XS650 Direct

"Haynes" Service Manual - covers XS650 1970-83

3.33 oz. (75 ml) tube of Autosol Metal Polish.
Cleans, polishes, protects and removes corrosion.
For all metal parts-chrome, brass, copper, nickel,
stainless steel & aluminum.
Made in Germany since 1929.

"A product that is superior to anything else available"

Metric Go Thru Socket Set - Rachet and Extension Hold Socket from the outside
eliminating the need for deep sockets. Reaches in Deep.
Set includes Thin Go Thru Rachet and Extension + 6 pint Go thru Sockets - 19mm.,
17mm.,16mm., 15mm., 14mm., 13mm., 12mm., 11mm., 10mm.,+
1/4" Drive adaptor with matching Sockets in Sizes - 14mm., 13mm.,12mm., 11mm.,
10mm., 9mm., 8mm., 7mm., 6mm., 5.5mm., 5mm., 4.5mm., & 4mm.
In plastic latched case.

Metric Nut Driver Set - Quality Forged Chrome 6 point Drivers with T- handle
Rachet with quick release. Set includes 3/8 drive rachet handle and 11 1/2"
inch long drivers in Deep mm sizes - 8,9,10,11,12,13,14,17 & 19mm. Includes
folding case.

1,000cc (1 Liter) plastic Graduated Cylinder for accurate measuring of fluids.

1 US Quart = 946cc (946ml.)

500cc (1/2 Liter) plastic Graduated Cylinder for accurate measuring of fork oils
and other fluids.

250cc (1/4 Liter) plastic Graduated Cylinder for accurate measuring of fork oil
and other fluids.

Fork Oil Level Gauge for adjusting the oil level on all XS650 forks.
Adjustable ring measures oil levels from 0-300mm. in 50mm. increments.
60ml. capacity syringe adjusts fluid levels.

27mm. Box Wrench to fit XS650 Oil Drain Plugs. Long (15") type for leverage to
loosen those tight oil plugs.

32mm. 6 point Box Wrench - chrome plated steel. Also has 39mm. size.

17mm. Hex (Allen) bit Tool to remove fork tube top caps.
Fits: Fork caps on TX650A (1974), XS650BC (75-76) and 1977D (version without
preload adjuster).

A perfect fit to remove those soft alloy fork tube caps without damage.

22mm. 12 Point Fork Cap Wrench. Removes alloy fork Tube Caps.
Fits: TX650 (1973), XS650 (1978-84).

100 Amp Battery Cables (8' Long) with alligator clips - For Motorcycle use.

Deluxe 12 Volt Battery Charger for AGM (Absorbed glass mat), Maintenance free,
VRLA, Gel and conventional flooded lead acid batteries. UL & CSA Approved.
Output is 1.25 Amps, 12 volt DC (maximum 14.5 Volts). 4 Stage Microprocessor
controlled charging with automatic shutoff at full charge. 120v AC Input.

1. Qualification - Ensures battery is safe to charge, and has minimum 3 Volts.
2. Bulk Charge - Raises battery to 80 percent of full voltage.
3. Absorption - Holds battery voltage at 80 percent and forces current to top battery
4. Float Mode - Maintains the fully charged battery at a proper working voltage.
Charger Features - 6 LED indicators to show charging status, reverse polarity
protection, overheat protection, overcharge protection and spark proofing.
Full instructions, quick disconnect alligator clip leads and fused eye terminal
leads included. (Not for outdoor use).

Electrical Continuity Tester (use with power off) - Detects open circuit in fuses,
diodes, switches, sockets and wires (requires one AA battery - Not included).
Long 48" leads.

Electric Circuit Tester - Checks all motorcycle primary electrical and computer
circuits for power. Plastic handle lights up if circuit is good. Icepick type
probe and 48" cable with insulated alligator clips.

Terminal Crimper Tool

Terminal crimper tool, fastens metric terminals to wires. Professional Crimps
like factory originals. Also can be used to cut and strip wire.

