1981 XS11 Special - DEAD DUCK Cafe

[fredintoon]

Hi Kurt,
that's a real nice resto you have and Oh! The nostalgia!
That paint looks to be the same as on my 1953 BSA Gold Flash.
Mind you, that ol' BSA had mebbe nine wires in it's harness (OK, if we'd had signals back then it'd have needed twelve) not that nasty rats nest the XS11 seems to need.
And I know the real reason you converted the bike to solo seating.
To stop your kid from picking up chicks.
Ain't gonna work.

[kboehringer]

Compression stinks....Marvel mystery aint fixin it.

I know the real reason you converted the bike to solo seating. To stop your kid from picking up chicks. Ain't gonna work.

Fredintoon,
Thanks for the compliment. The color was something my son picked out and I've come to like it a lot.

The kid has a GEORGOUS girlfriend and I am happy he can't get her on the back of this thing. Riding with a passenger is best left for those of us with a good bit of driving experience, he doesn't have enough for that!

Unfortunately, it seems compression is in the dumper on this one so it won't run. I've got to rip the head off, do a leak check (hope it fails), and then rebuild the head with new seals and re-lap all the valves. If it passes a leak check it's gonna need a set of rings. UGH!

I had hoped to take this on a trip next month but that seems a little out of the question at the moment. Even if I rework the head promptly there are still a few wiring gremlins to kill and not enough time for a proper shake-down....UGH

It'll be done in a month or two but not nearly as fast as I had hoped for...

KURT

[kboehringer]

Dead Duck is DEAD! - For a week or two...

XS Friends,
I'm rushing to get the DEAD DUCK ready for prime time and she's fightin' me all the way. Got a date with a event in North Carolina at the end of April I just gotta' make with THIS bike. I couldn't get 'er started as the compression is crappy and Marvel's Mystery just and gettin' it done.

Pulled the head to do a leak check.... FAILED. That's the pretty good news.


Took the head to work today and BEAD blasted the dickens out of 'er.
Found that there was some serious water damage within the motor. Probably sat outside for some significant period of time and got water in it....Is this the new Swamp Thing? (only kiddin' MadMax).


There is some strong pitting within a couple of the combustion chambers AND a couple of the valves have a bit of pitting too. Unfortunately, this is a '79 motor and I don't believe my spare valves (1980) are the same sizes?????

I'm gonna re-lap all these valves, replace the seals and get this head "As good as I can". It will PROBABLY be ok...

Since I ordered some new rings a day or so back it doesn't make much sense to re-assemble this DUCK without installing them. The rings are all probably complete crap after sitting in water for some long period of time. I'll have to wait on the post from JAPAN.

Got a TON of other stuff to keep me busy with this one including new Pirellis front & rear, new bearings front & rear, and a few wiring gremlins yet to address...

Hopefully, ready to run at North Carolina at the end of APRIL!
Fingers are crossed and I'll be burning the midnight oil.....



KURT

[Radioguylogs]

Cost Saving

I have a flex hone if you wish to borrow it.

[madmax-im]

oh man...sorry to see ...

[kboehringer]

Lapping Lapping Lapping....Assemble Valves.... Chase some threads

I have a flex hone if you wish to borrow it.

Mike,
Thank you very very much for the offer. That would be a lot of work for you to get that to me and that offer is extremely generous. Thank you!

I do have a couple good selection of flex hones for use on this. However, I also have a bottle-brush hone that is probably capable of giving me a nice quick cross-hatch pattern without removing too much material. Since I'll be using the standard pistons with new rings I need to be careful about removing much of anything while leaving something to hold oil in the bore.

oh man...sorry to see ...

MadMax,
It may be a little ugly inside her, but I think/hope it's gonna' be ok. I'm 'bout finished with the lapping process and the seats look nice now on all the valves. The exhaust on #2 & #4 were absolutely worthless before I started on them. This alone should help boost compression to an acceptable level.

I am a LITTLE concerned about the integrity of the E#4valve. If it drops through the piston, I'll be the first to know! Although I'd like some pristine combustion chambers, the pitting in #4 (the worst) does not extend into the cylinder sealing ring area.

I'll be burning the midnight oil again tonight trying to get this DEAD DUCK closer to life again......

Respectfully,
KURT

[Radioguylogs]

Same thing

Flex hone = brush hone

http://www.brushresearch.com/about.php

Sound like you have what you need, but don't hesitate to ask.

