Remote spin on oil filter and cooler for the XS650

[Tony saccParticipant @tonysacc93877]

Spin on filter and cooler.
This was a modification I made to the lubrication system some time ago.

The XS650 has two oil strainers, one in the sump and one in the right side cover. As said, they are strainers rather than filters and as such not particularly good at filtering the oil. The system works thus: There is an oil pump in the right side cover, it draws oil from the sump via the sump strainer, The pump pumps oil up a 10mm hole toward the front of the side cover, the 10mm hole is stoppered at the front of the cover via a 10mm bung. The 10mm hole from the pump is cross drilled from the right side cover, so the oil is pumped through the 10mm hole then off at a right angle via the cross drilling through a strainer contained within the right side cover then on to the engine.

So to fit a remote spin on filter I removed the bung at the front of the side cover, mounted the side cover on the drill press table and angled it so the 10mm hole from the oil pump was vertical. The hole is set at an odd angle on two axis’ to the cover, so setting the 10mm hole vertical was a job in itself. Once setup correctly, I drilled the 10mm hole out to 10.8mm then tapped it to M12 x 1.25 for 40mm so passing the cross drilling to the side cover strainer, I then countersunk the top of the hole to allow for an O ring and inserted a stainless spigot I turned up and threaded. This spigot covers the cross drilling leading to the side cover strainer.

I binned the side cover strainer cover and machined up a new one. Took a bit of doing this part as there is a raised section in the middle to allow for oil inlet and the outer side had to be angled to follow the angle of the side cover. Rather than use an ugly screw in fitting, I spun up a stainless barb and pressed it in place in the front of the raised section.

hose t

[Tony saccParticipant @tonysacc93877]

Next came the spin on filter base. I made this from a lump of 25mm ally, shaped it to the desired shape, drilled and tapped the side for mounting screws and an oil inlet, then mounted it in the lathe to machine the oil gallery recess. Once done I drilled a central hole for oil output. I then spun up a threaded piece on which to spin the filter, press fit it into the central hole in the housing, turned up a stainless, threaded barb and screwed it into the spin on filter threaded piece, sandwiching the filter mount between.

That done, I fabricated some new engine mounts on which to mount the filter mount and oil cooler. These have a 30mm protrusion at the front on which to mount an oil cooler and the right mount has been extended downward around 25mm for the filter mount.

 

[Tony saccParticipant @tonysacc93877]

The cooler bracket is just a flat piece of 3mm ally on which the cooler is attached via four grommets, four stainless T nuts and four long M6 stainless hex heads. Last of all, I polished everything.

So, the system now works thus: The pump picks up oil from the sump via the sump strainer, pumps oil up the 10mm hole exiting the side cover at the front via the stainless barb. It then travels through a short rubber tube to the spin on filter then on to the cooler and then back to the new side cover and the void where the side cover strainer once sat, then on to the engine.

These bikes have a tendency to blow holes in the front section of the sump filter where the filtering gauze is flat. Although oil pressure is low, around 15psi when cold down to around 5-10psi as the engine warms, the oil, when cold, is thicker and tends to blow holes in the front of the sump filter. To remedy, I fashioned a guard over the front section and drilled a few holes.

[OldironParticipant @oldiron]

Looks like a very nice job.  A great solution for a messy job.

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