1981H xs1100 rebuild project, started Feb.2017

[red bandit]

The engine has to be running for the headlight to come on, unless someone did some special wiring.

[FranksBMW]

The engine has to be running for the headlight to come on, unless someone did some special wiring.

Great. Thanks for that info!

[FranksBMW]

2 observations and a question:

The starter button/kill switch unit on the handlebar needs to be attached to the handlebar to be grounded and for the starter button to function.

The rear view mirror stalks are left-handed threads.

What amperage are the fuses? (1981H Venturer)

[bikerphil]

The rear view mirror stalks are left-handed threads.

Only the right hand mirror.

[TopCatGr58]

Hey Frank,

I think Scott/3Phase informed us that the 81 added a ground wire to the handlebar set so that it didn't rely on the grounding to the handlebars, but I'm not totally for sure. Okay, just checked the wiring diagram for the 81SH, and it shows a black wire connecting to the starter switch instead of just going to ground.

The fuses are all 10 A except for the turn signals which are 20 A. The other one is the MAIN fuse on the OTHER side of the bike and it's a 30 A.

T.C.

[3Phase]

Sorry, guys, I was spacing out while I work on and ride my XJ.

Yes, there should be a Black wire for ground in the right-hand controls on '81 switch sets and there should be a matching Black wire for it in the harness connector.

If there's no Black wire in the control, it might be from a different year/model and it will have to be grounded to the handlebar or the Start button won't work.

[FranksBMW]

Thank you for the info on the fuses!

My control unit must be from an older bike then. If I remember, the next time the tank comes off, I'll look at the loom end of those wires to see if there's a loose black one.

[FranksBMW]

So today I installed the repaired gas tank.(thanks Steve) For the first time since sorting out the throttle cable, I started the bike several times for brief running periods. The key works in the replaced ignition unit (thanks Steve) and the throttle controls the carbs. I adjusted the carb throttle stop so the idle speed was between 1 and 1.2K. My hand just barely fit and rotating the knob was just barely done with contorted fingers.

Weirdly, both horns are kaput. I tested them uninstalled from the bike with direct wires to a spare battery. Got spares, Steve?

[3Phase]

There's an adjusting screw on some horns to change the pitch, try turning it, it may just be cruddy contacts.

Tap the horns on the concrete or with a hammer. The coils and contact points may still be good but if the diaphragm cone is stuck or rusted then it won't tootle.

Or they may be really dead, not mostly dead.

[FranksBMW]

There's an adjusting screw on some horns to change the pitch, try turning it, it may just be cruddy contacts.

Tap the horns on the concrete or with a hammer. The coils and contact points may still be good but if the diaphragm cone is stuck or rusted then it won't tootle.

Or they may be really dead, not mostly dead.

I banged them around a little bit, but I'll be more aggressive. Nothing to lose.

[MaximPhil]

Frank,
Canadian tire carry FIAMM horns that make lots of noise and not expensive. Best mounted with a relay.

Phil

[FranksBMW]

I spent a few hours in the garage during yesterday's rainy afternoon. The brakes are now bled and function well. The stop light responds properly to the hand lever and foot pedal. All lights work properly.

With the bike project coming along so well, I decided to buy a battery for it. I've been using a spare car battery and jumper cables. An installed motorcycle battery will greatly increase my range. (beyond the 6 foot jumper cables.)

The right side side cover had a broken top mounting slot. I reinforced that with a strip of metal with a slot, JB Welded to the inside of the cover. I'm missing the rubber donut that holds the tang into the frame tab.
The other side has the lock tang broken off but the top mounting holes are good and I can secure the bottom with an elastic.

Coming along.

[FranksBMW]

Just rode my XS1100 project bike up and down the driveway!

[FranksBMW]

Maiden shake down voyage around the block. Runs well! 😄

[HalfCentury]

So today I installed the repaired gas tank.(thanks Steve) For the first time since sorting out the throttle cable, I started the bike several times for brief running periods. The key works in the replaced ignition unit (thanks Steve) and the throttle controls the carbs. I adjusted the carb throttle stop so the idle speed was between 1 and 1.2K. My hand just barely fit and rotating the knob was just barely done with contorted fingers.

Weirdly, both horns are kaput. I tested them uninstalled from the bike with direct wires to a spare battery. Got spares, Steve?

I bought inexpensive LOUD horns from eBay. I did the same test of the OEM horns with a hefty power supply and determined that the OEM horns were something to throw when aggravated. 35+ years is a long time to expect a transducer to transduce that is exposed to the elements.