1980 XS11 Special - Mayberry Duck Rebuild

[kboehringer]

Wheels Done - Balanced & Installed

Looking forward to seeing that wheel balancing stand and weights. I use milk crates and old style automotive lead weights.

My new balancer rig.....

Purchased on EVIL-BAY (Link below)
http://www.ebay.com/itm/272000148265...%3AMEBIDX%3AIT
1/4oz Weights Purchased for less than $5.00
http://www.ebay.com/itm/151645219494...%3AMEBIDX%3AIT

XS Folks,
The new balancing stand arrived today and was put right to use. It was purchased on Evil-Bay for $32 (shipped). Those that followed my other bike build know the difficulties I've had with the local Yamaha dealers: 1.) The dealer to my north apparently did a balance but unfortunately mounted the tire in the wrong rotation direction, I guess they didn't understand the ARROW I placed un the rim. 2.) The dealer to the South did a nice job of mounting although I suspect they didn't actually balance the wheel. They installed the completely wrong tire (tube type).

Although I've had a bunch of experience with dirt-bike and enduro bike tires I had none with big street bikes. I decided it was time to do it myself! Honestly, not at all a big deal....

The front was barely off and only needed 1/4 oz. to get it into static balance.

The rear required 1.5 oz to get the same result.....



Today was good day as I finally got these wheels back on the bike!

Drive Shaft Cleaned & Lubed
Oil Change in Mid & Final Drive
New Tires
Blasted, Polished & Re-Painted XJ Rims
New Swing Arm bearings & seals
ALL New wheel bearings & seals

Although the brakes work I have not rebuilt the calipers yet. I should not have to remove these wheels again for several thousand miles (fingers crossed!).

Kurt

[Radioguylogs]

Nice

Hey Kurt- you're getting way ahead of me....making me look lazy

That wheel balancer is the cat's meow. Easy to rationalize at $32 compared to paying someone more than that to do it wrong. I struggled a little when I did the tires on both my triples by myself- but it felt good to do it myself.

After the brakes, you are almost done?

[kboehringer]

Not even close to done.....

Hey Kurt- you're getting way ahead of me....making me look lazy

That wheel balancer is the cat's meow. Easy to rationalize at $32 compared to paying someone more than that to do it wrong. I struggled a little when I did the tires on both my triples by myself- but it felt good to do it myself.

After the brakes, you are almost done?

Mike,
I wish I was close! I actually have quite a bit to do, assuming my 2nd gear fix is actually fixed? Once I rebuild and polish the calipers the "Wheels" will be done.

I paid $35 labor twice for mounting & balancing, plus the cost of the wrong tire the dealer would not eat. Therefore, doing it myself has already long paid for itself with just this XS11. My third XS11 (Dead Duck) also needs new tires so I'll be way ahead of the game with my own balancing rig and the $5 in weights will probably last for 20+ years!

I have the following to complete, off the top of my head and in no particular order:

• Three intake valves are off and need new shims (all others in spec). Unless I find more redneck sanded shims in which case they will all need new shims.
• I might pull the head to replace the 35 year old valve seals and de-carbon the head and lap the valves.
• Carbs seem good but will get another round of cleaning & adjustment.
• Exhaust does not exist but I have another set of Harley muffs or might buy a better set. Currently only head pipes.
• Saddle bag brackets need to be modified which will be a TON of fabrication work & welding. Bags themselves are ready for paint but are still in high-build primer.
• Fork tubes are clean and with new oil but they have some bad pitting and should be replaced as soon as a nice set can be found.
• Need a windscreen before any longer rides are considered.
• Tank & Side Covers need a finish coat and then a buff & polish. Current paint is basically a base-coat.
• There's probably 100 more small items....

I don't think I'm closer to finished than you are.....

KURT

P.S. We were hopeful we could drive to Phillies Spring Training in Clearwater but I don't think MAYBERRY will be done by that time....... Might go on THE DUCK

[HalfCentury]

Quite a beautiful build. Congrats. Using XJ wheels is interesting to see on and XS. When I look at pictures of a bike I recognize an XJ by its wheels. Your bike will be mistaken for an XJ for sure.

[kboehringer]

XJ Rims on an XS

......Congrats. Using XJ wheels is interesting to see on and XS.......

Thank you. On my first XS11 (DUCK) I purchased a set of XJ rims for temporary use while I attempted to refurbish my extremely nasty XS rims. My wife and son preferred the look of the XJ rims and voiced their opinions rather loudly, and these do match my XJ550 Maxim. At first, I didn't care for them.