Alternator Rotor Puller - Safely pulls rotor without damaging it. Fits: All 650's.

Cable Luber - Yamaha pressure type (Sold each)
Water & dirt are blown down cable by lubricant when pressure spray can nozzle
is applied. Spray lube sold by most bike shops.

Dual Carb Sync Gauge Set with built in adjustable
Pulse Dampers mounted on bracket and with hoses.
Precision Diaphragm type gauge set originally designed
for Professional Motorcycle shop use in Japan.

Note: Sync gauges hoses hook up to carb holder vacuum air barbs (not included).
Your bike must have these air barbs in order to use this sync tool.

Inductive Xenon Timing Light. Operates from 12Volt Battery Power.
The only accurate way to set your 650's Timing and check advance.

Circular Spark plug gap tool. Marked in thousandths of an inch and millimeters.

Feeler gauge set with 45 degree ends.
Includes Sizes - .008", .010", .012", .013", .014", .015", .016",
018", .019", .020", .025", .026"
Marked in Metric and Inch sizes.

Feeler Guage Set- Metric Feeler Guage Set for setting valve clearances.
9pc. Set (marked in metric sizes only).
0.04mm. - (.0015")
0.05mm. - (.002")
0.06mm. - (.0025")
0.07mm. - (.0028")
0.08mm. - (.003")
0.10mm. - (.004")
0.15mm. - (.006")
0.20mm. - (.008")
0.30mm. - (.012")

Feeler Gauge Set- Metric Feeler Gauge Set for setting valve and contact
point clearances. 20pc. Set (marked in metric sizes only).
0.05mm. - (.002") 0.55mm. - (0.22")
0.10mm. - (.004") 0.60mm. - (0.24")
0.15mm. - (.006") 0.65mm. - (0.26")
0.20mm. - (.008") 0.70mm. - (0.28")
0.25mm. - (.010") 0.75mm. - (0.30")
0.30mm. - (.012") 0.80mm. - (0.32")
0.35mm. - (.014") 0.85mm. - (0.34")
0.40mm. - (.016") 0.90mm. - (0.36")
0.45mm. - (.018") 0.95mm. - (0.38")
0.50mm. - (0.20") 1.00mm. - (0.40")

Feeler Guage Set - Metric/Inch Feeler Gauge Set for setting valve and contact point
clearances. 32pc. Set (marked in metric and inch sizes).
0.03mm. - (.001") 0.04mm. - (.0015") 0.05mm. - (.002") 0.06mm. - (.0025")
0.07mm. - (.0028") 0.08mm. - (.003") 0.09mm. - (.0035") 0.10mm. - (.004")
0.13mm. - (.005") 0.15mm. - (.006") 0.18mm. - (.007") 0.20mm. - (.008")
0.23mm. - (.009") 0.25mm. - (.010") 0.28mm. - (.011") 0.30mm. - (.012")
0.33mm. - (.013") 0.35mm. - (.014") 0.38mm. - (.015") 0.40mm. - (.016")
0.45mm. - (.018") 0.50mm. - (0.20") 0.55mm. - (.022") 0.60mm. - (0.24")
0.63mm. - (.025") 0.65mm. - (0.26") 0.70mm. - (0.28") 0.75mm. - (0.30")
0.80mm. - (0.32") 0.85mm. - (0.34") 0.90mm. - (0.36") 1.00mm. - (0.40")

Cylinder Compression Tester set with quick coupling & release valve.
Includes adapters to fit 10, 12, 14, & 18mm. Spark plug holes.

Cylinder compression Tester with quick coupling, universal adapter and
flex hose with 14mm. threaded end.

Piston Pin Puller with adaptors (13,15,16,19mm. OD).
Easily removes XS650 Piston Pins (20 & 22mm. OD) without damage.

30mm. Diameter inspection mirror on telescoping wand 7-20" range.

Compact LED flashlight with 5" long flexable lighted tip. Ideal addition to your
bikes tool kit as a map light or for emergency roadside repair. Low power draw
LED bulb provides a bright beam and long battery life from one AAA battery (Not
included).

