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I’ll take a look on the next ride. Thanks for the advise.

The tank should be venting properly as it’s a tc bro’s narrow alien with a cam lock style vented cap. I have UNI filters that I recently cleaned with gasoline, then massaged oil into as suggested by a thread on this forum. Think that might be restricting the airflow at high rpms?

My 1978 xs650 hardtail chopper has been running rough after it warms up and I let’er rip on the highway, typically past half throttle. It seems like it starting doing it after I adjusted the cam chain tensioner. Carbs cleaned and didn’t change anything. The main jet size has been fine in the...

My stator went out again. I didn't buy the stator from HHB but from all the list of "compatible" stators for the banshee swap. First one went because it was too wide and was rubbing on the rotor, grounded and also cooked my small battery. This one was narrower, had the clearance, was wired...

I'm prepping to paint my frame now that it's almost riding weather here in Montana. First timer but I'm not looking for pro results. Read a lot on here and going the cheaper route and doing the rattle can method for my base coats, aka sandable primer and ivory enamel spray paint. I...

I found this link online somewhere that shows some pics of the process further down the page. This guy goes further than just removing the shift shaft but you get a visual non the less. http://www.xs650.org.au/XS%20Engine%20Rebuild/2sortout.html

It shifts fine just has stripped teeth where shifting pedal slides onto

The clutch holding tool you mention, is it this: https://www.mikesxs.net/yamaha-xs650-clutch-sprocket-holding-tool.html

I should'a been more clear. I went with a Hugh's stator backing plate and stator mount. It seemed easy and I like his quality with no further grinding of a banshee mounting bracket. I learned the hard way.

NOTE TO READER: I purchased the Kawasaki Drifter/Vulcan stator from the list above and it was too thick, causing the copper coil wires to rub and wear on the interior of the rotor/flywheel as it rotated. It was toast causing my charging system to only be putting out 5 volts +/-, running...

The Kawasaki Drifter/Vulcan stator is too thick for this swap so I ordered the Suzuki VZ800 Marauder stator since it looks like the same stator HHB uses with tighter coiling. It's also on the list of compatible stators for the swap. Let's hope that fixes it. Crank seems fine so I don't think...

It's a matter of Hugh knowing what fits. One thing I know for sure is that this Kawasaki stator is too wide and is dragging on the interior of the rotor.

No rogue washers, no pin, no woodruff. I emailed Hugh and he thinks the Kawasaki Drifter/Vulcan stator is possibly too thick and that's what's causing the rubbing on the interior of the rotor/flywheel. Going to measure mine in comparison to his and we'll see. If so, that's too bad because...

Then what's could be causing the stator to be rubbing on the rotor?

I installed a Banshee rotor and a Kawasaki Vulcan/Drifter stator to my '78 xs650 using Hugh's Hand Built stator backing plate, stator mount & hardware. I had a wire rubbed through by the rotor rotation because I didn't tucked it away enough. When I pulled the rotor to inspect and fix the wire...

Total idiot here. I bought this shit so long ago based on suggestions/emailed links and realize now that it is a Banshee swap out using non HHB stator and flywheel, just the stator bracket/backing plate and hardware. Saw the thread on this page where you have to keep the woodruff key unlike...

There is no rotor, just a stator with a flywheel. No woodruff key because it's not needed. I believe now that I received a sloppily wrapped stator since my copper coils over lap unlike the nice and tidy stock photo from Hugh's website.

It's not a OEM stator rotor assembly. It's a Hugh's Handbuilt Permanent Magneto Alternator system so that can run the bike kickstart only. It ran like a top until the wire from the stator was worn though by the flywheel.

HHB PMA on my '78 xs650. The flywheel was slightly touching the stator wires that I thought were tucked away from danger and caused a wire to get exposed. This caused my battery to not get full voltage making the bike very poorly. I pulled the flywheel and noticed some wear on the inside in a...

I had the flywheel run through a wire coming out of my PMA system so I got to pull the flywheel to repair it. Would anyone be kind enough I lend me their flywheel (not OEM rotor) puller so I can save the $25+? I'll mail it back to asap. Thanks