XS650 Transmission Problems & Repairs

XS650 Transmission Problems : identifying ,repairing and what tools you may need . Plus special engine mounts for working on the xs650 engine , transmission , what upgrades you can do for engine , transmission and clutch.

[@billjohnson4626]

Thanks for sharing your knowledge! Very much appreciated.

[@jameshunchuk3598]

Steph, you're a knowledgable guy, thanks for sharing !

[@antondahl8945]

I bought a 1979 XS650SF new,rode it 100,000 miles by 1989,replaced clutch plates once,but transmission performed flawlessly the entire time. I've owned many other XS650s and have had no transmission problems. And yes I always remove both drain bolts and change oil frequently. Great video thanks!

[@outlaw86custom]

Nice to know the transmission work that well. Thanks for watching.

[@antondahl8945]

@@outlaw86custom my pleasure, thank you. The XS650 is one of my favorite motorcycles to ride. I've put many tens of thousands of miles on several other XS650s I've owned.

[@lula6677]

fantastic work and loved the home made tools amazing !

[@huutee1]

I think with the help of your videos I'll be able to do the rebuild. Thank you for your efforts

[@chrisracer4094]

This was an amazing video! I hope you continue to post videos! cheers stay safe!

[@kevinficzere3826]

Your a great mechanic. Just what I was looking for. Thank you!

[@outlaw86custom]

Thanks I try

[@richardl.reed.7135]

Thanks you MASTER! Don't forget your shifting arm adjustment video, great Mécanique!

[@SondreForsell]

Thank you so much for a great video! I'm getting a 72 xs650 in a few days and will most likely have to go through this. So glad I found your channel!

[@outlaw86custom]

I really appreciate you watching the channel I try to do my best. Thanks for watching

[@michaellawrence5492]

Your one person who has amazingly helped it be that these machines will be around long after we are not, Ha!

[@BrentonIsRad]

Great video mate!

[@mrniceguy351]

Exactly the video I was looking for. Good job.

[@outlaw86custom]

Thanks I appreciate it. Thanks for watching.

[@marcuscrabtree]

Amazing video! I’m subscribed!

[@buddyharshaw9140]

Just seen ur video I run Yamaha vstars.your really skilled mechanic awesome work I watch these videos to educate my self more.thank you

[@outlaw86custom]

I do my best try to inform people. But thank you for watching my videos enjoy your life.

[@Thatmaninrio]

Great, humble presentation, much detail, and the Mickey Mouse bit was my favorite..

[@outlaw86custom]

I aim to please....

[@k5edd128]

Smiling! Good video sir.

[@outlaw86custom]

Thanks for watching!

[@LudovicOulivet]

Magnifique.monsieur respect.je suis fou de 650 xs j aimerais avoir un savoir comme le votre sa me cerais vraiment utile pour ma 650 xs 447 😊.merci super video.

[@outlaw86custom]

You're so very welcome thank you for watching

[@WILDGEESE399]

Awesome work there mr miyagi i had to sell my 650 special when my daughter was born 30 odd years ago i felt lost without it, but i found another one finally, a bit of a basket case but has alot of potential love your vids 😁👍

[@outlaw86custom]

Have putting it back to together.

[@WILDGEESE399]

@@outlaw86custom its basically all together missing left side footpeg ,gear lever ,wiring ripped off the bike no header clamps or nuts, no speedo or tacho ,no ignition key and barrel have a box of spare parts it came with ,speedos and tachos , new wiring harness ,came from the coast, so fork stantions speedo cups nuts bolts , headers, carbys all rusty ,turns over which is a good sign , needs hellicoil for spark plugs 78model red tank red side covers no grab rail twin disc on the front disc on the rear rear guard is good front guard is very rusty headlight bezel also rusty

[@outlaw86custom]

So what you are are saying it's all most done 😅

[@geevesy89]

Immensely detailed videos as always. I am having a weird issue with my 78 XS, the starter gear has recently been replaced and has the new thicker style spring, which I have tested and know engages. However, there have been a few occasions where I have had to do a compression kick on the engine for the electric start to engage. Over the winter I am planning on rebuilding the clutch, adjusting the boyer timing and switching out the carbs to VM34s, but do you think I will need to split the cases, or am I missing something basic?

[@outlaw86custom]

A lot of the problems on the starter gear is that spring sometimes you have to squeeze a little tighter so it stays on the gear better I occasionally have problems with the three that I own so don't feel lonesome. And no you don't have to split the case to fix that stuff.

[@marcostoledo5881]

simply perfect , thank you for sharing some of your experience !!!

[@outlaw86custom]

Thank you for watching!

