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The great o-ring, seal, gasket, nut, bolt, sizes used on the XS650 thread.

Discussion in 'The Garage' started by gggGary, Apr 28, 2018.

  1. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

    BS34 carbs
    Throttle shaft seal Suzuki part # 13651-51010 SEAL
    I replaced the butterfly shaft seals with these Suzuki seals they fit perfectly. Cost a dollar less than the Yamaha seal .....
    http://www.boats.net/parts/detail/suzuki/S-13651-51010.html 5twins tip

    BS34 mix screws 1mm thick x 3mm I.D. 5twins aug, 2017

    float valve to carb body 1.5mm thick x 7.5mm I.D. o-ring http://www.xs650.com/threads/float-valve-seat-o-ring-size.15162/

    Fuel line tee http://www.xs650.com/threads/fuel-t.7173/#post-74573
    replacement fuel T approx. 2.37"L0.343"W 0.365" at o-ring -xjwmx

    '81-on BS34 float bowl drain screw o-ring - 1.6 x 4.1 -5twins

    Idle mixture screw assembly, Not sold for the XS650 BS34s. But, similar Mikuni BS carb mix screw is the same, complete, screw, spring, washer, o-ring.
    https://www.partzilla.com/product/yamaha/12R-14105-00-00


    BS38 carbs
    Throttle shaft seal Suzuki part # 13651-51010 SEAL 5twins tip
    needle jet emulsion tube 1mm thick by 4mm I.D. http://www.xs650.com/threads/o-ring-size-on-bs38-needle-jet.10705/
    (2) 256-14956-01 - 08x13x1.0 (BS38 drain screw) 2many

    corrected 4-2019 carb 0-ring chart, thanks to 5twins

    XS650-Carb-Orings.jpg

    "Other" carbs

    Petcocks; 78-84 late model vacuum petcock to tank seal . 47mm OD x 3.1 mm o-ring
    Forks
    Drive Chain
    Engine
    Oil seals a research thread by the Guru 5twins has all? the seals with part numbers and decoding.

    Top end Copper Sealing Washers Compiled by 2many
    (1) 90430-14043 - 14x20x1.5 (Front oil tube, base at crankcase)
    (4) 90430-10027 - 10x16x1.5 (Front oil tube, top of head)
    (2) 90430-11033 - 12x18x0.5 (Cam chain guide hollow nuts to cylinder)
    (2) 90430-06014 - 6.3x11x1.0 (Cam chain guide fastening bolts) (6x10x1)
    (4) 90210-10004 - 10.9x22x2 (Outside head nut) (Suzuki 09168-10017 10.5x22x2)

    Bottom end Copper Sealing Washers compiled by 2many
    (6) 90430-08143 - 08x13x1.5 (Crankcase bottom nut washers)
    (4) 90430-06014 - 6.3x11x1.0 (Right clutch case cover lower screws) (6x10x1)
    (1) 90430-06014 - 6.3x11x1.0 (Tach drive retaining bolt) (6x10x1)

    https://www.ebay.com/itm/20Pcs-30mm...rush-Washer-Sealing-Ring-Spacer-/231470861472

    (2) 90430-38054 - 39x49x4.8 (Exhaust gaskets, head) (256-14613-00)

    (1) 256-12214-00 - 30.2x40x1.4 (Type A, B camchain tensioner cover)
    (1) 932-32172-02 - 33x39x2.5 (Type C camchain tensioner cover o-ring)
    (1) 93210-21190 - 2.6x20.6 (Type D, E camchain tensioner cover o-ring)
    (1) 90430-18130 - ??x??x?.? (Type E camchain tensioner lock nut)

    (1) 90430-11034 - 12x18x1.0 (Neutral switch)
    Tach drive 1.5 x 11 http://www.xs650.com/threads/tach-drive-o-ring-replacement.21252/#post-206956
    Rocker covers AS568-229 Silicone 70 "gggGary"

    drain plug washers
    1 3/16 ID.
    approx, mm - 37 x 30 x 01 xjwmx
    (2) 256-15353-00 - 30x37x1.5 (AN900-19) 2many

    Petcocks
    vacuum type petcock to tank oring 41mm ID 3mm thick
    Gas tank
    O-ring Gas cap for Special O.D.1-3/4" X I.D.1-1/2" (reportedly) xjwmx
    Gas cap 2M0-24641-00-00 GASKET,CAP 1 http://www.xs650.com/threads/gas-cap-seal-oem-number.25796
    Brakes
    Late model single piston caliper seal; courtesy 5twins.
    [​IMG]

    https://www.partzilla.com/product/suzuki/69107-05CF0

    A little over $5 sure beats $20 to $25.
    Side covers
    fenders
    gauges

    Thought I'd try to gather and organize bunch of the info into one place. I have an order started with http://www.theoringstore.com/ and want to flesh it out really well. I may set up a tiny store mailing o-rings "guaranteed to fit the XS650" in envelopes at low cost, cause we all hate running around town annoying countermen trying to find that odd little bugger or paying $15 shipping on a 25 cent part.
    So old posts, what you have found to work, what you haven't been able to find, post up! I'll try to organize and bring it into this post
     
