1980 XS11 Special - Mayberry Duck Rebuild

[motoman]

Kurt, just an observation but the bags in this photo make the back of your bike look a bit droopy



While you're doing mods to the bracketry to make them fit, have you thought about kicking them up a bit to try to clear the oem pipes you've got?
Having a quieter bike will help keep your other half much happier on long trips, so it'd be well worth the effort if this is going to be your long distance bike

Actually, stock exhaust(straight) or upswept like on Specials will work perfect, with no interference from side-cases. The 81Venturer like mine come from fctory with the Special up-swept exhaust(makes it handy for rear wheel removal).

[kboehringer]

Gears Replaced..... LOTS of damage



Just goes to show you CAN'T see all the damage with the gears in the bike! Once removed, I could easily see the SIGNIFICANT damage to the gears and fork. Fortunately, the donor motor had pristine gears and a perfect replacement fork.

There is damage on the other end of the shaft so this set is basically junk. I'm wondering if this motor has significant miles on it? The original speedo is long long gone so I have no idea of mileage.

I did not do the dremel fix nor did I take the gears to a machine shop. I moved the washer and replaced the entire shaft assy. from my donor. I'm assuming (hopefully not in error) that the washer move will reduce the possibility of damage to these replacement gears. I WILL get the damaged gears out to the machine shop and have them repaired for the DEAD DUCK (just in case they are needed there).

I followed TC's instructions very closely and had only a little difficulty clearing the kick-starter shaft/gear that is present in this '80 motor. Without that shaft the gear shaft in/out would have been a 30 minute job. I considered tossing the kicker parts in the trash but wondered if I would create some other complication.

Bye for now.... time for bed.

Sincerely,
KURT

[kboehringer]

Bag Status

.......... While you're doing mods to the bracketry to make them fit, have you thought about kicking them up a bit to try to clear the oem pipes you've got?.....

Motoman,
YES. I received a bunch of help from Mike who took several photos and provided a drawing of his set-up. With those pics and the drawing I will modify my bags to the newer (Venturer) level as closely as possible. This WILL BE my long-haul XS11 and we are anxiously looking forward to getting her on the road!!!! Nancy wants to take a trip to Destin as soon as we feel confident the bike is in as reliable a condition as The Duck.

Once I get her flipped back over , modifications to the bags & mountings will be the #1 priority.

Sincerely,
KURT

[motoman]

Motoman,
YES. I received a bunch of help from Mike who took several photos and provided a drawing of his set-up. With those pics and the drawing I will modify my bags to the newer (Venturer) level as closely as possible. This WILL BE my long-haul XS11 and we are anxiously looking forward to getting her on the road!!!! Nancy wants to take a trip to Destin as soon as we feel confident the bike is in as reliable a condition as The Duck.

Once I get her flipped back over , modifications to the bags & mountings will be the #1 priority.

Sincerely,
KURT

Went out and looked at my Venturers set-up.You have everthing mounted correctly. The trunk lids taper like that intentionaly, Remember to that the trunk bases set on bottom of the large L bracket, mounted to it with thin rubber spacers/washers and the bracket IS mounted correctly. For pipe clearance, no need to modify or change them. My bought new Venturer has the upswept exhaust like the Specials do. No clearance issue whatsoever. Besides, the upswept exhaust makes for a really easy wheel removal and replacement. That large center bolt holding wheel has plenty of clearance by exhaust system with nothing extra needed to be removed. Those side cases on your bike are AS THEY SHOULD BE., with the tapered look.

[kboehringer]

Minor Update

XS Folks,

I got the whole motor back together but have BASICALLY started over with this build. Since the bike "RAN" when I got it I jumped feet-first into silly things like saddle bags and accessories but had not done the same kind of job I did on "The Duck". Then I kept screwing around with clutch springs, plates, etc. when I should have jumped directly into the transmission....

When I had the bike upside down for the gear work I realized what a P.O.S. this thing really is and how poorly maintained it is. SO....I've kinda started over fixing all kinds of broken or worn items like: wheel bearings, swing arm bearings, cables, drive shaft & tunnel clean & lube, gear box flush & lube, brake line replacement, caliper rebuilds, wiring issues, valve adjustment, carb cleaning, etc.

I've have decided to mimic the XJ rims on my DUCK and purchased a set from our friend in N. Georgia, Bartman. I've got a bit more work to do to get these ready for the waiting rubber but I like the look (didn't like it at first on The Duck). I can confirm that the XJ rims ARE lighter than the XS rims. The front XJ rim is 2# lighter than the XS rim. I haven't compared the weight on the rear rims, YET.



I won't bore ya'll with tedious updates but will post as significant milestones are reached. The Mayberry Duck won't come out of the garage until it is SAFE to ride and all the 30+ years of poor maintenance have been addressed. Then I will worry about bags, back rests, and B.S.

KURT

[motoman]

XS Folks,

I got the whole motor back together but have BASICALLY started over with this build. Since the bike "RAN" when I got it I jumped feet-first into silly things like saddle bags and accessories but had not done the same kind of job I did on "The Duck". Then I kept screwing around with clutch springs, plates, etc. when I should have jumped directly into the transmission....