[@RattlerSnake]

Awesome video, sir. You are a professional old man 🤣

[@outlaw86custom]

Hahahaha. Thanks

[@maximelebredonchel8669]

Hi Mister , is it possible to remove the starter gear with its spring and everything? (in the case I have removed the starter)

[@outlaw86custom]

If you are going kick start only you only need to pull the starter and plug the hole of the starter or just leave it in place. I hope this helps. Thanks for watching

[@anthonydunn7043]

Jeez, great vid.. Im looking at an 1980 XS tomorrow, i hope i dont need to know any of this stuff Mr. M.. If i do please move to Melbourne Australia...lol

[@outlaw86custom]

Thank you for watching, I'll think about the move ☺️.

[@MrRogrod1]

Mr. Miyagi, How are you doing today? I love your channel and expertise on Yamaha XS650's. I have a question? What would cause or how the clutch pushrod would actually snap/brake inside the engine while the bike was running? The clutch handle felt great. Thank you very much... Also my XS is a 1972.

[@outlaw86custom]

No lubricant on the end of the clutch push rod that extends outside of the motor and probably clutch adjustment was too tight.

[@outlaw86custom]

Can you send me a picture of the broken clutch rod send : [e-mail]

[@MrRogrod1]

@@outlaw86custom o ok thank you very much. Could it be possible that the worm gear on the clutch cover could have been adjusted to tight? Im going to start working on the bike soon again. Thank you

[@davidrayner9832]

Mr Miyagi, I want to build an engine stand that rotates and given that the crank is the heaviest part of the engine, I wonder where the balance point of the engine would be. On yours, where would the centre of the pivot tube be in relation to the engine and does that cause the top end or bottom end to be heavy when you roll the engine over? In other words, if you made another one would you make it the same or would you have the engine higher or lower on the device than it is now? Also, is the pivot solid or tube? I was going to use 36mm, 3mm wall tube as I have some in my scrap bin. Do you think that would be strong enough? I also intend having the engine facing towards the stand rather than away from it as the front end is heavier than the rear end and I'd like to keep the bulk of the weight in close to the bench. Any advice would be appreciated. Thanks.

[@outlaw86custom]

As for me changing my stand now it works fine. Sounds like you're tubing is heavy enough as long as you got something able to rotate it. For having the engine face the opposite direction I think you're going to run into problems when you're assembling engine. Who is welding this together and what is their experience on welding and fabricating? That is where I'd focus my most my concerns.

[@davidrayner9832]

@@outlaw86custom If you got the balance point right, that's great but where is it? What is the pivot of your stand level with? Parting line of the cases, base gasket? I was thinking of having it level with the front engine mount. Slightly higher than the centre line of the crank so that more than half of the crank would balance less than half of the crank plus the top end. It doesn't have to be perfectly balanced as in if you rotated it to any orientation and let go it wouldn't move (like balancing a wheel) but I don't want it to be real heavy at one end so rolling it over is difficult with one hand while the other is waiting to tighten the lock nut. I could build it and see how it goes but the only way it'd support the weight is if it was fully welded and if I needed to adjust it I'd have to cut through all that weld, or I could just ask someone who has already done it.

[@outlaw86custom]

@@davidrayner9832 If you look at the stand's pivot arm the outer tube that pivot slide into has a welded-on nut and a hole through it to tighten down a bolt to holds the pivot arm in any position.

[@michaellawrence5492]

Thanks for all!

[@outlaw86custom]

My pleasure.. thanks for watching.

[@michaellawrence5492]

@@outlaw86custom I have been trying to figure out the historic reasoning behind Yamaha's team for the kind of changes they had done upon the SX650 over the years. They kept the underlining core frame and motor/transmission unit intact-ed with only some changes done like carb, ignition, clutch and adding even an oil level sight window on the casing clutch side cover still having a dip stick available. The last year sold in the states 1983 and yet continued them for two more years until 1985 still selling to other parts of the world. I am curious though why the various changes they decided to do as time lapped and believe we could have done better in ways. Timing and the ability to afford a model I own a 1983 currently at 68 although I would have preferred an earlier year to 1981 sets offered. My first regularly motorbike riding started in 1966 having ridden various types of motor bike machines from Glides to Cub 50's over the past 56 yrs riding Almighty's will to do and still. My style and manners and level skill has changed with time. I always start the bike also with a thought being turned on too, try not to get killed or anyone else, Ha! My heart will always be with a 650cc Scrambler set up having a four stroke 360 degree crank vertical twin under 400lbs and the Heritage limited special is a ways from that having a 16 inch rear wheel and their seat with no neck dampener and being a fat 441lbs but the final stock chain gear ratio would work, Ha! Recently I dropped from the stock for that year 34 to 30 tooth rear sprocket and at least now in a straight line she feels closer to the pull and sound like a 1960's BSA or Triumph. Yamaha's choice for quickness did not compliment that setup. The neck dampener was to help reduce the high speed wobble to a point.

