System # 07·0651 Install: XS1/XS1B/XS2/TX650 (1970·73)

NOTE: Mikes XS warranties Exhaust System Headpipes and Mufflers for 30 days against manufacturers defect or workmanship. Warranty does not cover hardware and damage caused by impact, modification, exposure to corrosives or deterioration caused by weather or wear. Owner is responsible for all damage caused by installation, accident or neglect. Chrome is Not warrantied against blueing or discoloration. All systems have been design tested prior to manufacture and seller is not responsible for final tuning.

Please Read All instructions first!

1. Do Not install this system without first having your bike tuned and running properly in it's existing configuration below we list the stock jetting originally used.

A. Stock original Mikuni 8S38 CV Carbs used on 1970-73 650's used a #130 small round N102l221 type Main Jet

8. Stock original Mikuni 8S38 CV Carbs used 1970 XS1's used a #45 8S30/96 type Pilot Jet C. Stock original Mikuni 8S38 CV Carbs used 1971 to 1973 650's used a #42.5 8S30/96 type Pilot Jet

2. Remove old exhaust system, old gaskets from cylinder head ports, passenger footrests and rider footrests .

3. Unpack the 07-0651 System - Examine, wax & polish the Chrome Mufflers and Headpipes.

4. A hardware kit is included with your Exhaust system and is packed with related parts in sequence.

5. Insert sidestand stop Rubber (HOW Ref. B) I

into LH muffler.

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System# 07·0651 Install: Fits: XS1IXS1b/XS2ITX650 1970·73

7. Slide onto each head pipe the assembled clamp, the muffler joint nut and the muffler joint gasket. Note: be very careful with the joint gasket as it will be fitted inside the nut.

6. Install New headpipes, cylinder head port gaskets and head pipe flange crown nuts and lockwashers (HOW Ref. A). Tighten but leave just loose enough that the headpipe will IL-----------------­still rotate in the head. Note that there is always an even gap between the finned headclamp and the head.

8. Try the fine threaded muffler mount bolts (HDW Ref. D) out by threading them thru each muffler to make sure they pass thru the holes smoothly. Install the center stand stop rubber (HDW Ref. 8) into the LH muffler.

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9. Insert the head pipe into the muffler, slide the joint nut up over the jOint gasket and thread the muffler nut up as far as you can by hand. We recommend that you apply a bit of never seize graphite lube to the muffler threads.

#07·0651 Install: Fits: XS1/XS1b1XS21TX650 1970·73

Insert the mounting bolt thru the lockwasher, (HOW Ref. 0) thru the passenger footrest, thru the frame bracket and thread it into the muffler. Do this to each side. Tighten the bolts.

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13. On each side position the clamp lock strap as shown, replace the center stand nut and tighten Tighten the cylinder headpipe flange nuts evenly.

14. Check that the mufflers are not touching the rear axel.

15. Re·install the rider footrests and check the rear brake adjustment and the travel of the brake pedal to be sure it does not hit the headpipe.

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11. Tighten the muffler joint nut with a ring wrench as shown. Push the head pipe bracket over the center stand bolts and position the muffler joint nut clamp on the jOint nut.

Ring Wrench:-__ ~_~~_ ......

~<'c«sharp hook backh~s positive grip

16. Wipe down the entire exhaust and remove all dirt, oil and fingerprints from it before starting ( or these will imbed in the chrome plating once the exhaust is hot) . 17. Start the bike, let it warm up a few minutes, check for exhaust leaks, adjust the idle speed, shut off engine and retighten the system mounting fasteners. 18. Roadtest, adjust jetting and idle as necessary and reo tighten All fasteners again. Enjoy!

System # 07-0751 Install: Ascot type Exhaust to 1978-84 "Specials"

" ----' .

. ---- - ..;. -...... - . !.~. - '-' .------ -=:. :~.-.=--~~

17. Insert the heads of the mounting bolts into the slider bracket of the lower muffler as shown and push the muffler onto the lower headpipe the dist­ance shown in photo 16. Insert the threaded portionl~~:::;;:;~==-_-:''''';':i.!!..''' of the forward bolt into the hole in the lower rear 18. Insert the rear muffler bracket's (HOW Ref. E) portion of the frame mounting bracket and install (upper bolt) head into the top muffler's slider bra-the flat and lock washer and nut (HOW Ref. C). cket and then the bolt head of the longer forward

;:;;;;;iiiiiiiiiiii-=:;;:r==:::::::;:;;:;;;iiiiiiiiiiiiiim;:;:==~_~ muffler mount bolt. Place 1 pc. of the thick washer

19. When installing Ascot footrests supplied in hardware kit (HOW Ref. B) note that they differ and match the correct peg to each side (RH side shown) Install Right side footrest and tighten it's mount nut before tightening up mou nt bracket nuts in step 18. Footrest sheetmetal positioning locktabs located

on the long bolt and slide it up to the muffler slider bracket. Slide the upper muffler onto the upper head pipe the distance shown on photo 16 and insert the threaded portion of the long bolt thru the frame (See photo 20). Install the washers and nut to the long bolt as shown in photo #20. The end of the upper mufflers slider bracket should now be about 5/16" from the edge of the rear frame stud as shown above, adjust as needed. Nuts on the slider bracket bolts should be hand htened.

on rear of footrest mount may have to be bent or 20. Final mounted assembly is shown above.

Lf_la_tt_e_ne_d_· ________ ~ _ _ _ ~_...J1 Forward bolts can be double nutted jf desired and

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may need to be shortened. Thickwasher may need

to be doubled up jf muffler alignment to headpipes does not seem to be correct after steps #21·24.

24, Push in outer headpipe as shown and hold this position while tightening the finned head clamp flanges, If exhaust system is in correct alignment as shown in previous photo's # 21-23 then check

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that all other nuts & bolts are tight. 23, Long view showing exhaust system positions.

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25. XS 650 "Specials" require the stock curved kickstarter that they came with. Clearance to the head pipes is very tight. If you cannot kick thru, you must loosen the exhaust system and adjust the spacers for the mufflers and/or the mount brackets, in order to push the system inward.

27. Re·install the rider footrests and check the rear brake adjustment and the travel of the brake pedal to be sure it does not hit the head pipe.

28. Wipe down the entire exhaust and remove all dirt, oil and fingerprints from it before starting ( or these will imbed in the chrome plating once the exhaust is hot) .

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26. The centerstand can be retained when mount· ing the Ascot system on a "Special" but the large ugly centerstand loop will hang out unless you modify it.

29. Start the bike, let it warm up a few minutes, check for exhaust leaks, adjust the idle speed, shut off and retighten the system mounting fasteners.

30. Roadtest, adjust jetting and idle as necessary and retighten All fasteners again. Enjoy!

31. WARNING! Do not ride with bare legs, this system

can get Very HOT! HOT! HOT!

07·0651 HOW XS1IXS1 b/XS2ITX650

1970·73 A

B

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