Professional Flexible Fibber Optic Image Scope for inspecting
engine internal parts.18" long wand with a 6mm.(1/4") OD tip.
Image resolution is 7,400 pixels. Packed in a blow mold case
with handle jacket and extra Xenon Bulbs and 2 AA batteries.

29" Long Flex Rod with lighted magnetic Tip.

Flexable Rod with magnetic tip.
23" Long, picks up to 3.5 Lbs.

5pc. Hook and Pick set with magnet in handle end.

Thread Pitch Gauge for measuring Metric thread pitch (threads per millimeter).
A very useful tool to identify the many various fastener threads used on
Japanese bikes. Gauge has the following sizes - 0.5, 0.6, 0.7, 0.8, 0.9, 1.0,
1.25, 1.75, 2.7, 2.8.

Metric Tap & Die Set in storage case.
Set includes Pitch Gauge, Die Holder, 2 Tap Wrenches & screw driver +

Metric Taps - M3 x 0.5, M3 x 0.6, M4 x 0.75, M4 x 0.7, M5 x 0.8, M5 x 0.9,
M6 x 1.0, M6 x 0.75, M7 x 0.75, M7 x 1.0, M8 x 1.0, M8x 1.25, M10 x 1.25,
M10 x1.5, M12x 1.25, M12 x 1.5, 1/8NPT x 27

Metric Dies - 17 Dies to match taps listed above.

Cam Chain Tool Kit in case - a "must have" tool to Break and Rivet cam chains.
Note: Do Not use for rear drive chains.

Replacement Breaker Pin for Cam chain breaker tool.

Slide Hammer with correct bolt thread to remove
Engine Rocker Arm Shafts from head cove. Works
on All 1970-84 650's. Easy to use.

Valve Spring Compressor - Large Honda heavy duty type.
This style valve spring Compressor works best on the XS650.

Valve Spring Compressor Tool in case
High quality professional tool to remove valve springs.

Now with 5 Tips! - 16, 19, 23, 25 & 30mm. Dia.

Valve guide Install / remove driver tool for 1970-84 650's

Valve Lapping Sticks - Set/2

Tool Kit for doing 3 angle Valve Seat Cutting & Finishing.
Kit was created by Mikes XS specifically for overhauling the XS650 cylinder head.
Works on All 1970-84 650 engines.

Kit Contains:
1 - Precision ground T-Handle Valve guide Pilot
1- 36 x 45 degree Carbide Cutter
1- 43 x 30 degree Carbide Cutter
1- 43 x 45 degree Carbide Cutter
1- 43 x 60 degree Carbide Cutter
1- 36 x 45 degree Finishing Stone, 1- 42 x 45 degree Finishing Stone
1 Set/2 Valve Lapping Sticks, 1 Tube Valve Lapping Paste, Instructions

Permatex Valve Lapping Paste

1- 36mm. Dia. x 45 Degree replacement Valve Seat Grinding stone for kit #36-0116

1- 42mm. Dia. x 45 Degree replacement Valve Seat Grinding stone for kit #36-0116

5pc. Screw Extractor Set - used to remove broken off studs, bolts, &
screws. Set includes sizes - 1/8", 3/16", 15/64", 5/16", & 3/8"

Metric Pin Punch Set
Set includes small sizes usually not available:
1.5mm, 2.0 mm, 3.0 mm, 4.0 mm, 5.0 mm, 5.5 mm,
6.0 mm, & 8.0 mm in storage case

15mm wide (9/16") Stainless Steel Gasket Scraper Knife.

20mm. wide (.79") Stainless Steel Gasket Scraper Knife.

8 pc. Driver Set for Allen Socket Screw

Hard to find deep 140mm. Long bits ideal for reaching up
inside lower for legs and other recessed spots. Kit includes
1/2"" drive socket sizes • 5, 6, 7, 8, 10, 12, 14 & 17mm.

1/2" Drive 27mm. 6 point deep Socket.

