1981H xs1100 rebuild project, started Feb.2017

[FranksBMW]

It's alive! Started and ran with a temporary fuel source and temporary car battery hookup. Some blue smoke but that's okay for now. Kept it between 2K and 4K rpm to warm it up nicely and make sure oil gets pumped to where it needs to go.
Happy, happy!

[FranksBMW]

Plus 15C today. Took the carbs apart again today, more completely, and used carb cleaner spray. Everything went smoothly except for the 2 inner carbs. There is what I think air/fuel mixture adjustment screws on top by the rubber boot closest to the motor. The screws would not budge and the previous owner mangled the screwdriver slot in them. I didn't try too hard though.

I still have to bleed the rebuilt brakes (original parts cleaned) and deal with a possible stripped bleeder hole on one of the front callipers. I'll need to run a thread tap through it, I guess?

Then I'm ready to replace or fix/clean gas tank and clean the fuel petcocks.
Still need a headlight bucket and a matched ignition unit with key.

There is something fairly large and loose rattling inside the mufflers, so they will eventually need to be replaced, like the ripped seat, but that can wait until the bike is running.

[motoman]

Yesterday I removed the carb rack and bought a can of carb cleaner spray in anticipation for this task.

Another warm day, Mar 19. Read the directions in a thread here and adjusted the cam chain tensioner. The area behind my engine's timing cover looked very clean and unmolested. Nice.

-bike on centre stand
-remove spark plugs
-turn engine clockwise with big square nut on timing plate
-turn just to match C with pointer, don't overshoot and turn back, not even a little bit



Once the bike is running, I'll look into replacing the cam chain tensioner with a more robust unit from a Yamaha 1300 v4. Question: from any year?

As T.C. stated, lots to choose from. If your kinda stuck on the Yammy V-4, either the ones off the 1200 or 1300 is just fine. Plus, if you pull both off the 1200 or 1300 V-4, ya got an extra, just cause'. I got one off the V-4 1200 Yammy here locally, then when 3Phase was here a yr. later, we went got the other one and installed it on his 80G dresser. IIRC, the cost was $15 for each one. I considered it cheap insurance not to have a loose timing chain, throwing that valve timing off a tad ever again. Besides, the stock one will not stay correctly adjusted anyways, specially with a hard de-cell.

[TopCatGr58]

http://www.xs11.com/forum/showthread.php?t=35501

Take your pick, lots to choose from.

T.C.

[FranksBMW]

Yesterday I removed the carb rack and bought a can of carb cleaner spray in anticipation for this task.

Another warm day, Mar 19. Read the directions in a thread here and adjusted the cam chain tensioner. The area behind my engine's timing cover looked very clean and unmolested. Nice.

-bike on centre stand
-remove spark plugs
-turn engine clockwise with big square nut on timing plate
-turn just to match C with pointer, don't overshoot and turn back, not even a little bit



Once the bike is running, I'll look into replacing the cam chain tensioner with a more robust unit from a Yamaha 1300 v4. Question: from any year?

[FranksBMW]

Another warmer day!

Today I reinstalled the rebuilt rear brake caliper and master cylinder, and the mufflers. Removed the carbs so I can go through them more comprehensively. After watching a video on youtube, I feel confident doing this for the first time.

Still to do: clean carbs, source ignition key with matched ignition unit, fix or replace tank, put up with duct tape or replace seat, source and install headlight bucket and front turn signals, bleed the brakes, replace fork oil.

Last thing is new tires but only when running well.

[FranksBMW]

Thanks Steve! Have you got a headlight bucket, front turn signals, gas tank, and seat in good condition?

[SS Clift]

XS1100 Rebuild

Hello Frank from Whitby, Ontario. It`s nice to know that there is XS1100 enthusiast close by. I bought a running `79 XS1100E Standard last summer for some parts . The frame is cracked at the left side foot peg. If there is anything that you need for your bike , that I may possibly have , perhaps I can help you out with your restoration .
Steve theclifts@rogers.com

[FranksBMW]

Good luck with your project, Mschor!

Thanks for the grease gun trick. I knew about it but had forgotten. Luckily I didn't need it.

[mschor]

I'm in the middle of getting an 81 Special up and running after 20yrs in a garage. Quite a process unlocking all the stuck parts, was losing confidence for a while, but I'm almost there now

[mschor]

Caliper Rebuild

If your calipers are seized, use a grease gun to push the pistons out. I fought my first two for a day, and tried the grease gun trick on the last one. WORLDS of difference. Youtube it or check on this forum.

[FranksBMW]

I took advantage of a warmer afternoon and spent 3 1/2 hours in the garage, focusing on the brakes, which I removed early on because the callipers were all seized and I needed the bike to roll.

I took apart, cleaned, and reassembled the 3 callipers. I reinstalled and bled the front callipers . It was slow going because there was a lot of air in the system so I used a vacuum technique with a large syringe to suck brake fluid out of the bleeders on the callipers. I think I may have cross threaded one of the bleeders though.

I also took apart, cleaned, and put back together the rear master cylinder. Installation of the rear brake system on the bike will require rear wheel removal so I'll leave that for next time as my back was getting sore.

Anyway, great day in March wrenching, and making progress on this project!


Forgot to mention that a few days ago I attended to the clutch cable and adjustment. The cable required wd40 and oil to free it up.

[FranksBMW]

Thanks Phil. Will do!

It will get warmer.

[MaximPhil]

Hi Frank,
looks like it will stay cold fora little longer so thow more logs on the fire and read what Gary has to say about waking an XS from a long rest.

http://www.xs11.com/forum/showthread.php?t=792

Phil

[FranksBMW]

Hi Pil. Just noticed your location. You're getting the same-ish weather as me.