    Last edited: Aug 7, 2019
    Marlin72xs, 5twins, Jim and 7 others like this.
  2. xjwmx

    xjwmx XS650 Guru Top Contributor

    7,071
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    oil drain washer
    1 3/16 ID.
    approx, mm - 37 x 30 x 01

    O-ring Gas cap for Special O.D.1-3/4" X I.D.1-1/2" (reportedly)
    would like to hear about results

    replacement Special fuel T approx
    2.37"L
    0.343"W
    0.365" at o-ring

    mag wheel tire size
    130/90/16 67s rear
    100/90/19 57H front
     
    MaxPete, Marlin72xs and gggGary like this.
  3. 5twins

    5twins XS650 Guru Top Contributor

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    Glad to see this thread happening, it's long overdue. I'll start with a couple engine related o-rings. This is the size I use for the '76-on cam chain adjuster acorn cover nut. It's an American size but is an absolutely perfect fit .....

    [​IMG]

    ..... and what I use for the valve covers .....

    [​IMG]

    Now, some carb o-ring sizes. Some of these have been revised from earlier listings. I recently did some BS34s and found the 7.5 I.D. for the float needle seat to be a little loose. It fit and appears like it will work OK, but a 1.5 x 7 is a better fit. I may even try a 1.6 x 7.1 next.

    The '78-'79 mix screw o-ring has been an on-going battle for me. Yamaha never sold this individually or listed it's size anywhere. If you bought a new mix screw, one came on it .....

    [​IMG]

    Originally, I tried a 1.5 x 3. It worked but was a very tight fit into the hole in the carb body, shaving a little off the O.D. of the o-ring as you installed the screw. So, I've moved down a size to a 1.5 x 2.5. This size works very well with no rubber shaving during install and a nice seal in the hole. But I know it's still larger than what Yamaha used. It fills the width of the o-ring groove in the screw. If you look at the pic of an original above, you'll see that one does not. My next try will probably be one with a slightly smaller cross section or thickness, a 1.3 x 2.5. I recommended this size to fellow member kshansen recently and he reported to me that they fit and appear to work fine .....

    [​IMG]

    [​IMG]

    I've been using a 1 x 4 on the BS38 needle jets for many years and it seems to work just fine. I did finally discover the actual size listed on Suzuki parts diagrams .....

    [​IMG]

    I haven't been able to locate any 1.1mm thick o-rings but the 1mm thick ones do come in several smaller I.D.s (3.3, 3.5, 3.7). I may try a 1 x 3.5 next.

    And while on the subject of carbs, this is what I use for slide needle shim washers .....

    [​IMG]
     
    Last edited: Aug 7, 2019
  4. 5twins

    5twins XS650 Guru Top Contributor

    18,590
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    Here's a couple often accessed screw replacements (points/advance housing covers, alt. cover). I originally switched to stainless Phillips but have now gone to button head Allens. I test fitted normal Allens but didn't like the look, the heads just stuck out too much in my opinion .....

    [​IMG]

    A note on the alt. cover screws - Yamaha cheaped out here and used screws that were too short. They don't reach all the way through the threaded tabs provided for them. I recommend switching to a slightly longer screw so you can utilize all the threads provided .....

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     
  5. YamadudeXS650C

    YamadudeXS650C Central New York XS650 XS650.com Supporter Top Contributor

    Gary,
    I have used your rocker cover O-rings successfully, and would appreciate it if you expanded your "store".
     
    Marlin72xs, TwoManyXS1Bs and gggGary like this.
  6. Mailman

    Mailman Hardly a Guru Top Contributor

    Hey Gary!
    I really like the idea of a mail order o-ring store! What a great service that would provide!
     
    Marlin72xs, TwoManyXS1Bs and gggGary like this.
  7. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

    Cool GUYS keep it coming! I'll try to get all your items added to that first post.
     
    Marlin72xs likes this.
  8. 5twins

    5twins XS650 Guru Top Contributor

    18,590
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    One I forgot - '81-on BS34 float bowl drain screw - 1.6 x 4.1.
     
    Marlin72xs and gggGary like this.
  9. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Copper crush washers?
     
    gggGary likes this.
  10. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    I think I found these in some of 5Twins' older posts.

    XS650-Carb-Orings.jpg

    Vesrah650GasketSet.jpg
     
    gggGary and Marlin72xs like this.
  11. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

    I kinda think the blue text one is blu biker blan?
     