Obviously, the look has grown on me significantly. When presented the opportunity to purchase another set for this bike, I jumped at the chance (thank you also to Bartman). I now have two(2) XS11's with XJ rims!

IN MY PERSONAL OPINION... of the several appearance/design changes they made on XJ series, the rims are the best thing they did to them!

Respectfully,
KURT

[madmax-im]

I'm partial to XJ rims...and the rest of the bike as well...IMHO this rendition of the XS1100 is the best looking of them all...YMMV...

[kboehringer]

Muffler Time!

XS Folks,
It's take to make the Harleys....

Like my other XS11, I'm modifying a set of Harley muffs to use them on Mayberry. I believe this set was from a sportster or a similar bike (I have almost no knowledge of Harleys). I used a set of baloney cut Dynaglide (?) mufflers on my DUCK and they work great. These will be as much, if not more, of a challenge to adapt to an XS11 and make them look good.



I've fielded a few questions about my Duck's muffler set-up and I'll attempt to provide a little better detail of the modification process as I proceed.

I've chopped the front taper/slip-on off both of these mufflers. The purpose is two-fold; 1) I will SS weld this section back on at an angle to provide the "Upswept Look" I prefer, 2.) cutting off the front also provided slightly better access to the Cat Converters which have been removed from the muffs.

The head pipes were originally from a standard and provide a nice length of straight pipe not available on an OEM Special pipe.

I'll try to provide better step photos with this mod than I did with the past set.

KURT

[kboehringer]

2nd Gear is FIXED! - (for now?)

XS Friends,
A little chilly here in Georgia but not so bad that a couple rides around the block couldn't be accomplished and test the 2nd gear replacement & washer move on Mayberry.

SUCCESS!!! IT WORKED!!! Shifts into second with no issue and does not slip out at ANY RPM. Hopefully, this is a long-lasting repair!



Thank you for all the help with that part of the build process......Time to get back to the mufflers now.... Fortunately, the neighbors did not call the police as an XS11 with open head pipes is absolutely stupid loud.

Have a great weekend all!

Sincerely,
KURT

[kboehringer]

Exhaust Thoughts PLEASE! Too Small? Too Harley?

Thoughts please.... Not sure I like this.... One possible benefit is this bike will be a BAGGER so the smaller pipes might be a benefit for clearance. If they don't LOOK good on this bike they will be partially hidden but could also end up on the DEAD DUCK. THOUGHTS ON THIS LOOK?









THOUGHTS?

KURT

[MaximPhil]

Hi Kurt,
I like the look. Very neatly tucked in. I presume there is some form of hanger hidden in there somewhere?
On a practical note I hope you have enough clearance for the axle removal for the all too frequent tire changes
Phil

[kboehringer]

Brackets & Matching

I presume there is some form of hanger hidden in there somewhere? Phil

This was easier to bracket than the Dyna-Glide pipes on DUCK were. Right side will be similar but slightly different shape


Thank you Phil.... I think this is gonna be a little like my love affair with XJ rims? At first, didn't like the look, now I LOVE them and want them on all my 11's. Hope this turns out the same.

I've got PLENTY of room for the Axle to be removed.



Now the hard part is to make them look the same from both sides, rear, and above.... Got to jimmy stuff around them to hold 'em for a 110v tack weld then drag it off to work for SS mig.



Headed back to the shop.....
KURT

[Schming]

Like!!!

Great work as usual Kurt, what are your thoughts on slash cutting the ends plumb for ease of axle removal ?

[kboehringer]

Muffs Done.......Sound Good..... Son wants 'em for Dead Duck

.....your thoughts on slash cutting the ends plumb for ease of axle removal ?

Schming,
A slash cut WOULD BE more attractive (my Duck has that). It's not necessary for removal of the axle. Unfortunately, these HOG pipes are manufactured in such a way that cutting the ends at a taper would be more difficult than the work I did on the front. The internal baffle is welded to the end of the tapered outer shell about 1/4" from the end.

The right is now done and the bike sounds GREAT (as compared to open head pipes). I found the removable heat shields I removed from these when I disassembled the HD system. My son now wants these for the DEAD DUCK Café. Guess he better go to the Flea Market to see if he can find a set for $20 like I did.

The look is beginning to grow on me....good or bad it's much better than rotted & rusted out 35 year old OEM muffs.







Respectfully,
KURT

[Schming]

Stellar Job Kurt !!!

[MaximPhil]

Hi Kurt,
Looks great. Well done.
Phil