Help identifying some parts & removing batt box

renloy

I'm tearing apart my xs for some upgrades and while I'm at it I want to give my battery box a coat of paint. The problem is that there are wires and relays all around it. What's the best way to get it out?

Also I'm trying to figure out what the parts in the pictures are...

dpmphoto

Take all the wires off,then fiddle around with it for 15 minutes it will come off through the top; however I think its easier to take it out through the back, that means taking off rear tire fender,fender liner or whatever you guys call that plastic fender piece.

weekendrider

On the right side are the starter switch/relay(R) and starter circut cut-off relay(L).
On the left side the jumper wire is in the side stand safety switch coupling and the other is the side stand relay assembly.

650skull · Support Staff Joined: Jul 19, 2007 Posts: 1186

Renloy, check out this links for IDing parts............ The year and models, go to model then look up electrical in the left column down towards the bottom Web Page Name...............

AMT82xs650 · Full Member Joined: Dec 22, 2007 Posts: 17

I've had luck removing and reinstalling it on the left side of the the bike. Take a look at the top of the battery box, there are cutouts in the sides of the box where the battery sits. looking from above, work the battery box around 90 degrees counter-clockwise and drop the box down a little so that the notches are under the left frame tube. The box can now be pivoted around the frame tube and removed thru the left side. Installation is reverse of removal.

Note: You are going to have to remove any components and wires that are attached to the battery box before removing it.

weekendrider

AMT82xs650 wrote:

I've had luck removing and reinstalling it on the left side of the the bike. Take a look at the top of the battery box, there are cutouts in the sides of the box where the battery sits. looking from above, work the battery box around 90 degrees counter-clockwise and drop the box down a little so that the notches are under the left frame tube. The box can now be pivoted around the frame tube and removed thru the left side. Installation is reverse of removal.

Note: You are going to have to remove any components and wires that are attached to the battery box before removing it.

Nominated for the vault

renloy

Thanks guys. Does anyone also know how to get the swingarm pivot bolt out? I just spent half an hour bashing it with a rubber mallet, hammer w piece of wood, my skull, and the damn thing won't move.

5twins · Full Member Joined: Aug 05, 2006 Posts: 1616

deleted

renloy

well lets hope pb blaster can do its thing heh don't really want to spend the money on a new bolt

xjwmx

If it's rusted stuck, you need a new bolt anyway.

blue900 · Posted: June 21, 2009, 3:14 pm Post subject: Swing arm bolt removal Idea

On my bike I soaked and pounded, soaked and pounded would not budge. So I though a while and came up with the idea of pumping something in the grease zerks. All I could think of was grease. And it worked for me. Pumped both sides full of grease (must have been real dry in there) Then it started moving with one person holding the bike and and me hitting it with my big hammer as carfully an hard as i could. Once it started moving I used a long punch to finish it.
Good Luck that was not fun!

renloy

Pounded it with a BFH and it came out. Are you guys sure it can't be reused if I clean it up? Only some surface rust on it as far as I can tell

EDIT: By the way the battery box is really easy to get out once you get the rear wheel off.

xjwmx

I'd worry more about the possibility of the old bolt breaking, myself.

As for the rust, if you used all new parts there's a lot of friction initially anyway, so rust wouldn't bother me much, especially if it cleaned up pretty nice.

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Yamaha xs650