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Decided I'm going to replace the OE sump filter setup with a spin on filter setup, then clean & repair the OE one and keep it as an emergency spare for someone in the local XS community. Was introduced to xs650direct.com and have new carb holders & parts to service the carbs arriving next week...

Now here are some pics of my blown out sump filter... haven't decided to fix or just upgrade to a spin on filter. The little round filter looks reusable though.

THANK YOU! Using the drain bolt to torque the sump plate off worked great!

Trying to remove the sump plate off but it is stuck on good. Used a piece of wood on the edge and hit it with a hammer to try and break it free. Nothing. As I am considering replacing the OE sump plate with a spin on filter version, what suggestions are there to pry the plate off without...

Purchased a 27mm socket to remove the oil drain bolts and needed to use an impact gun to break them loose! After removing the rear drain bolt, I've never been happier to have 24 year old black oil drip all over my hand.

Thank you for the confirmation. Can you assist me with where the kill switch is supposed to go? The switch itself looks pretty simple and does it just splice in series into a wire and break the connection?

I am familiar with how a bike should start, in this case I am sharing what the previous owner created as part of this hardtail build that I inherited. There is a minimalist theme as there are no hand switches, no turn signals, no kill switch and no front brake which I am now changing. The...

I was digging on the site to figure out where the kill switch should go and found this diagram from this thread: http://www.xs650.com/threads/some-wiring-diagrams.61/page-2 Here is the wiring diagram that the previous owner left with the bike and it does not show the starter relay or starter...

I think the gas tank is in great shape, but wanted to get a second opinion of this light surface rust that is visible. When I touch it, it turns into a fine powder and is mainly on the hump and the side walls of the tank at very clean with some tiny speckles.

Decided to remove the carbs and take it to a shop tomorrow afternoon for a service estimate. Examined the boots and saw some cracking. Took some WD40 and coaxing but was able to slide the assembly off. Shiny throttle blades but they are stuck closed What 15 year old fuel residue looks...

Now with the tank removed I can take pictures of the wiring the previous owner did. Here is the wiring diagram and the "to do" list that came with the bike The aftermarket ignition switch is a car style "twist to the right" to start the engine and the key springs back to the left. I have...

Well the charging system is original and if it works for now then I'll save some $$$ and run a battery. To remove the gas tank I had to pry off this 42 year old piece of rubber tubing from the petcock. Poking around I see a couple of things on the carbs that are definitely not original

DAMN! Right beside the clutch adjustment point you made me aware of! :rolleyes: I need to go buy a service manual...

Thank you for this information and it makes a lot of sense to go kickstart only. Is there an easy way for me to check to see if the bike has a stock charging system or if has been changed?

Previous owner made some cuts and additions to the frame, so it's possible he may have threaded the hole. I was planning to use that hole as an attachment point for a swingarm mounted rear fender, and wanted to drill & tap a hole on the right hand side to match.

I don't have a chainguard so that would make sense it would be an attachment point for it. Thank you!

Thank you for this information!

Does anyone know what size of bolt that is meant to go into this threaded hole located on the left side of the 650 swingarm?

Thanks for this suggestions and just read up on what to do for an oil change service. I'll remove the upper and lower filter to check their condition as well as their gaskets. Going to pick up some kerosene to clean the filters and Home Depot lists 9.5L of kerosene for $20.00 and Canadian...

Pulled the spark plugs out, used a straw to put some oil into each cylinder, pushed down on the kickstarter and heard air come out! Did this a couple of more times, reinserted the spark plugs and then pushed down on the kickstarter by hand and felt the piston stop due to the compression! I'm...