1980 XS11 Special - Mayberry Duck Rebuild

[MaximPhil]

Hi Kurt,
When "we" did my second gear it was slipping severely before "we" opened the transmission. "We" flipped the bike. When shown the gear I could see hardly any rounding of the dog yet it was slipping out of gear constantly.
James cut the gear on a small milling machine.
I did get to help to turn the bike right side up
Phil

[Rasputin]

When I did the swap it was so needed and was filmed, far from professional but adequate enough to show.

[kboehringer]

When I did the swap it was so needed and was filmed, far from professional but adequate enough to show.

Rasputin,
Do you have the video posted? Can you send or post a link? I would very much like to see that video.

FYI. I had to walk away from this Mayberry Bagger bike for a few days as I was getting apprehensive about the gear change. I'm still not sure what is truly needed, in addition to the recommended washer move. I see NO damage anywhere. I am concerned about the starter clutch area and the very poor feel of the drive clutch. WHEN I tear into this motor I want to do everything necessary all at one time...

I went to work on the DEAD DUCK Café for a couple days, and made some great progress. Otherwise tools would have been flying (and breaking stuff ) if I hadn't walked away for a bit......

I have about 10 days off over the next two weeks so I will be getting back to Mayberry with a renewed passion.

Sincerely,
KURT

[Rasputin]

Anything that I have left from that swap has been posted on the site. Most film and pictures went away over the years. You can still see the sound it made on the site and quite a few pictures of what I dealt with too.
http://www.xs11.com/forum/showthread.php?t=31895 is one of the threads I did about the swap. The first post in that link takes you to the video of the noise it made before the swap. I forget how many posts or threads I made but I think there were 2 at least.

[kboehringer]

Pre-Christmas Vacation Update

XS Folks,
I've been dancing around the other 11's and avoiding Mayberry's gear work. Today was no different........

The rims on Mayberry are in poor condition. I have a spare set from the Duck (Duck has XJ rims) and bead blasted these clean of all the old beat up and faded coating. I'm thinking of making these body color but not too sure how that will look. Might be a little too custom/goofy?

I have some dark grey metallic PPG from my T/A's snowflake rims that will probably be a LITTLE different than stock but not TOO different.... Thoughts?


Purchased a couple VMAX ACCTs on evil bay for $20 (pair shipped ). I've read all the threads on this upgrade and it seems like a great idea without any downside or chance of damage to the machine.

Mayberry and one of the other 11's will get the VMax ACCT upgrade.

I'll stop the procrastination tomorrow and get moving on the gear fixes during the holidays.....

Sincerely,
KURT

[Radioguylogs]

Go for it

Dark grey metallic wheels would be very tasteful, should be classy with that Jetstream Blue Metallic...might consider having the same areas of exposed aluminum that the factory paint had.

Red would be goofy.

[TopCatGr58]

XS Folks,

Purchased a couple VMAX ACCTs on evil bay for $20 (pair shipped ). I've read all the threads on this upgrade and it seems like a great idea without any downside or chance of damage to the machine.

Mayberry and one of the other 11's will get the VMax ACCT upgrade.

Sincerely,
KURT

Hey Kurt,

You say you've read all the threads, just making sure you saw this one.

http://www.xs11.com/forum/showthread.php?t=19719&highlight=minute+cam+chain

Near the end is where I provided an alternative argument against the ACCT. I think the ACCT "IS" a great design and idea, but just have concerns about monitoring chain stretch vs. the OEM or a MANUAL type. I provided examples, pictures about being able to measure/monitor the amount of chain stretch with the manual version, without having to take the MCCT or ACCT out to inspect the amount of slack in the chain, or how far in towards the engine you can push the chain slack to see if it's reached it wear limits.

You're a great mechanic with an affinity for perfection, and I'm sure you would be diligent in monitoring your cam chain's wear. But the ACCT's install it and forget it approach is what bothers me about possibly some of the members that might not be as prudent about monitoring the cam chain. As has been pointed out to me before, NO ONE has reported any actual cam chain failures to the point of breakage, but these machines are getting older, and with the use of the ACCT, this could lead to excessive wear and stretch of the cam chain since the plunger pushes farther than the OEM which will allow it to stretch further than it normally would. Will this excessive stretch contribute to an increased risk of actual FAILURE? The ACCT won't allow excessive slack to occur while it's within the wear limits, so skipping teeth seems a very remote and rare possibility with the ACCT vs. the OEM. YMMV.

T.C.

[jetmechmarty]

If you beat on the old girl real hard, you should check or replace the chain at 50K miles. Otherwise, it should go a lot farther. I replaced my chain and upgraded to the ACCT at the same time. I don't worry about it any longer.

[motoman]

Thanks for the idea Phil. Since I have all the hardware removed (rivets) from the lids and buckets I will install some form of lanyard when I re-rivet the hardware. I looked at the hinge idea and the only way would be to install it on the OUTER or REAR edge. There is just not enough room to swing them up toward the seat or forward because of the structure. Both of the possible choices for a hinge on this set-up would be pretty darn ugly......


