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  1. #1
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    Default How to: XS650 Starter Delete - $1.00

    While building an engine for a member, I was turned onto the idea of using a 1 53/64" freeze plug instead of the $15.00 MikesXS kit.







    I drove the freeze plug in with a large socket and an extension... I drove it in from the inside of the cases. If you wanna really do the job right, pull all the gears and shafts out of the cases while you are at it... Remember, less weight = free performance. This mod costs about $1... Go down to the local auto parts house, they should have it in stock
    Last edited by Punkskalar; 02-14-2011 at 10:34 PM.

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    So can I remove all of the gears and such minus the starter with the left side cover off ( like when I'm doing the perm mag swap?) and underneath the cover are there any gears that need to be left in for the kicker? And do you then replace the cover and gasket or leave that off also?
    Thanks
    Last edited by miller0613; 02-14-2011 at 10:25 PM.

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    Cool idea, looks clean! What keeps it tight enough so it wont fall out from vibration, or leak oil?

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    Quote Originally Posted by miller0613 View Post
    So can I remove everything with the left side cover off ( like when I'm doing the perm mag swap?) and underneath the cover are there any gears that need to be left in for the kicker? And do you then replace the cover and gasket or leave that off also?
    Thanks
    Yeah, put the cover back on... You want the engine to hold oil

    You can pull ALL the gears related to the starter, they are not connected to the operation of the kickstart in any manner. Easy to do while you have the side cover off for the PMA swap...

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    Quote Originally Posted by sweetpotato650 View Post
    Cool idea, looks clean! What keeps it tight enough so it wont fall out from vibration, or leak oil?
    Its a freeze plug like used on engine waterway passages. Its basically pressed in. It won't come out. They hold pressure in engines cooling systems without any sealer at all. I added the sealer as an extra precaution, but it is probably not needed. The XS Crankcase does not have near the pressure of an automobile cooling system.

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    awesome thanks I was literally just reading about this on the xs650 forum

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    Man I gotta get my cases blasted. That motor is so freakin clean.
    Great tip. Just about ready to bolt my cases together and hopefully finally get it started. soon as I sort the trans.
    banshee swap. oughta be fun getting it to start for the first time since I got the crate full of pieces.

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    Would some grey permatex give some extra insurance?

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    Quote Originally Posted by 10can View Post
    Would some grey permatex give some extra insurance?
    Won't hurt... I added just a dab around the edges too..

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    Great idea! Looks clean and frost plugs are dirt cheap! I pray I never have one fail in my car again....

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    Got any part numbers for the freeze plug? All the part houses around me can only look the part up by vehicle or part number.

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    Quote Originally Posted by Richf View Post
    Got any part numbers for the freeze plug? All the part houses around me can only look the part up by vehicle or part number.
    You are going to crappy parts houses. Got to a good family owned shop, instead of Advance Auto or Vatozone.... Places where they look up parts in a BOOK, not the computer...

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    1 53/64" expansion plug Dorman part #555-083

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    I have a BUNCH of these if people need one

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    Quote Originally Posted by Punkskalar View Post
    Won't hurt... I added just a dab around the edges too..
    What kind of sealer do you use?

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    Quote Originally Posted by claytronofrio View Post
    What kind of sealer do you use?
    I use a dab of hondabond, same stuff I use on the cases...

    Hugh

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    Quote Originally Posted by Punkskalar View Post
    I use a dab of hondabond, same stuff I use on the cases...

    Hugh
    Thanks!

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    will i have to remove the motor from the frame? i know it will be harder to do if i don't but can it be done?

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    No you can do it with the motor in, no problem.

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    Quote Originally Posted by jamesgs4 View Post
    1 53/64" expansion plug Dorman part #555-083
    everywhere i have called only carrys a 1 51/64" will that work

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