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Yamaha XS1100RH #000299
Restoration Details
The concept behind the restoration project of #000299 began after a conversation in 2022 between two pillars of the XS1100 community in Australia - Mal Pitman and Eddy Szmelter. The idea was to a create, as near as possible, an 'as-new' build of the XS1100RH.
Eddie had a rolling chassis for an XS1100RH that had the matching frame and crankcases for #000299, plus a hoard of hard-to-find XS1100RH components, and Mal had the expertise and time to drive the project forward.
Over a 5 year period Mal, plus several volunteer helpers, gradually collected all the original parts required and then meticulously set out to rebuild #000299 to the incredibly high standards that are evident through the images on this website. Mal's workmanship, in many ways, exceeded the standard and quality of the original factory delivered bike (i.e. to avert the notorious jumping out of 2nd gear issue, Mal undercut the transmission gear dogs and modified the selector forks to ensure rock-solid engagement under load).
Build Sheet
PART NUMBER | DESCRIPTION | Qty | COMMENT |
|---|---|---|---|
1J7-11138-00 | Head cam end seals | 2 | |
2H7-11193-00 | Cam cover gasket | 1 | In gasket set |
BP-6ES | Spark plugs | 4 | |
2H7-11181-02 | Head gasket | 1 | In gasket set |
2H7-11351-00 | Base gasket | 1 | In gasket set |
93210-77363 | Barrel o-rings | 4 | In gasket set |
91830-24016 | Barrel dowels | 4 | 99530-14016 |
93101-32087 | L/H main seal | 1 | |
93101-32088 | R/H main seal | 1 | |
Piston Kit 72.00mm | Cruizin Image | 1 | 0.5mm oversize |
Rings included in kit | 1 | ||
2H7-11633-01 | gudgeon pins in kit | 4 | |
90468-12069 | Gudgeon clips in kit | 8 | |
2H7-11416-21 | Main bearings | 9 | FAR |
2H7-11417-21 | Main bearing | 1 | FAR |
2F3-11656-00 | Big end bearings | 8 | FAR |
94500-02128 | Cam chain | 1 | |
2H7-12213-00 | Cam tensioner gasket | 1 | In gasket set |
93210-06001 | Cam tensioner o-ring | 1 | 93210-06632 |
Weld cam tensioner | |||
1J7-12119-01 | Valve stem seals | 8 | In gasket set |
93210-18319 | oil pump o-ring | 1 | |
005-879 | Inlet manifold set | 1 | |
93211-17317 | Oil filter O-ring | 2 | 93211-19413 |
2H7-13414-00 | Sump gasket | 1 | In gasket set |
93210-16314 | filter bolt o-ring | 1 | |
214-11198-01 | Sump plug washer | 5 | |
1J7-13440-71 | Oil filter | 1 | 1J7-13441-10 |
90201-20277 | Oil Filter washer | 1 | 90201-21608 |
93210-12152 | Oil cooler o-rings | 2 | |
91810-18016 | Side cover dowels | 6 | 91808-16023 |
93210-14369 | Oil line o-rings | 2 | |
341-14613-00 | Exhaust pipe gasket | 4 | In gasket set |
91830-22016 | Crankcase dowels | 2 | 99530-12016 |
2H7-11169-00 | Breather cover gasket | 1 | |
93210-61362 | housing cover o-rings | 2 | 93210-60538 |
93210-09350 | O-rings oil plate & case dowel | 3 | |
93210-18319 | Gallery plug o-ring | 1 | |
93210-13361 | Gallery plug o-ring | 1 | |
Cut valves | 1 | T W Engines | |
Cut valve seats | 1 | T W Engines | |
Refurb cylinder head | TW Engines | 1 | |
