Second Gear XS1100

[makzy]

G-day Phill,well thats good, glad to here it got ya out of trouble, well if ya gunna lift up one end i'd say stand it on the rear wheel, flip up the rear mudguard, never thought of doin it that way, cos mine was in the lounge room when i did it  but yeah that would work, not that i'm any expert, just be aware that the final drive will leak oil out the breather and probably the middle drive unit as well, probably best to just drain them, have fun!

[Rockman]

Thats good Phil, I'm about to remove the engine from my bike, thought my problem was the cush drive, i've already done second gear through the bottom but looks like i've got to do first now and ya can't get at it through the bottom, will try and get some pics when i do so you can get a bit of an idea whats inside, cheers.

G'day Max.
I fitted up the new carby with the parts out of my old one on the weekend. It now starts, idles, and runs much better. Took it for a 5km ride and it went well, except for 2nd gear jumping if I give it a liitle too much throttle.

I'll be interested in how you go with the gears. I was thinking of just lifting it up using a chain block to get a better look at what I was doing in there. I can get either end about 2 metres up using a cross beam in my shed. Which do you recon will be best -- lift it by the back end or front end??
Phil

[makzy]

Thats good Phil, I'm about to remove the engine from my bike, thought my problem was the cush drive, i've already done second gear through the bottom but looks like i've got to do first now and ya can't get at it through the bottom, will try and get some pics when i do so you can get a bit of an idea whats inside, cheers.

[Rockman]

The carby has arrived - thanks Max. I'll transfer parts over on the weekend and hopefully get it going.
Phil

[Rockman]

G,day Phil, going to try and put up some pics for you, these are 2 sets of carbs i have, as you can see there are broken posts on 1 and 4, both no 2's are ok, they have 28 mm slides, the set that is still together is the one i want to use, if there is a number where my finger is pointing on the little block on the choke side of your carbs, mine might not be any good to you, mine have no number. i'm seriously considering replacing mine on my second bike with either zrx 1200 kawasaki carbs or  xj 1100 carbs, might even go to a new set from mikuni, prices are a bit scary but there would be no worries with new ones, if i can't get the pics on here call me 0407628358 and i'll send them to you by phone, if the carb body is any good to you, you can have it for the cost of postage. Cheers.
Sorry Phill, have no idea how to put the pics on here, call me if your interested.

G'day Max
Its actually the No. 3 I need (dont know my right from my left.... ). Anyway I'll have a look at mine tonight and give you a ring.
Cheers, Phil

[makzy]

Phil, think i got it worked out!

[makzy]

 G,day Phil, going to try and put up some pics for you, these are 2 sets of carbs i have, as you can see there are broken posts on 1 and 4, both no 2's are ok, they have 28 mm slides, the set that is still together is the one i want to use, if there is a number where my finger is pointing on the little block on the choke side of your carbs, mine might not be any good to you, mine have no number. i'm seriously considering replacing mine on my second bike with either zrx 1200 kawasaki carbs or  xj 1100 carbs, might even go to a new set from mikuni, prices are a bit scary but there would be no worries with new ones, if i can't get the pics on here call me 0407628358 and i'll send them to you by phone, if the carb body is any good to you, you can have it for the cost of postage. Cheers.
Sorry Phill, have no idea how to put the pics on here, call me if your interested.

[Rockman]

PM sent

[makzy]

Phil i might be able to help you with a carb body, you'l have to tell me witch one, 1 on left, 4 on right, do they have any numbers on the side near the choke leaver? the set i have don't, i also have a float post broken off on one of this set, you can fix it with some DEVCON, clean the post, oil the pin, mold the devcon around the pin to form a post with new hole, i presume it's broken through the pin hole? then when it's properly set use a small grinder, dremel, or file to shape the post, it would be very difficult to weld, even a good man with a tig would have trouble, i asked 3 top alley welders if they could fix it, all said no, something to do with the type of cast alley they say. Cheers.

[Rockman]

I tried the US bolt/nut method - didnt budge them. Tried heating, tried cooling, tried prodding them. No go. So I drilled them out with the smallest drill bit I could find. I havent fitted them back on the bike yet to see how they go but I recon at worst I'll have to adjust the screws to suit.

In the same area, one carby has a cracked post for the float. Its been repaired before by the look of it and the rewelding hasnt taken properly. Would anyone have a spare carb body for sale. Its the older type with the brass floats. I just need one.
cheers
Phil

[Brian]

Hi Phil, it's a common problem with these carbs, there's a tech tip for it on the american site click here

Other solutions included putting the whole set of carbs in the freezer ('cos different metals contract at different rates) and winding up an acorn nut on the end of a bolt to push the tip out.

Drilling is the last resort.

good luck. 

[makzy]

G,day Phill, there was a post somewhere i think in the us xs site that explained how to get broken off mixture screw tips out, not sure but think there is a kit you can buy to do the repair, but Jonesy's method should work, try a piece of wire from a stainless wire brush bend it 90 degrees and try and bush the broken tip  back up the screw hole after you cook the carbs, new screws are available through Z1 ENTERPRISES, or just google MIKUNI, they've got everything you need there. Cheers,

[Jonesy]

G,day Phil
Hmm....sounds nasty. Is there anything left protruding you could grab with jewelers pliers? or jetting hole you could start a very small ezy out into? I'm working from memory here

I once used this method to remove a broken bleed nipple from a brake caliper.

Strip the carbies right down so you just have the main carby body with the offending broken jet remaining.
Get your camp stove out and fill a suitable container with oil to completely submerge the carby
Now bring the oil up to a hot temperature....(sounds a bit like cooking with margaret fulton ay) this could get a bit smoky so do it outside. The heated oil works better than any penetrene oil or WD 40. plus you get the added advantage of  expansion and contraction with the heat to help loosen it.
Now try removing while still hot.

Jonesy.

[Rockman]

Doesnt sound like a job I should do before easter so I'll park it up and take my Triumph Scrambler to Cameron Corner. I was planning to drop the engine out and clean it up anyway so I'll do the gearbox then. Its got other probs as well........

On another topic - a previous owner has overtigtened the pilot air screws and broken the tips off the screws. Trouble is that the brass tip is still stuck in the hole on three of the four carbies. Any suggestions as to how to get these out. I'm reluctant to try to drill them out because of the risk of getting off centre and destroying the carbies.

Phil

[coe1948]

   My XS has got the same problem,it has got a DJP sidecar fitted to it .it jumps out of 2nd gear also i have not ridden it for a while but i do miss it.I have got some spare parts so if you are stuck send me a pmi am not sure if i have got any gears but i have got sellector forks
  Regards Dale