When I had the bike upside down for the gear work I realized what a P.O.S. this thing really is and how poorly maintained it is. SO....I've kinda started over fixing all kinds of broken or worn items like: wheel bearings, swing arm bearings, cables, drive shaft & tunnel clean & lube, gear box flush & lube, brake line replacement, caliper rebuilds, wiring issues, valve adjustment, carb cleaning, etc.

I've have decided to mimic the XJ rims on my DUCK and purchased a set from our friend in N. Georgia, Bartman. I've got a bit more work to do to get these ready for the waiting rubber but I like the look (didn't like it at first on The Duck). I can confirm that the XJ rims ARE lighter than the XS rims. The front XJ rim is 2# lighter than the XS rim. I haven't compared the weight on the rear rims, YET.



I won't bore ya'll with tedious updates but will post as significant milestones are reached. The Mayberry Duck won't come out of the garage until it is SAFE to ride and all the 30+ years of poor maintenance have been addressed. Then I will worry about bags, back rests, and B.S.

KURT

Aww....C'mon.......cosmetic touch-ups are always fun when done correctly

[Radioguylogs]

Can be fun?

"I've kinda started over fixing all kinds of broken or worn items like: wheel bearings, swing arm bearings, cables, drive shaft & tunnel clean & lube, gear box flush & lube, brake line replacement, caliper rebuilds, wiring issues, valve adjustment, carb cleaning, etc."

Can be fun and interesting to putz with new parts if we don't put ourselves under pressure. I'm thinking about doing the splines, swingarm, and neck on the Bagger "while I'm at it".....'cause it has more miles and I need to learn those things for my other bikes.

[kboehringer]

Forks & Trees

..I'm thinking about doing the splines, swingarm, and neck on the Bagger "while I'm at it".....'cause it has more miles and I need to learn those things for my other bikes.

Mike,
I did the neck on all my bikes when I cleaned the forks. I was 75% there with the forks off for cleaning so I went and pulled the tree and cleaned an repacked the bearings. ALL of them were in horrible lube condition but the bearings all seemed fine once completely cleaned and re-packed.

I don't know if you have cleaned your forks yet (?) but my experience seems to reveal that NO ONE (aside from the folks here at XS11.com) clean and flush the forks in any meaningful fashion. I of course have the three sets the bikes came with, plus two additional sets I purchased on-line. The insides of EVERY set looked like absolute MUD. Some forks had no oil remaining in them just muck. If you're thinking about doing the trees, do the forks and replace their seals too!

Respectfully,
Kurt

[Radioguylogs]

Yup

Kurt:

I did the forks on my other 3 bikes already. It was just as you described- mud inside. I put new seals all of them and I have the seals for the Bagger in hand.

I had one dented fork stuck in the down position on the XS1100SF when I acquired it. It was very strange.

One of my XS750s leaked fork oil for 30 years until I finally got the attention span to figure out why and fix it.

Now....on to the leaky forks on the Bagger.

Meanwhile, I never did the neck on the other bikes because it seemed you needed a special tool to loosen the nut on top. I have to find one of those tools. I've think I've seen them on e-Bay.

Thanks for the advice.

[kboehringer]

Kurt:
..... it seemed you needed a special tool to loosen the nut on top. I have to find one of those tools. I've think I've seen them on e-Bay.

Spanner wrench. I have a couple..... Will send one.

[jetmechmarty]

Hook wrench



Mike's XS has the proper wrench. Buy two. It works on many shocks as well.

[kboehringer]

Spanner Wrench - Also a correct wrench


"Hook spanners
Exact spanner radius reduces the risk of nut damage"
Hook spanners HN series
The HN series includes 15 different size hook spanners based on the DIN 1810 standard. The hook spanners are designed for use with SKF KM nuts as well as any other KM nuts conforming to the DIN 981 standard. Additionally, they are suitable for use with N, AN, KMK, KMFE and KMT as well as nuts manufactured according to the DIN 1804 standard.

• Minimizes the risk of shaft and nut damage
• Plastic handle is oil, grease and dirt resistant to provide a better grip
• The plastic handle minimizes direct metal to skin contact, reducing the risk of corrosion in the handle area
• Hole in the spanner's handle facilitates easy storage
• Designation of spanner representing its size is laser-engraved allowing easy identification and selection"

http://www.skf.com/group/products/ma...ers/index.html

[Radioguylogs]

Thanks guys!

Marty and Kurt - very helpful. I appreciate it.

Now back to our regularly scheduled Mayberry.....

[kboehringer]

Quick Photo Update

Making some progress on the "Re-Start" of Mayberry.

XJ rims cleaned, polished, painted, & new bearings. Pirelli Tires arrived last week....mounted by hand, not a big deal.

Swingarm before... YUK!

Sandblasted years of rust and several crappy paint attempts.....

Everything re-painted, new bearings, waiting on Partzilla seals.......

Waiting on seals(6), new wheel balancing stand, wheel weights.......


KURT

[Radioguylogs]

Progress!

Nice work. Makes me want a sandblaster.

Looking forward to seeing that wheel balancing stand and weights.

I use milk crates and old style automotive lead weights.