Rebore & Hone cylinders | 1 | T W Engines | |
Under cut 2nd gears | Mal | ||
Engine gasket set | Cruizinimage | 1 | |
2H7-15451-00 | Clutch cover gasket | 1 | In gasket set |
2H7-15461-00 | Gear change cover gasket | 1 | In gasket set |
2H7-15455-00 | Generator cover gasket | 1 | In gasket set |
2H7-15456-00 | Ignition cover gasket | 1 | In gasket set |
93210-27370 | Filler plug o-ring | 1 | 93210-27778 |
1J7-81847-60 | Starter motor o-ring | 1 | |
90338-30096 | K/starter plug | 1 | |
2H7-16139-02 | Primary chain | 1 | 63HV305-54A |
93104-14059 | Clutch actuator seal | 1 | |
341-16321-13 | Fibre clutch plates | 8 | measure & refit |
90501-23142 | Clutch springs | 6 | measure & refit |
93210-48364 | Clutch adjuster o-ring | 1 | |
BSP 012 | Bleed nipple covers | 3 | |
MSK 013 | Rear master cylinder kit | 1 | Yambits |
MC8 | Front master cylinder | 1 | |
360-25862-00 | Brake line boot | 1 | |
MSK 043 | Rear M/C rubber diaphram | 1 | |
93103-35105 | Middle gear shaft seal | 1 | |
1J7-17518-00 | Middle gearbox gasket | 1 | |
4R0-82305-10 | Ignition box | 1 | |
Ignition rotor | XS1100RH special | 1 | |
4R0-81672-10 | Ignition timing end plate | 1 | |
4BP-82370-01 | Outer plug caps | 2 | 5,000 ohms |
1J7-82370-00 | Inner plug caps | 2 | 5,000 ohms |
93410-30012 | Selector drum circlip | 1 | |
2J2-W1814-00 | Gear drum quadrant | 1 | |
93102-12106 | Gear change seal | 1 | 93102-12321 |
93210-12327 | Gear linkage o-rings | 2 | 93210-12790 |
93430-10016 | Gear change circlip | 1 | 99006-10600 |
99530-12016 | Crankcase dowel | 2 | |
93210-05098 | Aircleaner bolt o-ring | 4 | |
3H3-83513-00 | Speedo mounting damper | 2 | |
Paint head & Cylinder | Max - satin black painting | ||
Paint engine cases | Max - satin black painting | ||
Plating | Zinc plating | ||
Plating | Black zinc | ||
Plating | Gold zinc | ||
Fuel tank repairs | Dentknock tank | ||
Black colour | Paint fuel tank | Max | |
Black colour | Paint fairing assembly | Max | |
Black colour | Paint 2 x sidecovers | 0 | Max |
Paint Rims | Paint wheels and discs | Max | |
Prepare engine covers | Max | ||
Paint engine covers | Max | ||
L/H mirror | Max painting | 1 | Max |
R/H mirror | Max painting | 1 | Max |
L/H switch | Repair and paint | 1 | Max |
R/H switch | Repair and paint | 1 | Max |
Clean gasket surfaces | |||
Confirm carb condition | |||
Airbox intake hoses | Cruizin Image | 4 | |
Carby diaphram | Cruizin Image | 1 | |
Clean main oil gallery | |||
Plastic covering | Ignition wiring loom | ||
MOTOR BUILD | |||
MAINS | 1 2 3 4 5 | ||
Cases | 5 5 5 5 5 | 0 | |
Crank | 2 1 1 1 2 | ||
3 4 4 4 3 | |||
Bearings | Br Gr Gr Gr Br | These fitted | |
BIGENDS | 1 2 3 4 | ||
Rods | 4 4 4 4 | ||
Crank | 1 2 2 1 | 0 | |
3 2 2 2 | |||
Bearings | Blu Blu Blu Blu | These fitted | |
Sand blast fuel tank | |||
Prepare frame | for sand blasting | ||
Straighten frame | |||
Grind cases, covers etc | |||
Prepare parts painting | |||
Rear guard | Steel wool clean | ||
Front guard | Steel wool clean | ||
Headlight | Steel wool clean | ||
