Winter project FINALY started

[DiverRay]

It's been 15 years since I had the crank sent off to get balanced. I am just now starting to clean and assemble the 1978 engine! Yeah, life gets in the way, but at least I'm starting this project.
I have the cases almost cleaned, so I can fit the crank and plastigauge the bearings. I do have an almost complete box of new crank and rod bearings, so everything should be within spec.

Yes, I got the crank back from APE in 2009!!

[Radioguylogs]

Good things improve with age?

I hope you keep us updated as the project progresses. It will be interesting to follow.

Do you plan any special modifications, or will engine be built as an usually nice restoration?

[Socer4m]

I am guessing with Ray's skill, the bike will be pretty dang nice when done. ,,,,its good to see another xs being restored. I just picked up a ratty xj1100, hoping also to get it to its former glory. Like a dummy I sold my original xj 1100 and been sorry since, I figure for a 100 bucks its worth a shot. Keep us informed Ray,,,,we are all curious...........Mike in San DIego and Pa

[DiverRay]

It will NOT be a stock E. The engine has an 1197 kit going in, and possibly a newer big valve head. I don't know if you can read the paper, but the crank is balanced for 14,000RPM sustained operation. My plan is 10K redline, but I can bump it up if need be. Intake and exhaust depends on what I can find at a good price.

[DEEBS11]

Ray, this is great. A motor build from the crank shaft up. What do you use to clean the cases and what seals will you be using on the ends of the crank shaft?

[DiverRay]

I'm using brake clean in a metal pan for cleaning the cases. I've not purchased seals or gaskets yet, as I figure it will be about a month before I'm to that part of the build. I have plenty of parts from more than one engine, so measure and use the best of each. The exception is the crank and rods, as they are from the original engine and matched to the cases. The need for the rebuild was a broken gear in the transmission. The PO was a large guy, and he liked to drop the clutch a LOT...

[DiverRay]

Well, when they balanced the crank, they destroyed the markings for the bearings!! I've started to S-L-O-W-L-Y check all the bearings with plasti-gauge so I can have the correct clearance on the mains. I also need to do the same on the rod bearings. Sounds bad, but I need to wait for parts, so I have the time.

[DiverRay]

Well, I'm going to have a little loose clearance issue with the mains and rods. Stock Yamaha bearings are NOT able to make up for any machining. So far, the mains should work, just. They will be about 0.001mm big. I'll be checking the rod bearings in the morning, after I vote.

[DEEBS11]

Ray, perhaps oversize bearings are in order?

[DEEBS11]

Rod bearings if needed.

[DiverRay]

I have the complete set of these bearings! Two boxes, one crank, one rods. They cover all the sizes, though I only have a few of two.Five sizes per, but clearance is a little big. I may try and see if there is a hot rod shop here in the Boise area that can "build" the bearings for me.

[Mathh]

I have the complete set of these bearings! Two boxes, one crank, one rods. They cover all the sizes, though I only have a few of two.Five sizes per, but clearance is a little big. I may try and see if there is a hot rod shop here in the Boise area that can "build" the bearings for me.

That is a shame as these bearings are expensive enough now. I also bought one of these boxes many moons ago and they were cheap then compared by now. I remember you writing about that crank long ago. I can't remember if I told you the story of my French friend Baloo who owned and prepared the yellow XS1100 endurance racer with #94. In 2008 I visited the classic endurance race at Spa Francorchamps and did not find the bike in the pit box.When I finally found him he told me the primary chain had broken and had punched a hole in the upper case. Although they swapped it every year for a new one it could not stand continuous riding over 10k rpm. I think however he rode with higher rpm (if possible). That's how he is I don't know your riding plans but I think you should remember that in the back of your head.

pic of that chain:



Pic for the people that don't know that bike:

[DiverRay]

I'll need to keep that chain in mind! If I go much above 10K, I'll need to have the correct valve springs in as well. I also don't know how well the valve shims will handle high RPMs. My thought has always been "If it's balanced to Y, it will be smooth at X".

[DiverRay]

Well, just back from a local machine shop. I was NOT able to measure the bearing inserts, as my micrometer does not have a ball anvil on it. The gentleman checked my crank main and rod measurements, and then was able to check all the bearings. Yamaha bearings are Blue, Black, Brown, Green, and Yellow for both mains and rods. Blue is the thickest bearing, and they get thinner as you go right to Yellow. The difference is 0.00025". Yes you are reading that correctly! I also got my parts from MikesXS today, so I can start to put some of the parts back into the cases. I still need seals and a few other small bits, but should be able to get it all in about two weeks.

[DiverRay]

No pics this time, but a lot of cleanup work left to do. I have a transmission from another bike that needs to go in, as one main shaft gear is missing three teeth on the trans that was in this engine. I figure early next week I should be able to start putting in new parts.
I still have to get the numbers and find seals, but that should not be too hard, as most seals fit basic sizes.