MAYBERRY PROGRESS REPORT
Exhaust Bad News...
This weekend I purchased an OEM LEFT side Special exhaust from our friend Bill Kapher for just a few bucks. I quickly found a VERY cheap and VERY beat up RIGHT online and it's headed my way. The bike hasn't had a real exhaust on it yet. Both exhausts are in pretty darn poor shape but would still be functional 'til my friend at the muffler shop has time to help me with the SS set-ups.

Unfortunately, because of the bags, an OEM Special exhaust won't even come close to fitting. Another problem with adding Standard bags to a Special! I guess this exhaust will find a new home on DEAD DUCK! Looks like Mayberry is gonna get a custom set of Harley Muffs like the DUCK!

Clutch or Second Gear Bad News....
Doesn't look like the Mayberry Duck is gonna make it easy on me! Took her for a LITTLE ride and had trouble getting her into 2nd smoothly. The clutch is trash and I have the new fibers just waiting on the Barrett springs to show. I don't BELIEVE this is the common second gear issue as the bike does not come out of gear under heavy load as I ran her to 7000 a couple times without an issue. All the linkage has been checked and nothing looks bad there. Hopefully, the new clutch will solve the issue....FINGERS CROSSED!

Crankcase full of fuel bad news...
THOROUGHLY Cleaned the carbs the other day and set the floats to spec. When I went to check the clutch linkage noticed the oil smelled of gas... YEP! Got a sticky float (or two, or three, or four), and some bad petcocks and probably a bad OCTY. Kinda figured these old parts would need more than a cleaning.

One LITTLE piece of good news....
Figured out what to do with the rear turn signals that had to be removed to fit the bags. I had some of those cheapo little signals laying around and decided to extend their wires and give 'em a try. These little things are bright as the dickens! I like 'em!



Looks like Mayberry wants to fight the idea of becoming a handsome ride! I'll win in the end but it might cost me a small fortune......

Respectfully,
KURT

Bike lookin' nice Kurt!...........still like better what's setting there on four wheels to the right of the bike.

[kboehringer]

Off topic....Maybe Not?

Bike lookin' nice Kurt!...........still like better what's setting there on four wheels to the right of the bike.

Brett,
"YOU" like the car better? Wow? Thanks! I guess the car is in a lot better shape, at the moment. Here's a better look at 'er, I'm pretty proud of my work on it:

https://www.youtube.com/watch?v=KRFw1yvjYgs

-------


The poor 'ole girl hasn't gotten much attention since the XS11's starting showing up next to her. Honestly, last weekend was the first time in MONTHS I drove it I had to get 'er out and washed off as all the grinding, welding, and sanding on the XS11's put a bit of crud on 'er. I took her for a short ride, smoked the tires once or twice and set her back in her space.

How's this XS11 related?
Well, the T/A is the only car in my stable (excluding my Z-28) that could easily drag a bike trailer (it could probably drag an 18 wheeler). It's my plan to set-up a custom hidden hitch/receiver hidden behind the GA plate. I might drive one of my XS's to XSSE '16 and have Nancy trailer another with the T/A. If we have another rainy weekend (fingers crossed not) I can drag a couple 11's and not have to deal with ATL traffic in the rain.

The Thrill of the "Hunt" and Restoration:
For SEVERAL years I hunted parts and pieces and made incremental improvements to the T/A. It was in a similar crap/POS condition as my XS11's. It's basically finished and not quite as much fun anymore.

Sanding, Painting, Buffing, Rebuilding Heads & Valves, Rebuilding Carbs, Packing Bearings, and Making HD muffs fit an XS11 are just some of those accomplishments you don't get with a ready-to-ride purchase. Restoring a POS is a LOT more FUN for ME than buying one ready to ride.

I love the thrill of the hunt and have found several local junk yards and people with Yamaha's ready for parts pickin! I also watch the web for those hard to find bits & pieces. Now, the XS11's had US hunting parts and traveling all over the region: Ugly DUCK=Huntsville, Alabama, DEAD DUCK=Soddy Daisy, Tennessee, MAYBERRY DUCK=Mount Airy, North Carolina, 1980 STD Parts Bike/Motor=Bowling Green, Kentucky.

Why's the XS11 better than a 455 T/A?

• I've lived in Georgia for nearly 20 years but not until I was cruising around the state on the XS11 DUCK did I realize how really nice this State is! It's actually beautiful in many areas (not ATL ).
• After SEVERAL years of car shows, I didn't meet as many cool people at all of those car shows as I met at ONE XSSE Event!!!!!
• Also, my wife enjoys the back of the XS11 a lot more than she does the T/A. No radio, no rumbling 455, etc.

