1. Guest,
    We need good tech writers that are willing to help out here at ZL-OA. If you like taking photos of jobs as you perform the steps on your repairs, have historical ads/documents from old magazines, or any else you think belongs in the Technical Library than you might be able to help. Send a private message to Furchin, Mudrunner88, Chris, Jarney, Wuputt, or Markus56 and we can lead you in the right direction to get started.
    Dismiss Notice

Bringing a 79' XS11 Special back to life

87kawzl Aug 6, 2019

  1. 87kawzl

    87kawzl Supporting Member

    1,641
    155
    158
    7200 mi bike with a 1980 parts bike. No key or battery, bought on hope and a prayer that it would run with some TLC. Found it for a good price and felt up to a small challenge. It seemed like a good idea at the time:roflmao::roflmao::roflmao:

    This thread will document my path in hopefully breathing some life back into the ol girl with some BS along the way. I know it's not an eliminator but I can't seem to find one of those on the cheap. Stick around if you like.
    IMG_20190713_150359.jpg IMG_20190713_154552.jpg
    Parts bike and project upon arrival.
     
  2. 87kawzl

    87kawzl Supporting Member

    1,641
    155
    158
    Ordered a key from eBay, cyclekeysonline. $14 shipped to the house and will be here in a few days. Polished some paint and chrome in the meantime.
     
  3. 87kawzl

    87kawzl Supporting Member

    1,641
    155
    158
    Front master cylinder was empty and full of crust. Time to go through the front brakes. Hoses and calipers will be cleaned up next as I wait for my key. I will use the eliminator battery to see if the motor turns over once the key shows up. Just putzing around cleaning and making a parts list for now. If she cranks over I will reward her with new parts!
    MVIMG_20190805_180236.jpg
     
  4. 87kawzl

    87kawzl Supporting Member

    1,641
    155
    158
    Piston was stuck in there with what seemed like gorilla glue... $15 Harbor freight pliers barely made it with the pins fully extended. IMG_20190806_182137.jpg
     
  5. R. J.

    R. J. Supporting Member

    8,563
    412
    128
    :hello: Nice to see that someone else is documenting a bike project. :notworthy:. Looks like at least 35 years of sitting.
     
  6. 87kawzl

    87kawzl Supporting Member

    1,641
    155
    158
    Thanks to cycle keys online I was able to open the crusty fuel tank and turn the ignition. What a mess...things ain't so pretty on the inside as they say. IMG_20190807_182137.jpg IMG_20190807_182137.jpg

    Like I was expecting a nice clean tank after what the master cylinder looked like! Here we go!
     
    Last edited: Aug 7, 2019
  7. R. J.

    R. J. Supporting Member

    8,563
    412
    128
  8. 87kawzl

    87kawzl Supporting Member

    1,641
    155
    158
    I've got a 5 gallon bucket, at least I'm not going to have to deal with a flaking tank coating.
     
  9. R. J.

    R. J. Supporting Member

    8,563
    412
    128
    :hello: I never seen any tank coating hold past 5 years. Most likely you will have to use the EVAPORUST more than once. It took 3 times for my ZL 10 tank in order to get all the rust and it was not all that bad. You can buy a probing scope for your smart phone. They cost around $45.
     
  10. 87kawzl

    87kawzl Supporting Member

    1,641
    155
    158
    I have a camera, thanks for the tip. I need some paint strainers for recycling the evaporust. Had to do my ZL tank twice because it flash rusted, coated it with marvel mystery oil after the second soak.

    Took off the front calipers and the pads are in good shape except the backings are a bit crusty. Crazy setup pivots on a single mounting bolts and the friction material is beveled, odd.
     
  11. 87kawzl

    87kawzl Supporting Member

    1,641
    155
    158
    Front calipers will just be getting rubber, rear caliper needs a piston and rebuild kit. Rear master was in the same condition as the front, ugly. I rodded the front brake lines with the core wire from coaxle cable and now they are clear. Rear lines blew freely with air. Looking like ~$150 for brake parts. Some pics... IMG_20190811_112405.jpg IMG_20190811_122219.jpg IMG_20190811_140140.jpg
     
  12. R. J.

    R. J. Supporting Member

    8,563
    412
    128
    :hello: Inside the calipers looks to be pit free. Are you going to replace the seals and dust seals in the calipers. Did you ckeck the brake lines for dry rot.
     
  13. 2manybikes

    2manybikes New Member

    11
    2
    3
    The black one is an 81 Special and the red one is a 79 Special IMG_4029.JPG IMG_3175.JPG IMG_3388.JPG . With the discussion about Evaporust, I thought I would share a photo of my high tech tank dryer!
     
    R. J. likes this.
  14. 87kawzl

    87kawzl Supporting Member

    1,641
    155
    158
    On eBay there is a set of all 5 brake rebuild kits for $108 (2 masters & 3 calipers). The piston will be ~$25 and all the hoses are clear and free from cracks. I tried the ZL battery and it came up short on CCA, the ZL size usually is around 230 and the XS specs out at 350. The ZL battery yielded just a click with each press of the starter button.

    2manybikes, you have some fine examples of the XS11, I've been looking hard at the current generation California for some longer range rides and I think we need to see some pics of that Kaw! Thanks for sharing the tank drier details.
     
  15. R. J.

    R. J. Supporting Member

    8,563
    412
    128
    :hello: Thats great that someone offers a complete rebuild kit for the XS 11. Who makes it and what Country is it made in.
     
  16. 87kawzl

    87kawzl Supporting Member

    1,641
    155
    158
    K&L brand and the seller is out of FL. Pretty sure we know country of origin at that price. They just sell all 5 kits as a package.

    I've really got to watch the spending on this or if will quickly cost more than I will ever get out of it. I liked the idea of having an air cooled liter bike again and was hoping at 7200mi there wouldn't be too much cost in getting it going again.:roflmao:
     
  17. R. J.

    R. J. Supporting Member

    8,563
    412
    128
    :hello: I've only sold one bike for more than what I had in it. It was my first Moto-Cross bike which was a 1974 Yamaha YZ 125 mono-shocker. Which was the first singal shock bike on the market. I paid $600 for it. Put a new crank in it and first over piston. I sold it for $850 in 1976. I raced it for 3 years (74-76) at Ground Hog Valley Moto Cross Track in Punxsutawney PA. ________________________________________________________ IMG_7956.JPG IMG_7955.JPG
     

Share This Page