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

gggGary

gggGary

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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 .....
https://www.partzilla.com/product/suzuki/13651-51010 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
https://www.siriusconinc.com/pro-detail.php?pid=&product_id=121090 jetmechmarty 1-21
BS34 mix screw sets with the o-ring https://www.partzilla.com/product/yamaha/12R-14105-00-00
'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

rubber caps, fit over pilot jets 2/2022 price, 4 for $9 USD
https://www.georgefixs.com/xs650-xs1100-carb-plugs/

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.
0cPxHCX.jpg


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

A little over $5 sure beats $20 to $25.
Side covers
fenders
gauges
Engine seals
Shift Shaft Seal 14mm ID 24mm OD 6mm thick

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.

can't post these too many places....
CarbSpecs.jpg


mikunipilotjetsmoddedam2.gif


BS38 SCREW SIZES
DIAPHRAGM COVERS
with bracket 5) M5 X 16
W/O 3) M5 X 14
CHOKE HOUSINGS 6) M4 X 12
CHOKE LEVER 1) M4 X 12 UP TO 16, VARIES
CHOKE LOCK TAB 1) M4 X 8
BOWLS 6) M4 X 14
BOWL UNDER CHOKE 2) M4 X 13.5 CAREFUL!
ANGLE BRACKET 4) M6 X 16


BS34 SCREW SIZES
DIAPHRAGM COVERS -
NO BRACKET 2) M5 X 10
ONE BRACKET 4) M5 X 12
TWO BRACKETS 2) M5 X 14
BOWLS 8) M5 X 16
ANGLE BRACKET 4) M6 X 16
Thanks to 5twins!
 
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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 .....

UR92NoM.jpg


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

M0PkYiR.gif


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 .....

96i404f.jpg


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 .....

jY1oN2p.jpg


iKGFd0S.jpg


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 .....

1UJ8RsE.jpg


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 .....

iEVv8Mf.jpg
 
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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 .....

YXiD3Ey.gif


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 .....

hX8JSxN.jpg


vJhhpKQ.gif


BVWCAkd.jpg


coE3RkJ.jpg
 
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.
 
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 .....

cFKrzJt.jpg
 
xjwmx said:
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.
Click to expand...
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.
 
*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)
 
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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
 

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