1981 XS11 Special - DEAD DUCK Cafe

[kboehringer]

Washer Move, Gear Replace, Shift Fork Replace

XS Folks,
Been working my butt off trying to get Dead Duck ready for "THE MELTDOWN" NEXT WEEKEND in North Carolina.

Finally got tags & insurance so a good test ride was in order.... Unfortunately, not all went well! The bike runs well and has TONS of power. BUT, 2 out of 5 shifts to second under heavy acceleration and the bike dropped out of gear. THE TYPICAL 2nd GEAR ISSUE.



Ripped into the gear box and decided to try it right side up as removing all the pieces necessary to do a flip would be difficult on this custom ride. Having done this before up side down getting those shift arms back in correctly (fighting gravity) was a pain in the butt. However, now that I've done it this way I won't flip one again.....

Now, time to finish the few bits left to reinstall and get moving on the Harley Muffs TONIGHT... NO TIME TO WASTE!

KURT

[motoman]

XS Folks,
Been working my butt off trying to get Dead Duck ready for "THE MELTDOWN" NEXT WEEKEND in North Carolina.

Finally got tags & insurance so a good test ride was in order.... Unfortunately, not all went well! The bike runs well and has TONS of power. BUT, 2 out of 5 shifts to second under heavy acceleration and the bike dropped out of gear. THE TYPICAL 2nd GEAR ISSUE.



Ripped into the gear box and decided to try it right side up as removing all the pieces necessary to do a flip would be difficult on this custom ride. Having done this before up side down getting those shift arms back in correctly (fighting gravity) was a pain in the butt. However, now that I've done it this way I won't flip one again.....

Now, time to finish the few bits left to reinstall and get moving on the Harley Muffs TONIGHT... NO TIME TO WASTE!

KURT

Can see from your pics. the ends of those gear 'dogs' are rounded just enough to not hold in gear. Also, glad to see someone agrees that removal/installation of that lower shaft assembly and shift forks is way easier done with bike upright.

[BA80]

glad to see someone agrees that removal/installation of that lower shaft assembly and shift forks is way easier done with bike upright.

not even!!!!!!!!

[kboehringer]

Both ways have some benefits....

way easier done with bike upright.

Motoman,
I would agree there are much less parts to remove and re-install (seat, tank, controls, handlebar (I used an old spare bar for the flip), tail lamp, rear fender, rear signals, etc.). I also messed the VCT tile floor in my garage when I did the flip.

BUT, the shift forks were a TON easier upside down. I believe that ease was totally related to TC's great instructions which I had followed very closely the first time. It's also a lot easier to SEE everything in there.

This time I got a little confused trying to PARTIALLY use TC's instructions and struggled a LOT with shift arm #2. If I hadn't gotten myself confused with the two methods, I would have made better time with the repair.

Now that I've done this both ways and know how to do it. I will stick with the right side up method because there is a LOT less stuff to remove and reinstall. Nancy helped me with tools this time, but I didn't need her help flipping the bike over

KURT

[BA80]

Here's the special tool you need to install the shift forks Kurt....

http://www.livepatina.com/wp-content/uploads/2015/01/LP-Wire-Hanger.jpg

Just use the straight piece to replace the shift fork rod to hold them in place so you can slip the rod back into them one at time.

[kboehringer]

Here's the special tool you need

NICE! LOL

I actually used one of those.....My problem was they FELL OUT and orientation of the #2 was confusing me. I kept putting it ON TOP of the drum and it wouldn't line up in either orientation DUH~!!

[kboehringer]

Yama-Sportster?

Yama-Sportster?



Lots of work done.... still more to do..... Ready for a test drive....
SOUNDS EXCELLENT!

KURT

[motoman]

Motoman,
I would agree there are much less parts to remove and re-install (seat, tank, controls, handlebar (I used an old spare bar for the flip), tail lamp, rear fender, rear signals, etc.). I also messed the VCT tile floor in my garage when I did the flip.

BUT, the shift forks were a TON easier upside down. I believe that ease was totally related to TC's great instructions which I had followed very closely the first time. It's also a lot easier to SEE everything in there.

This time I got a little confused trying to PARTIALLY use TC's instructions and struggled a LOT with shift arm #2. If I hadn't gotten myself confused with the two methods, I would have made better time with the repair.

Now that I've done this both ways and know how to do it. I will stick with the right side up method because there is a LOT less stuff to remove and reinstall. Nancy helped me with tools this time, but I didn't need her help flipping the bike over

KURT

Actually meant bike is oreinented the correct direction for disassembly and gravity for temporary holding up of shift forks resting on that shaft IS a plus. Pull the shaft anf forks drop exactly in place.