[kboehringer]

Cylinder Honing.......

Flex hone = brush hone
Sound like you have what you need, but don't hesitate to ask.

Thanks Mike!


Got to work on 'em tonight......



The cylinders are SIGNIFICANTLY improved but not nearly as nice as I would like. Tried both the flex hones (2) and a spring loaded hone. I'm fearful of taking off too much as I could end up with an issue of piston slap or ring end gaps out of spec....

I practiced on a spare set of cylinders and if they hadn't been from an '80 with different codes on the cylinder skirts and different numbers on the pistons (only have three of them). I might have considered tossing this set aside and going with the '80 jugs.

Rings will be here tomorrow.... this will probably be a better runner than either of the other two XS11's in the stable.

Time to go and prep the pistons.

KURT

[kboehringer]

NOT so DEAD Anymore!

XS Friends,
Today, I finished the install of the jugs, head, and readjusted the valves. Compression is now up about 50% to about 100# (prior to starting). I hope the new rings will seat after a little running and getting hot to increase the compression.

http://vid1353.photobucket.com/albums/q679/poconos/IMG_0349_zps9xkwaqjx.mp4

http://vid1353.photobucket.com/albums/q679/poconos/IMG_0350_zpsnpkqpqbo.mp4

This is the FIRST time I've actually had this one running. New Rings, Cylinders Honed, All Valves re-lapped....VAROOOOOM! Old mufflers shot rust and debris all over my shop....

Hopefully, the gears are good (fingers crossed) and I have enough time to get it ready for an event in North Carolina next month....

KURT

[Radioguylogs]

Yeah!!!!

Sounds great!....and you probably haven't even tweaked the carbs yet.

[BLK86TRBO]

Sounds good so far! Your threads are great, thanks for sharing your journey

[jetmechmarty]

It's always exciting when these old things come back to life. Especially after we put a lot of effort into it.

Kurt, your threads are inspiring!

[kboehringer]

OMG What a BEAST! - What a DUMB BUTT I AM! OXYCLEAN?

XS Friends,
Thank you for the notes of encouragement. I must say these 11's are the most fun I've had in YEARS! No Kidding. I promised Nancy a trip out-of-town this weekend since it's been XS11's for the last million weekends. Taking Friday off and headed to 'BAMA.

SO... I raced home and got right to work trying to get a nice idle, good timing, carb tuning etc. before departure tomorrow and a couple days without my beloved 11's... I can't quite get those pretty equal readings on all cylinders/carbs but the thing sounds great now, idles good, and feels strong. The readings are very close to equal.

Like a COMPLETE DUMB BUTT (change that word in your mind) I jump on it and decide I must immediately check 2nd gear... Mind you the rear brakes are not bled, and the shoes are crap...(New ones are sittin' on the bench ) no tank, no seat, carb gauges still attached, sitting on rags, NO helmet, NO gloves, short sleeves, home alone...... ATGATT was NOT on my stupid butt mind

Go UP the street seems ok 1st-2nd-3rd but I'm not REALLY sure. Turn around headed DOWN the street. Hit third OH CRUD! (change that word too)...NO BRAKES doing like 30mph.... Hit the kill switch, drop a gear release the clutch, pump pump pump the fronts, feet down swerve into the drive, still pumping fronts, feet and toes draggin.... stops 2' from my rear fence. Darn near need some OXY-CLEAN for my shorts.

Somebody come over here and kick me in the BUTTOCKS. That was ABSOLUTELY STUPID! Acting like a dumb kid in a candy store...Will I EVER GROW UP?

Sincerely,
KURT

P.S. It does seem 2nd is OK....Thankfully I'm not headed for the hospital.

[kboehringer]

Better Video (not of me driving) - LOL

http://vid1353.photobucket.com/albums/q679/poconos/IMG_0359_zpsqav4pxwo.mp4

It really is a beast.... I am soooooo happy the rings and valve job solved the non-running problem....

[tomcos67]

http://vid1353.photobucket.com/album...psqav4pxwo.mp4

It really is a beast.... I am soooooo happy the rings and valve job solved the non-running problem....

Good for you Kurt you work hard on these bikes we all want success for you.!Nobody wants to do it twice.(like me every time I do something) lol.And that wow I forgot I got no brakes.That will get your attention.! Glad no mishap.!Hope your new members in family are well. Good Spring.!