1981H xs1100 rebuild project, started Feb.2017

[MaximPhil]

Frank,
The LEFT SIDE cover LOCKS on. You need the ignition key to release it.
look for a barrel on the front side with a flip cover.
Save everything some items are no longer available and used ones can be very expensive.

78 had a Kick starter lever that was stored on the bike down near the frame" V" below the side cover. Yours may be long gone
Phil

[FranksBMW]

Hi Ian. I did find an owners' manual on the 'net and it mentioned a wire/string/chain tool that goes from the end of the swing arm on one side, and goes over the wheel to the end of the other arm, in the section about removing the rear wheel. That left me confused.

But I can drift it out? Great.

[MaximPhil]

Hi Frank,
Off and running on your rebuild. Yours is not the first to be rescued from a snow bank or swamp Lets hope the motor frees up with a bit of oil and patience. The XS crank turns backwards to most bikes.
The axle has been in there so long it might just be force of habit holding it in
or more likely some rust build up. I recommend PB Blaster having had excellent results to free rusted nuts and bolts.
put the nut back on loose and hit it with a rubber mallet or brass drift.
Take a picture of the spacers on the caliper side, assuming they are on correctly as you may not remember in a few weeks when it is time to reassemble.
You have a busy time ahead. As the manual tells how to do things it does nnot mention all the tricks and details that are on this site. I would suggest trolling the forum and looking at the tech section.
Always best to ask first if you are not sure saves breaking stuff or having to do it over.

Phil

Manual available from Marshall's site.

http://www.ringler.us/family/mybike.html

[motoman]

Earlier this month, I bought a project bike in a snowbank at the end of a driveway in another town. It had been sitting there since the end of the summer, so the price was really good for me.

The bike is now in my garage. The luggage rack, hard bags, fairing, seat, and tank have been removed. The bike is complete but the tank has rusted through in a few places. The seat needs recovering. I'll need a headlight bucket, but luckily the ears were there under the fairing. The side covers are unusable - brittle and cracked. The brake callipers are seized and need to be rebuilt. I put some oil into the cylinders but I don't know if the engine is seized or not. Did every bike come with a kickstart lever stored somewhere?

Does anyone have a link to a service/shop manual? I've done a Google search without success.

Is there a trick to remove the rear axle? I've removed the crown nut on the left side, and the cinch bolt on the right side. The axle rotates but I couldn't pull it out.

Thank you in advance for your collective knowledge and assistance with this lovely bike!

No, just the 78-79 XS11's came with it. 80's still had the access shaft assembly, but, IIRC, no kick-start lever came with bike. 81 and XJ models had a rubberized cap over the opening....and NO kick start assembly inside.
Hope that helped you. As for axle shaft, pulling on it to remove sometimes works.....sometimes not. Just take a rubber mallot and give it a whack...then pulling it rest of way should work. Have no rubber mallot?.....screw the nut on several threads, then give the nut itself a few whacks. The nut on there keeps from screwin' up the threads on the axle.

[IanDMacDonald]

Exciting!

Andreas Weiss is your source for parts. Send him a PM.

Kick starter is stored under the battery compartment I believe.

XS manual. Check CatatonicBug's webpage.

Rear axle. Get a brass drift and pound it out. No real harm done.

[FranksBMW]

Earlier this month, I bought a project bike in a snowbank at the end of a driveway in another town. It had been sitting there since the end of the summer, so the price was really good for me.

The bike is now in my garage. The luggage rack, hard bags, fairing, seat, and tank have been removed. The bike is complete but the tank has rusted through in a few places. The seat needs recovering. I'll need a headlight bucket, but luckily the ears were there under the fairing. The side covers are unusable - brittle and cracked. The brake callipers are seized and need to be rebuilt. I put some oil into the cylinders but I don't know if the engine is seized or not. Did every bike come with a kickstart lever stored somewhere?

Does anyone have a link to a service/shop manual? I've done a Google search without success.

Is there a trick to remove the rear axle? I've removed the crown nut on the left side, and the cinch bolt on the right side. The axle rotates but I couldn't pull it out.

Thank you in advance for your collective knowledge and assistance with this lovely bike!