[@outlaw86custom]

@@michaellawrence5492 That's a good question I've tried to understand. I've own triumphs in the pass and a bunch of xs650 along with old Harleys. Why these companies did what did is beyond me. I just do my best to keep them running. Thanks for watching'

[@christigges4172]

Hey great video. Quick question, my xs will always pop out of first gear into neutral or a false neutral around 15 mph. If I hold my foot on the shifter it helps but still jumps. It only does this in first gear, it shifts and runs great in every other gear. I tried replacing the clutch cable but I don't think it's clutch related. It shifts and runs great in every other gear. Any chance of fixing this without splitting cases or is that inevitable? Thoughts? Thanks in advance

[@outlaw86custom]

Nope got to split the case bent shifting fork or shifting drum dogs is out of alignment behind the clutch pack. Sorry sometimes fun isn't easy.

[@outlaw86custom]

Yeah the more I think about it check the shifting drum dogs for proper alignment. That you don't have to split the cases.

[@christigges4172]

@@outlaw86custom thanks, I'll give it a shot!

[@dreamquestawn2392]

Super informative, thanks a lot for making these amazing videos. Also good to know on that last note about the "new" starter gear. Just ordered mine and would probably have just figured it was good to go... appreciate it.

[@outlaw86custom]

You are welcome... thanks for watching.

[@wolfeyes9357]

Mr Miyagi What about the half moon retainer for the transmission? I lost mine on rebuild...need them

[@outlaw86custom]

Yes you need that better find one.

[@maclagat3865]

do you have a video on the shift shaft star alignment? I been trying to get mine correct, I can shift up too a 2-3 but then stops or cant go any further, i had to replace shift shaft recently. i was able to shift through all gears before i notice the shifter was welded..

[@outlaw86custom]

Yeah I don't remember exactly which one but it's a there's one on adjusting the shift drum. But it sounds like to me you've got problems with your shift forks and the shift from things are wore out. Lot of reasons why people weld those shifters in place is because they've been jamming them or they crashed. I'm afraid you're going to have to open up the case to really look at it. Thanks for watching

[@maclagat3865]

@@outlaw86custom thanks for the reply, I ended up figuring it out. I really appreciate all the videos you posted, helps out so much!

[@everydaygolf1473]

Mr. Miyagi, Where can I get the starter upgraded starter spring, clutch bearing and 5th gear sprocket? Thanks in advance sir!

[@outlaw86custom]

Mikesxs.com would be good start.

[@hemantv.5409]

Will you make a vedio on xs-650 and Interceptor-650 with neck to neck comparison and give a final verdict.

[@outlaw86custom]

Now that would be fun but I don't have any Royal enfields around this area for me to play with. I'd love to get a hold of one to do a comparison thanks for the question.

[@lska7853]

Hi Mister Mitagi, I replaced the gears from another motorcycle and shift drum and shift spool and forks. Goes into low fine..but goes out under pressure the clutch needs adjusting. Tried adjusting shift spool and got them align evenly,

[@outlaw86custom]

Not sure what going on. How did the shifting forks look any worn spots on the forks.?

[@lska7853]

Hello Mr. Mitagi, I am going to take my low and fourth gear to the machinist and they are going to put a 1.5% under cut on the gears so they will lock in place. They are normally flat. I'll keep you post on my results.

[@lska7853]

@@outlaw86custom There was some wear on the low gear shifter.

[@topturretgunner]

Wow Miyagi 😮. That big knobby rear tire and those case mounts tell me that you must do a little off roading with that bike. You seem to have quite a collection of bikes in the background of your videos. Have you put together an XS 650 hard tail with a springer front end and a 750 conversion kit? That would be a cool 😎 bike.

[@outlaw86custom]

Have been thinking about another chopper with a springer but never thought about a 750 kit. Yeah way to many bikes....lol and yes the bike has done a bit of off-road.... Thanks for watching.

[@huutee1]

rewatching and have a question: at 32:17 you mention the circlip on the drive axle. Is there only that half clip? I want to make sure the other case does not need the other half clip? or does it? Sorry i did not take mine apart... I bought it in pieces

[@outlaw86custom]

Needs two half clips

[@huutee1]

@@outlaw86custom I have a Clymer and a Haynes Manual, both show only a half clip. I believe you but never see you put it on the bearing or lower case when you drop it on at 37:20 of the video

[@huutee1]

@@outlaw86custom I rewatched this video just for the circlip hoping to answer my own question

[@outlaw86custom]

Sorry only one clip I was thinking of something else like the starter Bendix which has two half

[@huutee1]

@@outlaw86custom Many thanks Sir. That has been a big question mark floating over my head for a while. I am about to order some seals and gaskets and attempt my first rebuild. Your videos and OLD BIKER in the UK are the only reason I think I might actually get it done. I truly appreciate your time and sharing of the knowledge of the XS650. I am 57 and my friends had these bikes when I was too young to have license. I have always wanted one like the TX models. love the dual sports you have done and the hardtails

[@richardgrognard6394]

hello, I would like to reactivate my electric starter xs650 whose drive shaft is broken do you have a video how to take it?

