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This bike underwent a complete resto-mod in 2010. Many parts were replaced or upgraded to modern spec using parts sourced from 650 Central and MikesXS. I'll try to list what I've done to it but I'm sure I'm forgetting a lot of stuff. Frame: The frame, swingarm, triples, fork sliders, and many...

I've just finished restoring a '78 Special and have put about 50 miles on it so far (very exciting!!) Anyway, I've got a bunch of little issues but the only one I'm totally stumped on is this: I'll shut down the bike with the kill switch and everything's normal. But when I turn the key off...

I noticed the wiring diagram in the back of my Clymer manual doesn't match the wiring on my bike exactly. A lot of the colors are off, but what's got me confused is the starter button. The wiring diagram says it should have a blue/white wire and a black wire. The switch I have only has the...

I have the Pamco ignition with the Ultimate coil (the black one). There are two tabs coming off one end of the coil, where you hook up the red and green wires from the Pamco. The problem is I don't know which tab is positive and which is negative. Does anyone know which tab is which?

I've got a bent left footpeg for a '78 Special and I'm wondering a few things. First of all, I'm not sure how it got bent but I have 2 ideas: 1. The bike was crashed back in the 70s and it may have got bent in the wreck. 2. The peg may have gotten bent from kick-starting and coming down...

I bought these shocks from MikesXS: http://www.mikesxs.net/products-18.html#products The second ones on the list - Monza Cafe gas shocks. Guess what? They don't fit on the fucking bike. The spring diameter is too big, it doesn't fit past the chain guard. Even with the chain guard off...

How do you install the coil wires in the coil? And how do you install the plug caps onto the wires? The stuff I have is the stuff from Mikes that comes with the Pamco ignition. I've got 2 yellow wires, a coil, and 2 NGK plug caps. No idea how it all goes together. Can someone point me in...

One of the filaments in my headlight is shot. It looks like the whole unit is sealed tight so you can't just replace the filament. What are my options for headlights? I'd like to get something that uses less power than the original if that's possible. I want to conserve as much power as I...

My sidestand bolt sheared off today, so I tried to get it out with vise grips. No dice. Then I got an Easy-Out in there and started turning it. The bolt came about 1/4 turn out, then the Easy-Out sheared too. Now I'm clueless as to how to get the Easy-Out out of the sheared bolt. I can't...

What's the regular chain length for a '78 Special? I bought a new chain but it has too many links and I want to cut it down to the right size. It's a 530 o-ring chain. Also, I thought the chain came with a master link but it didn't. Where's the best place to get a rivet-type o-ring master...

I'm trying to take apart my forks, but I can't get the fork tubes out of the sliders. The manual says to remove the allen bolt at the bottom of the slider, then just pull the fork tube out. I got the bolts loose but they don't come out, they just spin in their holes. Pulling on the fork tubes...

I'm putting my clutch back together and I'm having issues. I originally put it all back together in the same sequence that I took it apart. I tightened down the clutch springs and there was 1/4" of play between the clutch plates and the pressure plate. Is this normal? I have it all apart...

I bought these shocks from Mike's: http://www.mikesxs.net/products-18.html#products The second item, gas shocks with black springs. They came with little black rubber spacers which you can see in the picture, but I don't know where they go. It seems like the top eye is pretty snug on the...

I bought a 750cc kit from MikesXS. On the back of the cylinders, it has just a round threaded hole for the cam chain tensioner. The old cylinders have a rectangular plate that the cam chain tensioner assembly bolts to with 6 bolts. Is there anything special that I need to do or just use the...

I'm rebuilding a Special and I need new pipes. Mikes has a "Commando" set for $330 and an XS1 style reproduction that fits a special for $550. I'd rather go with the cheaper set but I am looking for a nice quiet exhaust. Are the Commando pipes loud?

Hey guys, this may have been posted before but I couldn't find it. Anyway, BikeBandit has all the microfiche schematics for the XS. I tried '78 but they didn't have that year, but I knew the part I wanted was the same on an '83 and they had the fiche for 1983. I'm not sure what other years...

Sorry, this double-posted. See the other thread here: http://www.xs650.com/forum/showthread.php?t=2072

I pulled the head off my engine tonight, as the whole bike is being rebuilt including the motor. I should note that this is the first time I've worked on an engine, so I'm kind of new to things. I rode the bike from 2006-2007 and had some issues, including oil coming out from between the head...

My wheel bearings need replacing, and they are not coming out. The rear has a little collar pressed into the sprocket side bearing that will drive the center spacer into the inner race on the opposite side bearing. First I put a socket on the collar and hit it with a rubber mallet. Nothing...

I'm considering putting heated grips on my bike. Does the stock alternator put out enough juice to run the grips and all the lights?