.
Myself, I've found it's worth the wait to find something that's belonged to someone who cared for that "pristine" bike. The amount of time required ( and money ) to get it into shape I no longer have.
I applaud your enthusiasm and look forward to seeing your progress.
As far as the wiring harness goes I think you should ask around for one from one of the members here. Just a thought.