Very Sincerely,

[oldyam80sg]

Just curious-why does your video say Pocono Mountain? Your screen name? By the way-I like the color-definitely one of a kind!

[kboehringer]

Just curious-why does your video say Pocono Mountain?

Oldyam80sg,
I spent most of my life (aside from a long hitch in the Navy) in the Poconos. I was raised in Pocono Lake, Graduated from Pocono Mountain High School, purchased by first home in Pocono Pines after the Navy, ran my family owned print shop in Pocono Lake for 13+ years, all my children(4) were born in the Poconos. My screen name for YouTube is "MrPoconoMountain", my personal e-mail addresses all have "poconos" in them.

Unfortunately, the place I knew & loved no longer exists...... It's now a bedroom community for NY & NJ.

Kurt
Peachtree City, GA.

[oldyam80sg]

Some of the best riding is in the Poconos!

[motoman]

Brett,
"YOU" like the car better? Wow? Thanks! I guess the car is in a lot better shape, at the moment. Here's a better look at 'er, I'm pretty proud of my work on it:

https://www.youtube.com/watch?v=KRFw1yvjYgs

-------


The poor 'ole girl hasn't gotten much attention since the XS11's starting showing up next to her. Honestly, last weekend was the first time in MONTHS I drove it I had to get 'er out and washed off as all the grinding, welding, and sanding on the XS11's put a bit of crud on 'er. I took her for a short ride, smoked the tires once or twice and set her back in her space.

How's this XS11 related?
Well, the T/A is the only car in my stable (excluding my Z-28) that could easily drag a bike trailer (it could probably drag an 18 wheeler). It's my plan to set-up a custom hidden hitch/receiver hidden behind the GA plate. I might drive one of my XS's to XSSE '16 and have Nancy trailer another with the T/A. If we have another rainy weekend (fingers crossed not) I can drag a couple 11's and not have to deal with ATL traffic in the rain.

The Thrill of the "Hunt" and Restoration:
For SEVERAL years I hunted parts and pieces and made incremental improvements to the T/A. It was in a similar crap/POS condition as my XS11's. It's basically finished and not quite as much fun anymore.

Sanding, Painting, Buffing, Rebuilding Heads & Valves, Rebuilding Carbs, Packing Bearings, and Making HD muffs fit an XS11 are just some of those accomplishments you don't get with a ready-to-ride purchase. Restoring a POS is a LOT more FUN for ME than buying one ready to ride.

I love the thrill of the hunt and have found several local junk yards and people with Yamaha's ready for parts pickin! I also watch the web for those hard to find bits & pieces. Now, the XS11's had US hunting parts and traveling all over the region: Ugly DUCK=Huntsville, Alabama, DEAD DUCK=Soddy Daisy, Tennessee, MAYBERRY DUCK=Mount Airy, North Carolina, 1980 STD Parts Bike/Motor=Bowling Green, Kentucky.

Why's the XS11 better than a 455 T/A?

• I've lived in Georgia for nearly 20 years but not until I was cruising around the state on the XS11 DUCK did I realize how really nice this State is! It's actually beautiful in many areas (not ATL ).
• After SEVERAL years of car shows, I didn't meet as many cool people at all of those car shows as I met at ONE XSSE Event!!!!!
• Also, my wife enjoys the back of the XS11 a lot more than she does the T/A. No radio, no rumbling 455, etc.

Very Sincerely,

.............Yeppers......was gonna be my guess as to the car it is in that pic.....saw a portion of what is the emblem on the hood. The 400incher motor is(was) hard to beat in the earlier ones. Hsd the '64Goat with the RamAir IV Judge motor I built myself. It owned the street in Durango,Colo. all the way down to Farmington,NM. back in the day(1974-1976. Had it professionally painted Firethon Metallic Red with white interior, Mr.Gasket Vgate shifter on top of the 'rockcrusher' Muncie M-21 4-spd. tranny. At the strip back 'in the day', twisted mid to hi 12's with street tires(N-50 series) and capped headers. Definitely wasn't bad for that time. Brings back lots of ole' memories.

[kboehringer]

I can see it now! Upside Down and ready for repairs.....

XS Friends,
Been a while seen I posted an update on the Mayberry Duck as I have been avoiding the 2nd gear work...I started realizing how stupid it was to continue messing around with the Saddle Bags, Instruments, Wiring, etc. when it was clear that the gear box needed to be addressed first.... Time to STOP the procrastination ......

Nancy and I managed to get 'er upside down.


Now that Mayberry is upside down, I can clearly see the damage to the gears which could not be seen when Mayberry was on her wheels.


Honestly, it really doesn't look THAT BAD but it is very much worse than some of the photos I've seen posted in other threads. There is also some visible wear on the other end of this set (5th?).

I will re-read TC's rebuild thread and any/all others BEFORE I start "Diggin' In". Fortunately, I recently acquired a spare short block with gears that look pristine compared to these!

Respectfully,
KURT