1981H xs1100 rebuild project, started Feb.2017

[IanDMacDonald]

Hi Frank,
Some have replaced the original JIS Screws with socket head cap screws using metric allen keys instead and eliminating the need for multiple tools in the kit.

Phil

Yup. Not a single fastener on my bike except the final and mid-drive plugs are original. All S/S SHCS on my bike.

[MaximPhil]

Thank you for this suggestion, and I agree. The proper tool for the job is very important.

The screw heads were already mangled by previous owner, so I'm replacing the 4 screws on top and 4 screws on the float bowls (per carb.)

Hi Frank,
Some have replaced the original JIS Screws with socket head cap screws using metric allen keys instead and eliminating the need for multiple tools in the kit.

Phil

[FranksBMW]

Yamaha 1981 SX1100

$150 cost

$50 winch to pull it up onto the trailer
$20 cut key from internet
$20 motor oil
$20 gear oil and WD40
$15 new screws for carbs

[FranksBMW]

Thank you for this suggestion, and I agree. The proper tool for the job is very important.

The screw heads were already mangled by previous owner, so I'm replacing the 4 screws on top and 4 screws on the float bowls (per carb.)

[DeanR]

I"d advise you to invest in a set of J.I.S (Japanese Industry Standard) screwdrivers so you don't ruin any more screw heads on the bike. It'll save a LOT of heartache in the future.

highly recommend this

[Eveready1100]

Frank, if you're planning on doing much work on the carbs etc, I"d advise you to invest in a set of J.I.S (Japanese Industry Standard) screwdrivers so you don't ruin any more screw heads on the bike. It'll save a LOT of heartache in the future.

[motoman]

Ideally, I want to get the bike running with just my labour before investing in expensive parts.

Good idea. Initially then, I'd suggest use a portable plastic tank of some sort hung from a three legged or roll-around stand. If all seems to be good and just may need a carb rebuild and some serious tunin'......THEN find an internal non rusted tank.

[3Phase]

Good luck with your project then, Frank.

[FranksBMW]

Here's a UK tank listing that doesn't really want US biz but may deal with the Canada:-

http://www.ebay.co.uk/itm/yamaha-xs1...gAAOSwLEtYjz4t

Ideally, I want to get the bike running with just my labour before investing in expensive parts.

[FranksBMW]

So today, I went through the carbs. There were a few stubborn screws and I had to grind off 2 of their heads because the impact wrench still mangled the cross slots and the vicegrips slipped off their heads.

3 slides were stuck and I cleaned off the varnish with some break cleaner. (keeping that liquid away from rubber diaphragms) On the bottom end, I cleaned out the bowls and the orifices where gas gets sucked up along the needle. The floats of one of the carbs were frozen and I was able to pull the pin and clean off the sticky varnish.

There may be more work to be done to them but this was my first time and I did the obvious.

[3Phase]

Oh! Canada!

Here's a UK tank listing that doesn't really want US biz but may deal with the Canada:-

http://www.ebay.co.uk/itm/yamaha-xs1100-petrol-tank-/132103698779?hash=item1ec1fe795b:g:WMgAAOSwLEtYjz4t

£50.00 | 0 bids

yamaha xs1100 petrol tank
Bedford, UK

May not post to United States - Read item description or contact seller for postage options. | See details

Item location:
Bedford, United Kingdom

Posts to:
United Kingdom

[3Phase]

Do tanks from other years fit?

Yes.

The '81 Venturer has a larger ~6 gallon US tank with higher handlebars so they don't hit the tank but you can fit others like an XJR1200:-

gas tank sizes

Apparently, the European tanks are larger than the Standard ~5 gallon US tanks too so it might be worth checking around Canada and across the pond too:-

Fuel tank conversion

Have fun, life's too short to screw around with rusty tanks.

[FranksBMW]

Just get another tank, Frank, you really don't need to mess around with a rusty one with visible holes.

Do tanks from other years fit?

[3Phase]

Fire

Just get another tank, Frank, you really don't need to mess around with a rusty one with visible holes.

[FranksBMW]

The lower parts - yes. That's where the water would settle. I do know someone who might be able to weld it. But the tank is a later task (in my head.)