Author Topic: RH ReHab  (Read 5538 times)

Offline Jonesy :-)

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Re: RH ReHab
« Reply #155 on: January 15, 2018, 04:15:29 PM »
Onto the exhaust repairs

The left muffler is cracked all the way round and i think the internal baffling/piping must be the only thing holding it together, opposite side to crack pic is covered in what can only be called weld spatter that even 3 coats of paint wont strengthen, a few  tacks will be applied to hold everything together while previous repair attempts are ground off and then its out with the old bbq lid to donate some patching material.
« Last Edit: January 15, 2018, 04:21:48 PM by Jonesy :-) »

Offline makzy

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Re: RH ReHab
« Reply #154 on: January 11, 2018, 10:14:37 PM »
I had the same problem a few years back when I fitted new manifolds, no matter what I tried just couldn’t get them on.
So next day I put the carbs in the sun on the concrete path all day then smeared rubber grease over the carb spigots and inside the manifolds and with the manifold cap screws loosend off just enough to let them move a bit it was in like Flyn, and have remained easy to remove and refit since.
Bloody frustrating tho!

MAX
 79 XS1100 STD (hack)
 80 xs1100 STD
( yet to be played with )
   ( ride the way you want to)

Offline steptoe

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Re: RH ReHab
« Reply #153 on: January 11, 2018, 09:42:09 PM »
excellent progress

Offline Jonesy :-)

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Re: RH ReHab
« Reply #152 on: January 11, 2018, 02:27:09 PM »
since the carby battle, motor was topped up with oil, gear selctor gizmos assembled with 2nd gear selected and witness marks all lined up, I was then able to select neutral. plugs removed and the starter button hit and wound motor over with no rattles bangs or clunks. Oil dropped away in sight glass so pump appears to be working and hopefully all the little internal weirs and filter are oiled up for ignition sequence
Before that happens I need to get on with exhaust repairs........more to follow

Offline Jonesy :-)

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Re: RH ReHab
« Reply #151 on: January 11, 2018, 02:13:33 PM »
No carby manifold clamps?, no problem! these wont come off. That rope is gunna hold em on real good


Not really,this is part of the process I had during a 4 hour epic battle to get the carby's into the manifolds which I think are near new and quite stiff.
Anyway, I'd get one side started, and tighten the hose clamp to hold it while I went to the opposite side to work the carbys in to manifold only to have the first hose clamped side pull out again, this went on for ages, during the process I used silicon spray in the hope of getting the carbys to slip in with ease, another desperate measure was cutting off the top airbox bracket as I was 1/2 convinced that was preventing carbies to fit.......Eventually i tied one started side like in pic to prevent it coming out while working the opposite side in, by now I was using a rubber mallet to bash the frellin carbys in while applying pressure with a spanish windlass, I thought about softening the rubber mainfolds up with a heat gun, but this was the same day Penrith had 47 deg C and in my shed it was 43 so I figured they were as soft and supple as they were ever going to be. 
« Last Edit: January 11, 2018, 02:37:36 PM by Jonesy :-) »

Offline BrettS

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Re: RH ReHab
« Reply #150 on: January 08, 2018, 07:42:14 PM »
Oh shit yeah, or the new spoked bike. You might need a few friends to ride them all up.
Or you n Eddie can hire a truck.
« Last Edit: January 08, 2018, 07:44:21 PM by BrettS »

Offline Jonesy :-)

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Re: RH ReHab
« Reply #149 on: January 08, 2018, 04:41:22 PM »
Yeah should be ready by then but I'm thinking of taking my old bike that I got back off chrisso a while back...........its next up on the operating table, decisions decisions?
I

Offline BrettS

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Re: RH ReHab
« Reply #148 on: January 08, 2018, 02:23:34 PM »
Looking good, will it make it to the Rally?

Offline steptoe

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Re: RH ReHab
« Reply #147 on: January 04, 2018, 10:26:19 PM »
forward steps are steps forward, even if a backward step is taken inbetween

Offline Jonesy :-)

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Re: RH ReHab
« Reply #146 on: January 04, 2018, 06:29:05 PM »
It's been a bit quiet round here lately so thought I'd do a bit of an up date on Re-Hab.
I've almost got a long motor now, just needs gear selector gizmos'put back on and alternator on the other side of motor to complete
and the out of service tag is to remind me to fill up the middle gearcase

As usual the Routine Hazards of things not going right on this build have reared there ugly head again. This time the bottom banjo bolt for the oil feed line to the head snapped at just a tad more than finger tight when a spanner was introduced, shit photo but closer inspection shows it was already cracked on one side, wether the last rebuilder was heavy handed or just fatigued over years of duty? who knows but not a lot meat around that oil hole. Luckily the ute load of spares came in handy with minimal disruption to the build.

Finding top dead centre and setting up the timing was pretty straight forward with dots on cams lining up spot on with cam cap indicators

and I eventually tracked down some brake pads on ebay pyramid parts part No: PP70 just for future reference if you've been duped like Hen and me with ferodo pads.


Offline steptoe

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Re: RH ReHab
« Reply #145 on: November 23, 2017, 09:11:21 PM »
I don,t recall having seen bevels on the inside of "our" rings, small edge on the outside to show the  top of ring is all I remember/ have seen

Offline Jonesy :-)

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Re: RH ReHab
« Reply #144 on: November 22, 2017, 08:26:53 AM »
Thanks for the offer Eddy, much appreciated
But its already back together, well cylinders are on anyway. I went with the as is set up based on I've seen this bike on the road and it went well and ran clean. If theirs trouble down the track its a quick job to do the top end, After all I was originally only going to fix the jumping into gear problem ::)

Offline XSIIE

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Re: RH ReHab
« Reply #143 on: November 22, 2017, 07:47:55 AM »
Paul, do you need a set of standard pistons and rings. I have a few sets.

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Offline Jonesy :-)

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Re: RH ReHab
« Reply #142 on: November 22, 2017, 07:14:16 AM »
G,day Errol
you might be onto something?
You or Steptoe might be able to confirm (between you 2 you've probly built more motors and more recently), but I noticed that all the 2nd or middle rings had a bevel on the inside top edge and It's been too long ago that I built 581 to remember if those rings had the bevel. Its still the original bore(s), all cylinders measured up at 71.57, limit is 71.6 mm. Also the top and middle rings seemed a tad too big, but then again I can't recall what 581's were like? maybe I've got 1st oversize rings on standard piston?
But all the rings were the same, it was just this ring groove that was different,
EDIT:
Build progress is cylinders have had a light hone to bring back the cross hatching
Dodgy rings and pistons have been re fitted and cylinder block back on.
« Last Edit: November 22, 2017, 07:19:11 AM by Jonesy :-) »

Offline Eveready1100

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Re: RH ReHab
« Reply #141 on: November 21, 2017, 09:40:06 PM »
Paul, are the rings on the other pistons the standard thickness. Just thinking that someone might have got some oddball rings (Focus maybe) and went to machine the lands a bit wider to accommodate them if they were thicker but made an error on that piston so just slotted in an extra ring to fill the gap???
Errol
1979 XS1100 SF Special
1978 XS1100E Donor
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