[BA80]

Actually meant bike is oreinented the correct direction for disassembly and gravity for temporary holding up of shift forks resting on that shaft IS a plus. Pull the shaft anf forks drop exactly in place.

If you don't mind laying in the grease and dirt and having stuff fall in your face.

This is MUCH easier I think.........





I've tried it this way and didn't like it...

[kboehringer]

Oil in the face.....

If you don't mind laying in the grease and dirt and having stuff fall in your face.

Greg,
I wish I had the ability to lift the bike up from the rafters as you did. I did mine with the bike on its center stand! I had to tape a flashlight to the cross beam on the center stand so I could see up into the gear box. My floor is kinda nice but I did get some dripping in my face.

Maybe that's why my neck is so sore today?

KURT

[BA80]

Maybe that's why my neck is so sore today?

KURT

Removing easy to remove parts is much better than suffering because you didn't. Learned that a long time ago in the automotive repair field.

[TopCatGr58]

Yama-Sportster?



Lots of work done.... still more to do..... Ready for a test drive....
SOUNDS EXCELLENT!

KURT

Looking good there Kurt,

Now I know what the Sportster Seat will look like on mine, but may be a little different since I'll also be putting on a grab rail, saddle bags and such, and possibly a seat spring kit??

T.C.

[kboehringer]

Grab Bar, Sporty Seats, Almost Done, What's Missing?

I'll also be putting on a grab rail
T.C.

T.C.
Funny you should mention the Grab Rail....

This is my only MAJOR remaining project to complete the install of the Grab Bar you provided to me. It will be much easier to complete this now that I can get the bike up next to the Aluminum MIG Welder. Doing this delicate work at home and traveling back & forth with the piece was going to be too hard. I started on it again tonight....



The mufflers worked out great! In a way were a LITTLE easier than my other bikes as I did not have to hack the mufflers apart to make them fit.. The special head pipes have their own challenges to adapt the pipes to but Autozone provided the 1-3/4" OD to 1-3/4" ID adapters. The chrome trim covers all the sins!





The HD "Sporty" seats have a number of different styles. Some have said mine is from a 883 others say it's from a "Sporty". I know nearly nothing about HD but know this is an OEM HD Seat. What it came from is unknown. I have seen several seats that look similar to it but have yet to see an IDENTICAL seat on any HD I've seen. Obviously, they have a BUNCH of different seats on their bikes.

BOOBER - Bobber - Café
Although SOME believe every 11 should be returned to OEM stock (i.e. FULL RESTORATION) this PO failed BOOBer attempt was not a candidate for such a restoration. I'm very pleased with the look and tried to retain as much of the FLAVOR of the XS11 as possible without turning this into a file of POOP. This is EVENTUALLY going to be driven mostly by my son Karl (age 20). When I feel he has enough experience with the Mini-Maxim (550) I'll let me loose on this. Without these modifications, my son would have nothing to do with an XS11....The XS11 just does not seem to appeal to his age group.

I don't think this bike qualifies as a BOOBER, or a Bobber, or a Café. I prefer to think of it as a MODIFIED XS11?

BUT, it seems like something is missing?:confused: I thought of adding "1.1" to the side covers but have delayed that. Are the side covers too bland? The chrome on the rear fender is really nice so I don't WANT to paint it to match the front but does that make it look GOOFY?

It FEEEEELS like something is missing? Eventually, the OEM shocks will likely be replaced as these OEM's are junk. Will that make it look better?

What would you do with it from here?

Respectfully,
KURT

[jetmechmarty]

What would you do with it from here?

Respectfully,
KURT

Call it done! It looks great!

[motoman]

If you don't mind laying in the grease and dirt and having stuff fall in your face.

This is MUCH easier I think.........





I've tried it this way and didn't like it...

Well, fortunately floor and bike was clean on underside. Was in no hurry and inside garage, so layed a large piece of outdoor carpet underside, the Venturer on centerstand and up on 6"x 6", block under front wheel with rear wheel removed so front of bike sat up real high. Drained and removed the pan,layed a large peice of cardboard underneath on cardboard, sprayed a whole can of Bra-Kleen up on internals and let drip dry for a couple days.Pulled cardboard out and did all the disassembly(air gun/socket on lower shaft bolt). All was nice and clean upon removal. Dove-tailed all the dogs on ALL gears and and backcut slots to match, no washer swap needed as full engagement with dogs flush with backside of slots was taking place, and a couple days later re-assembled. Took it to a Friday nite test'n'tune at the dragstrip with three passes throwing speed shifts every gear to test trannies gear holding ability. Ran mid 13's with .40 reaction times and 105's and 107 mph. Not shabby for a factory full dresser at 5,000ft. elev. with stereo full on. All held well and that was 6yrs. ago, and still holds any gear well.