1980 XS11 Special - Mayberry Duck Rebuild

[Radioguylogs]

Intake screen on oil pump?-But you would have seen it easily.

[kboehringer]

Starter Springs?

Intake screen on oil pump?-But you would have seen it easily.

Mike,
No it's not that. The intake screen looks good, actually better than The Duck did. I think this could be a chewed up small spring of some sort. But the clutch springs are much heavier and they'd have a heck of a time getting out of the basket.

I've yet to pull the starter on Mayberry but it makes a very crappy noise when it disengages. I had the one on DEAD Duck out and I rebuilt it but I don't recall a spring on the actual starter. There may be one inside the cases related to the starter? I'll look at the parts breakdown and look for a small spring somewhere......

Whatever this is....It got MUNCHED!

KURT

[MPittma100]

Tool

There are dial indicator adapters that screws into the spark plug hole for checking TDC.

[MPittma100]

Fod

TC,
That's a good idea ,to share it. We don't buy too much from Grainger (we prefer McMaster-Carr) the parts coordinator orders Grainger only once or twice a week or so. He'll be adding my roll of wire to the next order. I should have it within a week.

The parts guy printed out the spec sheet with the numbers & etc. and it's sitting on my desk at work. When I get back to work Monday I'll post up the numbers & a link.

NEW TOPIC: WIRE IN OIL PAN
I pulled the oil pan to see what I could find and found something I didn't want to find....

Anyone have any idea where WIRE would come from? This is not shavings from a bearing it is truly metal wire. Could this be from the clutch?
Thoughts?

KURT

Not sure what this is, but I'm guessing it may be from the transmission.

[DiverRay]

It looks all round, and not flat like a locking clip. It almost looks like a someone put something in the pan?!?! Almost ALL the springs in the engine are larger diameter than that.

[MaximPhil]

Kurt,
I wonder if it a a left over from when the head was removed by a PO.
Used to secure the timing chain then
accidentally dropped down the tunnel ?
Phil

[kboehringer]

Unknown Wire....

It almost looks like a someone put something in the pan?!?! Almost ALL the springs in the engine are larger diameter than that.

Ray & Phil,
Thank you for the input. I hadn't thought of something foreign that didn't belong there to begin with. Maybe some form of intentional or unintentional sabotage like a wire to hold the cam chain as mentioned. The wire really reminds me of "safety wire".

Like all my XS's I don't know the REAL mileage on any of the engines as the speedo is either not original to the bike in the case of two of them or there just isn't a speedo in the case of '81 Dead Duck with it's '79 engine. I was very surprised not to find more debris from age/use/wear in the pan, only the wire. Being 35 years old, the pan must have been removed at sometime earlier but it must have been a LONG time ago!

Before I put the pan and oil filter housing back on I looked up in the gear box and there was no OBVIOUS damage of anything that I could see. Actually looked very nice.

Early yesterday I pulled the starter, completely cleaned out all the old carbon, lubed the gears, polished the comms (with a comm cleaning stone), and tested. No longer makes ANY funny noises. Sounds like new!

Now that I'm done replacing my Daughter-In-Law's ABS control system, I can get back to MY fun stuff for Sunday

Today, I will pull the clutch side cover and make a thorough inspection of that area. I need to make sure there isn't anything else "CHEWED UP" in there before I set TDC and attempt to start the bike again.

Respectfully,
KURT

[kboehringer]

MMO Smoking out the neighborhood.....

XS Folks,

Got a bunch of stuff accomplished so now I can slow down a bit....

The bike needs A LOT (not quite what The Duck Needed) but I was very anxious to test all the repairs I've accomplished.

• Replaced the Ignition Pick-Up Damage
• Reset the ignition to TDC.
• Repaired all the misc. wiring BUTCHERY
• Installed ATM fuses replacing all the glass fuses
• Cleaned the carbs (basic clean, will need to be done again)
• Pulled the pan and oil filer cleaning and polishing both.
• Pulled the clutch cover and readjusted clutch (Clutch seems good was severely over tightened making it seem like it was slipping when it was partially disengaged.)
• Re-Plumbed the OCTY
• Stole the head pipes off the DEAD DUCK so I could start it as the Kerker was bent and contacting the oil pan and could not be used.
• Repaired the rear brake pivot shaft

When I first got the bike home I put some MMO in the cylinders just because it seemed so helpful with The Duck. The bike started right up and didn't need the jump start I was expecting but it sure smoked out the entire neighborhood.

The attached video link taken by the wife is pretty crappy and not worth watching in its entirety except for the beginning where all the smoke from the MMO can be seen moving up the street.... They're isn't a mosquito left alive in this neighborhood.

https://youtu.be/XuWZIEWZqaU

Hope ya'll had a great weekend!

Sincerely,
KURT

[Radioguylogs]

Happy Day!

Lookin' forward to findin' that '80 Special seat?

[kboehringer]

Requested link to test lead wire for Pick-Up repairs

Or a link to buy it or at least a part #.

Here it is.....

http://www.grainger.com/product/POMO...rchQuery=4FB27

Grainger Item #4FB27

KURT

[kboehringer]

Seat needed....

Lookin' forward to findin' that '80 Special seat?

Yes! Frame rails hurt the butt!
One of our XS friends in New Jersey may have found one I can get pretty darn reasonable. Even a beat up ole' seat would feel better than the Frame rails and allow a slightly longer ride.

Unfortunately, the tires are also junk so anything much more than a ride around the block is out of the question.

The bike showed a seat in the Craigslist ad but that seat was not even able to be attached properly as it was not designed for an XS11.

Kurt

[tomcos67]

XS Folks,

Got a bunch of stuff accomplished so now I can slow down a bit....

The bike needs A LOT (not quite what The Duck Needed) but I was very anxious to test all the repairs I've accomplished.

• Replaced the Ignition Pick-Up Damage
• Reset the ignition to TDC.
• Repaired all the misc. wiring BUTCHERY
• Installed ATM fuses replacing all the glass fuses
• Cleaned the carbs (basic clean, will need to be done again)
• Pulled the pan and oil filer cleaning and polishing both.
• Pulled the clutch cover and readjusted clutch (Clutch seems good was severely over tightened making it seem like it was slipping when it was partially disengaged.)
• Re-Plumbed the OCTY
• Stole the head pipes off the DEAD DUCK so I could start it as the Kerker was bent and contacting the oil pan and could not be used.
• Repaired the rear brake pivot shaft

When I first got the bike home I put some MMO in the cylinders just because it seemed so helpful with The Duck. The bike started right up and didn't need the jump start I was expecting but it sure smoked out the entire neighborhood.

The attached video link taken by the wife is pretty crappy and not worth watching in its entirety except for the beginning where all the smoke from the MMO can be seen moving up the street.... They're isn't a mosquito left alive in this neighborhood.

https://youtu.be/XuWZIEWZqaU

Hope ya'll had a great weekend!

Sincerely,
KURT

That's what I want my bike to sound like.!sounds good!!?

[HalfCentury]

It sounds like your brakes are partially seized. Is it difficult to push? My front sounded like that and eventually fully seized in my driveway. Lucky they did not seize driving it resulting in a header over the handlebars.

Its relatively easy to push not that all the caliper soft parts are replaced.

[bikerphil]

That's what I want my bike to sound like.!sounds good!!?

Then you have to find a Kerker.

[tomcos67]

Then you have to find a Kerker.

Yep.! Have to look into that .Bike has stock exhaust. Be nice to have a little sound!!!