Headlight brackets | Steel wool clean | ||
Tailight assembly | Steel wool clean | ||
Clean plastic parts | |||
Cut spare key | |||
Straighten triple clamps | |||
2H7-22189-00 | Drive shaft boot | 1 | |
Machine disc | |||
HEAD SHIMS | |||
INLET | SHIM | CLEARANCE | |
1 | 265 | 4 thou | |
2 | 270 | 5 thou | |
3 | 270 | 5 thou | |
4 | 270 | 4 thou | |
EXHAUST | |||
1 | 270 | 7 thou | |
2 | 270 | 6 thou | |
3 | 275 | 7 thou | |
4 | 270 | 7 thou | |
2H9-18154-00 | Gear linkage ruber covers | 2 | |
1A0-27114-00 | Main stand rubber | 1 | |
1J7-27413-00 | Footrest rubbers | 2 | 4L0-27423-00 |
341-23469-00 | Handle bar bolt plugs | 4 | |
3J6-23145-00 | Front fork seals | 2 | |
90480-15235 | Oil cooler rubber mounts | 4 | |
90105-06116 | Oil cooler mount bolts | 4 | 95817-06016 |
90176-10009 | Shocker/guard mount nuts | 5 | |
95821-10020 | Rear guard bolts | 2 | 95817-10025 |
90480-14023 | Number plate mount grommet | 1 | |
90480-16014 | Head light mount grommet | 1 | |
90209-05182 | A/box lower bolt fibre lock washers | 4 | |
2H7-26240-00 | R/H handle grip assembly | 1 | |
2H7-26241-00 | L/H handle bar grip | 1 | |
130/90-17 | Bridgestone BT46 rear tyre | 1 | |
110/90-19 | Bridgestone BT46 front tyre | 1 | |
Fit tyres to rims | |||
Assemble front forks | |||
Add fork oil | 15wt 287cc per leg | ||
1J3-25834-01 | Disc bolt lock washers | 9 | |
90480-15058 | Side covers rear rubbers | 2 | |
2N8-85111-00 | Side reflectors | 2 | |
90430-06012 | Reflector gaskets | 2 | |
2J2-83922-00 | Front brake lever | 1 | 4L0-83922-00 |
Breather hose | Middle gear box | 1 | 1/8" hose |
Crankcase hose | Geoff's XS | ||
Bleed front brakes | |||
Helicoil R/H caliper | Lower mount bolt | ||
Clutch cable | Yambits | 1 | |
Throttle cable | Yambits | 1 | |
MBTX24U | Battery | 1 | |
Speedo cable | Yambits | 1 | |
90152-05005 | H/light rim screws | 2 | 98707-05012 |
Weld rear footrests | Repair tube ends | ||
Rear brake spring | 1 | ||
Refurb rear brakes | Paint and plate | ||
Clean exhaust system | |||
Ceramic coat exhausts | |||
Seat cover | Seatclone | 1 | |
O/haul carbies | |||
3X0-21783-00 | Side cover 1.1 badges | 2 | B/Replica YS18 |
3J6-24161-00 | L/H fuel tank badge | 1 | B/Replica YT10 |
3J6-24162-00 | R/H fuel tank badge | 1 | B/Replica YT10 |
Repair stator loom | |||
Front axle split pin | 1 | ||
Rear axle split pin | 1 | ||
Airbox top bolt & plate | |||
Engine oil | 4 Litres 20/50 | ||
Middle gearbox oil | 330cc 80/90 Hypoid | ||
Diff oil | 300cc 80/90 Hypoid | ||
Brake fluid | |||
16G-13569-00 | Inlet manifold plugs | 3 | |
90467-11028 | Inlet manifold plug clamps | 3 | |
1T5-26372-00 | Front brake lever cover | 1 | |
1E6-26342-00 | Clutch adjuster cover | 1 | |
1E6-26372-00 | Clutch lever cover | 1 | |
3F7-14984-00 | Carby bowl gaskets | 4 | |
95702-05500 | Rear M/cyl cap nuts | 3 | |
Repair seat base | Steve to weld up holes | ||
Paint seat base | Max Thompson | ||
Battery earth lead | |||
Fit fuel taps | |||
Fit fuel cap assy | |||
Fit tank badges |
Reconditioning: About
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