burabbit

How in the world do I get the starter motor out ? Motor fits like a glove and when the motor is angled it still will not pull out. Now that I have the left motor case cover off, any idea's

Sounds like a heat problem/very hot exhaust causing the same thing that happens when "tempering" metal. The second situation maybe related to heat also, I have the same problem on an XS500 after running 5K - 6k, for over an hour and it being >98 degrees outside. I recently found out that heat from the engine block was transfering over into the carbs causing gas in the bowls to get very hot (not quit a vapor lock, but getting there) and also break down of the engine oil viscosity. You might also look at the spark plugs, they could be "breaking down" at high compression/high load (inclines).

Looks like you ran into the same situation I did about a year an half ago. I went through the same search and tries as you. I looked for the replacement adapter, but there all gone and I finally got tried of looking for the "green grass" over the next hill. I solved my problem by duplicating the original XS500 oil adapter and changing the metric threads to accept the threads of american oil filters. Of course I had to make the drawings, present them to the machinist so that we where on the same page, have the threads turned and so on. After brushing up the two cavities and verifying the flatness of the mounting surfaces and making a gasket, I mounted the new adapter. Works like a champ. I use the M108 filter and can also use the PH6607 and the STP filter of the same size (the last two filters clear the extanded cover of the drive sprocket area by a whisker but they fit and thread onto the new adapter without a problem (had I spec'd the thread length 1/8 in shorter a racing pit crew could change the filter in 2 seconds). Total cost of labor about $325. I wish you luck finding and trying ready made oil adapters, but for me that was a hard road to travel and I probably sent more in time trying to find a soluation on the web, but give it a try.