1981H xs1100 rebuild project, started Feb.2017

[FranksBMW]

Finally a picture. This is how she looks today.

[FranksBMW]

Good info on the switching locks, thanks!

[TopCatGr58]

Hey Frank,

As has been stated, solder of some kind is the proper external seal. JB WELD will NOT hold....we have attempted to use it on the broken float posts, but it just dissolves!
So...solder external, and then sealer/liner internally is the best combo to prevent further leaks!

BTW, was your original ignition switch bad, or just missing the key, can't remember and didn't want to reread this whole thread! You can take the ignition switch apart, and put the lock portion with the key onto the switch portion so you can keep the same wire connections! JAT

T.C.

[FranksBMW]

Wise advice, thank you. This project is in the early stages and some repairs are going to be somewhat makeshift until it all comes together.

IF it all comes together, then I'll throw some money at it.

[MPittma100]

Tank Leaks

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.

Be advised that you should, in fact, strongly consider a tank liner. Nothing worse than going down the road with fuel all over your lap and legs. Be safe, not sorry.

[bikerphil]

I have soldered holes with an iron with the gas still in the tank, just tip the tank so the gas is away from the pin hole. I did it outside as a precautionary measure.

[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

[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]

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]

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.

[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]

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.

[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]

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

[FranksBMW]

Unfortunately there's more broken than just the post.

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