1981H xs1100 rebuild project, started Feb.2017

[motoman]

Airbox "reinserted" into its place with a new air filter. Boy, what a goofy design for how it's held together. Silly little bushings too, just to add complexity. Going to wait for warmer temps (more flexible boots) to install the carbs.

A shot of silicone spray inside each boot will resolve that issue. Works nice, even when things are warm.

[FranksBMW]

Thumbs up!

[FranksBMW]

Rattle-canned my tank and side covers a satin black. (Sorry purists, I just don't like the relish colour that was on it. I also found and installed round front turn signals, from a Special, I guess.)

The left side panel is broken along the bottom edge. The broken part is still locked in, with a key I do not have.

[3Phase]

You changed the paint color and put on round signals! Heretic!

Frank, the ignition key is supposed to unlock the ignition, fuel tank cap, and the left-hand side cover.

The side cover lock can be taken off the frame and disassembled. Unless you have a different ignition key now, it's probably just rusted and needs to be sprayed with some oil-like substance like PB Baster, octopus juice, or whatever you have in the garage, you know?

'Work' the key and the lock until it loosens up and the key can turn without torquing it off in the cylinder, remove the side cover piece, then put the side cover back together with some fiberglass or just find another one that's not broken. Good side covers are getting kind of expensive.

[FranksBMW]

Hi Scott, thanks for your reply. The bike came without any keys. The left side broken panel is missing pieces so no chance of rebuilding it with what's left in the lock. Luckily it's just the bottom angled-in ledge that's broken off so it won't be visible once installed. I'll find another way to hold the covers on.

In previous post #123, I meant to write "reddish colour."

[MaximPhil]

Frank if it is just the "post' that is nroken on that cover there is a fix to rebuild it. Search the forum for instructions. I expect any XS key will open that lock as it only goes in 1/2 way.

Phil

[FranksBMW]

Unfortunately there's more broken than just the post.

I have a Yamaha key blank. I'll give that a try, thanks Phil!

[FranksBMW]

Nope. Wrong key. No worries. Other ways to skin cat.

[3Phase]

The lock's actually kind of handy. It can be taken apart and the tumblers massaged a little with a file to work with the 'new' key. They can just be filed down completely or removed so it works with a screwdriver or a road penny.

The missing pieces on the side cover are easy to fix. Get almost any kind of plastic except milk jugs and glue or glass them in place. When you get bored you can make a new lock tab for the cover or build it up in place with super glue and baking soda.


There's a forum thread around here somewhere too. Ah, here it is, it's basically everything you never wanted to know about side cover repair and didn't want to ask:-

XS11.com Forums | Idle Talk Forum | XS11/XJ11 Discussion | Question about side cover repair

[FranksBMW]

Installed the airbox and the carbs. The silicone spray worked great. Removed the fairing pigtail and I'll have some questions about some loose/unconnected wires soon.

[DiverRay]

Questions about the wires were asked in another thread just a little while ago. You WILL have wires with nothing connected, as they are for "options" no longer available.

[FranksBMW]

Many thanks to fellow SX11 owner Steve, for some needed parts from his parts bike! Most critical was an ignition unit with fitting key. (My project bike came without a key.) I have the wiring figured out except for one thing: My wiring loom ignition unit plug has 4 wires - thick red, thick brown, thin blue, and thin red with yellow stripe. The ignition unit I got from Steve has only 3 wires - it lacks the thin red with yellow stripe. (Perhaps Steve's ignition unit is from a previous year or a different model.)

I'm guessing that I should tie in the red/yellow wire to the thick red wire on the loom side. (Please correct me gently if I'm wrong.)

Does anyone have a link to a colour wiring diagram for a Venturer '81 H?

Another question: Are there only 2 key positions? (on/off) Or are there 3? Is there a difference between 1981's and previous years? I'm thinking that the 81's had a park setting as well as on/off.

[MaximPhil]

Many thanks to fellow SX11 owner Steve, for some needed parts from his parts bike! Most critical was an ignition unit with fitting key. (My project bike came without a key.) I have the wiring figured out except for one thing: My wiring loom ignition unit plug has 4 wires - thick red, thick brown, thin blue, and thin red with yellow stripe. The ignition unit I got from Steve has only 3 wires - it lacks the thin red with yellow stripe. (Perhaps Steve's ignition unit is from a previous year or a different model.)

I'm guessing that I should tie in the red/yellow wire to the thick red wire on the loom side. (Please correct me gently if I'm wrong.)

Does anyone have a link to a colour wiring diagram for a Venturer '81 H?

Another question: Are there only 2 key positions? (on/off) Or are there 3? Is there a difference between 1981's and previous years? I'm thinking that the 81's had a park setting as well as on/off.

Hi Frank,
On mine if you push down the key and turn all the way to the left you activate the lock which requires the handlebars to be all the way to the left to engage.
Before installation it would be a good idea to clean and then lube with some grease the ignition switch. soaking in EvapoRust is an easy way of cleaning by soaking overnight. That extra wire might be for the 4 way flasher switch under the left side controls.
Phil

[FranksBMW]

Thanks Phil. Yes the key in the ignition does push down but I didn't know about the handlebars needing to be turned to the left so I had no idea what that function was for.

Here's a new question: Can you repair a pinhole in the gas tank with a dab of JB Weld on the outside? (I would sand down to bare metal first.) I know about lining the tank to fix leaks but am looking for an economy solution and there are just 2 or 3 pinholes.

[MaximPhil]

Thanks Phil. Yes the key in the ignition does push down but I didn't know about the handlebars needing to be turned to the left so I had no idea what that function was for.

Here's a new question: Can you repair a pinhole in the gas tank with a dab of JB Weld on the outside? (I would sand down to bare metal first.) I know about lining the tank to fix leaks but am looking for an economy solution and there are just 2 or 3 pinholes.

I would sand the whole area in question and Silver Solder the holes. Sadly one hole frequently leads to another. Obviously tank must be clean and dry both out side and in. Being a scardy cat after draining and rinsing I would have an airline blowing air into the tank too to ensure no trapped fumes.
Phil