[@outlaw86custom]

Thanks for watching.

[@marcuscrabtree]

is there a trick to removing the cam follower from shift arm #2? because of the angle of the arm I can't seem to get the cam follower out. Thanks!

[@outlaw86custom]

I'll try and do a better video on this subject. But after carter pin is moved using a small shaped pin or rod to work out the small guide pin from the shifting fork. A small magnet will also help. Sometime they come out easy and other time they can be a bitch. Let me know if this helped. Good luck mate, Miyagi

[@marcuscrabtree]

@@outlaw86custom Thank you that worked. I cut a bobby pin in half and the fat end fit perfectly in the guide pin. How much force can I use to remove the shift rod itself? can I use a bar to pry it loose? Thanks again!

[@outlaw86custom]

Did you remove the outer keeper for shifting drum on the clutch side? If so it should just pull out easy.

[@marcuscrabtree]

@@outlaw86custom yup removed keeper. I think it’s just gummed up with media. Will keep spraying with lubricant until it gives way. Thanks!

[@cjd4525]

Gold mine!

[@andymcdowell7917]

Where do you find parts for these bikes

[@outlaw86custom]

Which parts are you looking for?

[@wolfeyes9357]

Mr Miyagi, I have a stroker ironhead with jyst a front headlight and brake light. Can I use a 12 cell lithium battery without problems. It is 360cca. Thanks Johnny

[@outlaw86custom]

I don't see a problem, I take it you are running the stock charging system and points ignition?

[@wolfeyes9357]

@@outlaw86custom No points...dyna ignition. Brand new low voltage cycle electric regulator....new generator.

[@outlaw86custom]

You should be fine with lithium battery .

[@C-Anes]

Cool !!!!!!

[@outlaw86custom]

Thanks for watching!

[@sethwarhol548]

You are bad ass!

[@derekpowell1266]

Thanks for the video! I can only kickstart my xs in neutral. When I dis-engage the clutch to kick in gear, its like I have the clutch engaged but clutch works fine when riding...please help master miyagi!!!!

[@outlaw86custom]

First off why are you disengaging the clutch if you're going to kick start you need that clutch involved the kickstart make sure you're in neutral.

[@derekpowell1266]

I pull the clutch lever and it should dis engage the clutch disks and when I let go of the lever it engages the clutch disks to the friction plates. Im not a motorcycle sensei maybe Im wording it wrong. I really over thought the quessstion before asking but either way I word it it would not be up to a master motorcycle guru's standards. Im just a mere mortal. sorry to bother you..never mind

[@outlaw86custom]

To me it sounded like you were pulling in the clutch lever and then trying to kick the bike over you need the friction from the plates to kick the engine over but it needs to be in neutral to do that.

[@outlaw86custom]

If friction plates are stuck together which is possible jack up the rear of the bike so the tire is off the ground but a good solid base kickstart or use electric start to fire up the bike. See if you can get it in second gear .Pulling the hand clutch now tap the rear brakes, you may kill a engine but just started back up and continue until the friction plates brake loose.

[@derekpowell1266]

Thanks for the reply. Sorry I came across like a prick. It seems like every bike ive ever had will kick start in any gear if the clutch "lever" is pulled in. It kicks in neutral perfectly but a pulled in clutch "lever" in gear and it acts the same with or without the clutch "lever" pulled. I dont have electric start wired up..

[@caesarkurniawan7227]

My xs 650 when the engine is running is very difficult to put the transmission in neutral but when the engine is off it is very easy how to fix it and what causes it to happen 

[@outlaw86custom]

Try adjusting the clutch again and when you're just about to put it in gear give it a little rev on the engine and that usually helps them slide in and out.

[@huutee1]

What state are you in?

[@outlaw86custom]

Washington

[@huutee1]

@@outlaw86custom I just acquired a XS 650. it ran when it was parked, lol. your story sounded like the guy I got mine from. Thanks for the videos. you would have more views if not for an older bike I believe. I watched about 4 of yours since I got the 650 last week. I might tackle it myself since I am in South Carolina.

[@Burritosarebetterthantacos]

Holy shit, Walter White opened a motorcycle shop!

[@outlaw86custom]

But all we do is motorcycle stuff none of shady stuff... hahaha

[@davidandlaurablevins68]

I had the same problem Tamil actor never figured it out I was just going to sell the bike. And a friend told me to put "Motul 7100" in. I did that and everything is been fine since.

[@outlaw86custom]

You could have probably used any Synthetic Engine Oil to improve the bike performance. Thanks for watching.