Got to Home Depot. Buy a Briggs and Stratton #5052 air filter for $13. Sometimes available on Ebay or Amazon for much less.
Saw it in half.
Fab an "L" shaped plate 2 7/8" wide to seal the end and top from a piece of roofing flashing.
Shape the filter half and plate to fit inside the filter housing, flat end on the bottom. Trim the metal plate to clear the housing cover. Use Permatex Clear RTV Silicone #66B to seal and secure the plate to the top and end of the filter half. Clamp for 1 hr. to set the RTV.
Installed in my "New" '81 Special II. I used a piece of 1/8 alluminum as a spacer and reinforcer for the spring clip that holds the filter in place. You could use the salvaged back from a filter for the same purpose.
Work slowly and carefully. Do a trial fitting in the filter housing with the lid installed to ensure a proper fit before you apply the RTV. Trim the lower left (left side) and lower right (right side) corner to clear the cover when it is installed. Make sure that the far inside edge covers the opening to the carb.
I posted a similar idea for '78 and '79 models as well.
You my friend are a very clever (and resourceful) person. I was just looking at my air filters and they look ragged. They need to be replaced but I was disappointed at the $22 cost (per) and was going to hold off. Now thanks to you, I can get new filters for a fraction of that .
No. The bottom flat edge sits in the corner below the opening to the carbs, so if you cut the flashing square, it's not necessary. However, it wouldn't hurt to do so as long as you cut the metal so the tubing is flush with the rubber molding on the filter.
Last Edit: Nov 19, 2008 20:51:14 GMT -5 by pamcopete
r80rt: :)This is a splendid write up, THANK YOU!!!!
Dec 26, 2015 16:54:05 GMT -5
mashermoto: What the what is this shoutbox for? Or should I shout, WHAT THE WHAT IS THIS SHOUTBOX FOR!
May 12, 2016 22:22:21 GMT -5
motormike: Good Day ...just a FYI.. Wild Cat is this Labor Day weekend. Still go'n on. A few 650's still make the scene. Various rides at different skill levels each day.. awards dinner sunday eve. BS in the park'n lot after dinner.
Aug 23, 2016 7:57:01 GMT -5
lsettle: First post in over 6 years!
Aug 28, 2016 19:45:17 GMT -5
kardon: Wow quiet here, where did they all go.
Oct 7, 2016 2:18:13 GMT -5
gggGary: XS650.com LOL
Feb 16, 2017 20:49:02 GMT -5
buell88: Anybody have any idea who built the xs650 tracker used in the Draggin Jeans Ad on Pipeburn?
May 16, 2017 16:24:09 GMT -5
joshua: The regulator/rectifier unit I got from Mikes PMA has closer hole spacing than original. Are we supposed to mill the holes to fit?
Jun 7, 2017 19:25:58 GMT -5
joshua: My bad. I found the bracket they supplied to mount the rectifier/regulator... Uh oh. How is this meant to work? Which way is it meant to mount? Looks like I have to use some spacers or something. Good instructions would be nice.
Jun 7, 2017 22:09:52 GMT -5
craig8johnson: Not sure if this is the right spot or not but oh well...
Jul 11, 2017 18:04:15 GMT -5
craig8johnson: I'm checking the charging system. I'm afraid I might have fried the last battery. With the solid state regulator (after market) what should it be charging at. The book says, I think, 15 volts. I'm hitting 17 when revved. Is that too high?
Jul 11, 2017 18:06:19 GMT -5
gggGary: Yes 17 volts is too high, about 14 volts is max, sounds like you don't have the right regulator or it's wired wrong.
Jul 13, 2017 6:54:33 GMT -5
dean: Just saying Hello, new member who is going to fix up a 79 XS650 that has seen its better days. I will definitely have lots of questions coming up.
Jun 23, 2018 16:45:32 GMT -5
tt650: Trying to breathe life into a 1980 that's been stored (indoors) for 25 yrs. Air filters are dry rotted. Have cleaned carbs but she only runs briefly on choke then stops. Need jet setting info and other ideas that might help her idle and rev.
Jul 3, 2018 19:15:19 GMT -5
trix13: Hey everyone! New to the forum and am fighting those gremlins!! New charging system, ignition switch, coil and fuse box. Resistance is higher than normal on the ignition pick up so I'm trying to find one. No such luck yet.
Aug 16, 2018 8:50:48 GMT -5
trix13: Also, even though all of my connections are clean, I cannot seem to find out why , when at higher rpms, I hit the signals and the rpms pulse with the signals...hahah. same with the brake light. I appreciate all input!!
Aug 16, 2018 8:55:08 GMT -5
bob99: how do I post a question. I am new to the forum
Jun 6, 2019 10:52:10 GMT -5
adlpc: Hello all! Been enjoying your edifying posts and discussions - and as a fan of the XS650 since my early teenage years happy that I now own a 1980 Special which I plan to turn into a vintage half faired racer. Thank you all for being here!
Oct 1, 2019 0:58:56 GMT -5