XS650 project

The left side engine cover needed some work. The first step was to apply Rust-Oleum aircraft stripper inside and out. On the outside it removes any remaining clear coat. On the inside it just melts away all of the years of chain lube gunk that otherwise takes lots of scrubbing. After sitting for a few minutes I hit it with the pressure washer, and it was clean.


I decided to trim off the rear "fin" on the cover, so marked it where I wanted to cut.


I used an angle grinder with a cut-off wheel to make the cut, and then a flapper wheel to finish it off.




Next was to wet sand with 800 grit paper and dish soap and water.




Then some Autosol to shine it up.




I got a Parts Unlimited part #44-402 clutch lever, since it matches the GSX-R brake lever better compared to the straight stock lever, and a Motion Pro part #05-0100 clutch cable. The cable is a bit long, but routing it in a loop behind the air filters made it fit fine.


I cleaned and lubed the clutch actuator, and put it all together.