XS650 project

One of the last things to do is finish up fitting the XS360 tank to the '75 XS650 with a new gas cap gasket from MikesXS.


On this style Yamaha cap you remove the two lock screws and the cap opens up to make it easy to change the gasket and clean it up.


Here it is cleaned up, and making sure the vent holes are clear. Clogged gas cap venting is a big cause of poor running on older bikes.


You need to hold the spring loaded latch in position when reassembling.


One of the first things I had done on this project was finding a smaller petcock in order for the tank to fit.


I had made an adapter to use this style of petcock, and tapped it at an angle to clear the engine.


Here is the finished adapter plate.


This is how it fits to the tank. I traced it with a knife, and then removed any paint for a better seal.


Making a gasket for the adapter, I used an modelers knife to cut out the center.


I used a leftover throttle body gasket.


For thread sealant I'm using Blue Monster since it is recommended for use with gasoline and gasohol. It also comes in a tape, but I'm using the paste.


I left it to sit for a couple days to dry, and then a couple more with fuel in it before installing on the bike in case it leaked, but no problems so far.


This is the stock huge XS360 petcock that wouldn't clear.


The new one has plenty of clearance.


I'm using a brass "T" fitting with the single petcock. With small fuel line that fits snugly over the barb fittings I like to use zip ties, pulled tight and then cut. Automotive worm type clamps can squeeze the hose into a "D" shape and actually cause leaks.


So close to the first test ride!