    TwoManyXS1Bs likes this.
  12. kshansen

    kshansen XS650 Junkie Top Contributor

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    Here's the info on the idle jet screw orings I used on my 1978 carbs;

    First picture is the old needle with OEM used oring:
    Needle OEM used seal.JPG
    Below is picture of same needle with the McMaster Carr 1.32.5 oring part number 1302N123 installed: Needle with 1.3X2.5 oring McMaster Carr.JPG

    If anyone would like some of these I will send 4 of them to US mail for $1.00 on PayPal. I will agree that the origianl one probably would have been fine but had new needles in kit so thought I would replace them.
     
    gggGary likes this.
  13. 5twins

    5twins XS650 Guru Top Contributor

    18,590
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    Yes, the list in blue text was from blubikerblan, but I think he gathered the info from some of my postings. The Vesrah gasket listing is something I "doctored", inserting part number changes and I.D.ing the various o-rings. There should be one more correction there. Yamaha incorrectly lists the valve guide o-rings as being a 1.5 x 4.5 in their parts listings. They should be a 1.5 x 14.5 .....

    [​IMG]
     
    gggGary, robinc and TwoManyXS1Bs like this.
  14. xjwmx

    xjwmx XS650 Guru Top Contributor

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    It would be good to have the size of the o-ring that goes between the tank and a vacuum petcock. It ends up oval in a groove but it starts out a regular round ring.
     
    gggGary likes this.
  15. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Here's a 50 pack to fit the head bolts at Amazon for 10 bucks. Less than Mikes want's for 4.
     
  16. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

    I've been using metric 3.5 x 41 ID from the red box kit but ordered 3 x 41 which I think will be slightly better.
     
  17. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    *Whew*, this project is kikkin' my a$$. Gettin' tired.
    Where I could, got the original dims from the early parts manuals.
    Otherwise, from MikesXS, 5Twins, gggGary, other posts.

    Top end Copper Sealing Washers

    (1) 90430-14043 - 14x20x1.5 (Front oil tube, base at crankcase)
    (4) 90430-10027 - 10x16x1.5 (Front oil tube, top of head)
    (2) 90430-11033 - 12x18x0.5 (Cam chain guide hollow nuts to cylinder)
    (2) 90430-06014 - 6.3x11x1.0 (Cam chain guide fastening bolts) (6x10x1)
    (4) 90210-10004 - 10.9x22x2 (Outside head nut) (Suzuki 09168-10017 10.5x22x2)

    Bottom end Copper Sealing Washers

    (6) 90430-08143 - 08x13x1.5 (Crankcase bottom nut washers)
    (4) 90430-06014 - 6.3x11x1.0 (Right clutch case cover lower screws) (6x10x1)
    (1) 90430-06014 - 6.3x11x1.0 (Tach drive retaining bolt) (6x10x1)

    (2) 256-15353-00 - 30x37x1.5 (Bottom oil drain plug) (AN900-19)
    https://www.ebay.com/itm/20Pcs-30mm...rush-Washer-Sealing-Ring-Spacer-/231470861472

    (2) 256-14956-01 - 08x12x1.0 (BS38 drain screw)
    (2) 90430-38054 - 39x49x4.8 (Exhaust gaskets, head) (256-14613-00)

    (1) 256-12214-00 - 30.2x40x1.4 (Type A, B camchain tensioner cover)
    (1) 932-32172-02 - 33x39x2.5 (Type C camchain tensioner cover o-ring)
    (1) 93210-21190 - 2.6x20.6 (Type D, E camchain tensioner cover o-ring)
    (1) 90430-18130 - 20x25x2.5 (Type E camchain tensioner lock nut)
    (Per 5twins:) AS568A Dash Number 117 ('76-'83) Type D, E camchain tensioner lock nut)

    (1) 90430-11034 - 12x18x1.0 (Neutral switch)
     
    Last edited: May 14, 2019
  18. 59Tebo

    59Tebo 59Tebo Top Contributor

    Ya gotta love Allen head screws and bolts! Fewer wrenches in the kit....
     
    weekendrider, Jim and gggGary like this.
  19. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    A few odds & ends.

    Early tank (70-72, 73?) cas cap gasket. Aftermarket (MikesXS) gasket is a bit small at 56mm OD, barely covers the opening. OEM size of 60mm works better.
    256-22612-00 OEM01.jpg

    Sometimes you just have to make your own o-rings. NAPA offers a kit.
    NAPA-O-Ring-Kit.jpg

    Using their method (joining bologna cuts) and Gorilla superglue (has rubberized plasticizers), an oversized o-ring can be cut down to make another of the desired size.

    Some reference threads:

    http://www.xs650.com/threads/early-model-rubber-parts-source.51026/#post-533558

    http://www.xs650.com/threads/o-ring-for-vacuum-petcock-sealing-to-tank.31506/#post-318170

    http://www.xs650.com/threads/front-brake-m-c-reservoir-o-ring-part.50478/#post-523699

    http://www.xs650.com/threads/o-ring-identification-help.40736/#post-408508

    Early petcock rubber parts.

    http://www.xs650.com/threads/review-of-some-parts-purchases-from-mikesxs.10849/page-6#post-532180
     
    YamadudeXS650C, Jim and gggGary like this.
  20. xjwmx

    xjwmx XS650 Guru Top Contributor

    7,071
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    It could be useful to know the thread and size of the hollow allthread that holds the signal stalks on. Along with where to buy 2" pieces of it.
     

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