Fits: Clutch Hub Nut on All 650's 1970-84

Clutch Holder Tool - Holds inner and outer clutch hubs so that the center nut
may be removed without damaging hubs.

Fits: All 650 clutches (1970-84).

Professional adjustable vise grip style clutch basket and sprocket holder tool.

36mm. 1/2" drive, 6 point, Impact Socket.

Fits: Front Sprocket on all 650's 1970-84.

Impact Screwdriver with bit set in case. A must have tool used to break loose
engine screws with slot or phillips heads.

Replacement Driver Bit Set (1.5" Long) - Set contains 2 Phillips & 2 Slotted
impact driver Bits.

Replacement Driver Bit Set ( 3" Long ) - Set contains 2 Phillips & 2 Slotted
impact driver Bits.

Drive Chain Riveter Tool - Rivets high strength rear drive chain Rivet links with
hollow pin ends as on our IZUMI 530HT Chain ( Rivet link #56-0235 ) and many
DID brand chains. This quality tool is sold by Mikes XS at below cost.

Note: Discount of $25.00 for this tool if you purchase any IZUMI chain at
the same time.

Drive Chain Riveter Tool - Rivets high strength rear drive chain Rivet links with
hollow pin ends as on our IZUMI 530HT Chain ( Rivet link #56-0235 ) and many
DID brand chains.

Drive Chain Rivet Tool Replacement Rivet Pin - Fits: 35-0006

Chain Puller Tool, Pulls new rear drive chain ends together so that
the joiner link can be slipped in place. Ideal for new chains that
are difficult to get together for the first time.

Chain Press Tool
Used to press on sideplates (rivet or clip type) onto rear drive chains.
Most late type High strength drive chains now use a press on sideplate
on the connecting link ( including IZUMI 530 HT ).

Drive Chain Breaker Tool.

Brake Caliper Piston holding/detaching Tool for
77-84 brake calipers.
Grabs Brake Caliper Pistons internally so seized pistons
can be worked loose from the caliper.

High Quality Vacuum Brake Bleeder Tool suitable for motorcycle use.
All metal construction. This is the best way to get the job done quickly.
Note: Do not use this tool with Speed bleeders.

Right Angled Snap ring Plier Set - Reaches in deep to remove clips when
rebuilding master cylinders.

Spoke Wrench Set - A must have for lacing, truing & tightening spokes.
2 Pc. Set - Fits: #8,9,10 & 11 nipple sizes.

Tool for installing and removing spoke or mag type wheel weights.

Digital Tire Pressure Guage
LCD Display. 1-100 PSI

Tire Lever - 16" long Dunlop type - For those tough tires needing lots of leverage
to remove. You need 2-3 of these to do the job!

Rim Savers Set
Designed to protect rims from damage caused by tire
Irons when installing tires on rims.

Damper Bolt Driver - Deep type damper bolt driver used to air
impact recessed damper bolts from lower fork legs.

Strap Wrench with rubberized strap for good grip.
Fits: 29-160mm. (1 1/8" - 6 1/4" diameters)
Ideal for holding fork tubes and other round smooth shapes.

Ring Wrench to adjust shock preload.
Fits: Our 06-3601/07/08/21/27/41 & 47 shock sets and many
other aftermarket shocks.

Ring Wrench to tighten Muffler Joint Nut on Early XS1 type muffler

Ring Wrench to Tighten Steering Head Cogged Nuts
Also fits preload adjuster on some stock Yamaha Shocks

Snap ring Plier Set - Removes internal or external snap rings. Set includes 2
straight and 2 angled tips.

Spring Puller Tool - Used to Pull Springs and Hook them into place

Heavy Duty Tiedown set - 1 inch Wide x 5 1/2FT. 4000 LB. Strength with
Quick Release. - Set of 2 (Black Color)

Long Heavy Duty Tiedown set - 1 inch Wide x 10FT.,
4000 Lb. Strength with Quick Release. - Set of 2 (Black Color)