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I've replaced the former Regugulator/Rectifier with a new one from MiesXS. Still no spark. I saw that Rick's Motorsport Electrics sells a Regulator for Lithium batteries - https://ricksmotorsportelectrics.com/Universal-Rectifier-Regulator-Lithium-Compatible-14_504 Now I wonder if this has been...

Today, I discovered that the three yellow wires from the stator to the Regulater/Rectifier (under the black wire sheath) were frayed and possibly arcing, potentially causing the failure. There is a melted section of the three-prong plug, and the wire coarting under the black plastic sheathing...

Oh yeah, I know all of that, and have read all of the threads. I've done all of it, both with the original clip and the newer heavier one. I've replaced the bendix gear as well with the kit from MikesXS. That's why I am wondering about the flywheel. Thanks.

Hi JOHNDADDY, Thanks for responding. I am not sure how to test the starter. I mean it "works"... it responds when I press the start button, and the engine will turn over once in a while when the bendix gear engages. It's just that most of the time it does not engage and just makes that horrific...

So, what does it mean if, after doing all of this, the starter problem still exists? Do I need to replace the flywheel? See photo. Are there instructions, videos, etc., anywhere that I can follow to replace the flywheel? Any recommendations on where to buy a new one?

Okay, so since I do not have the factory stator, the extra yellow wire goes nowhere. Explains why it was cut off. I don't remember doing that, but I must have because the bike was running fine. I do not have the OEM center "Pilot Box" on this bike either... just running 2 gauges from MikesXS...

Thanks for the responses. They made me realize the wiring diagram was not accurate regarding the MikesSX X-Charge system that is on the bike. The bike does have the full Mikes X-Charge system on it, including the regulator, and it has been working since 2019. I believe that I followed the...

So, I may have found a significant issue that would make a big difference. The yellow wire out of the Safety Relay was cut. According to the OEM wiring diagram, it connects to a 4th yellow lead out of the OEM stator/generator. But, there is no 4th yellow wire out of the XS Charge stator. So...

Thanks for the help. I've decided to document the current wiring on the 1977 Yamaha XS650, in hopes that it may help us all understand what I am dealing with and to find the cause of no spark. Remember that it experienced a direct short from the positive battery cable to the frame. I suspect...

gggGary, yes, sorry for the typo... 1977 Yamaha XS650. I have the blue e-advance center kit, and the aluminum advance replacement. I'm not sure which three wires you are describing... red, green, black. The wires that exit the stator are all yellow and go to the black rectifier. The wires out...

Hello friends! It's been a while! This 1977 Yamaha XS750 has been running and enjoyed by my friend ever since I started posting about this project in 2019. About a month ago, he called me, stranded on a Wisconsin farm, unable to get the bike started. I met him and discovered that the positive...

Gents, Thanks for these suggestions. We will definitely check it out with no pods and see what happens! This is an 81 and it has BS34s with plastic floats. We tried setting the floats at 22, but the gas ran right through the carb bowls - overflowing. So, I assumed the spec was 27.3 mm based on...

Greetings! It's been awhile since I've posted in the forums. This project bike was sold to a friend and we are scratching our heads on how to fix an issue that has plagued us for a couple of years. The engine starts, idles and runs well until you want to give it full throttle to pass, or...

That would explain it - thanks! I'll see if I can bend them back!

I'm losing my mind. I can't figure out why the OEM headlight brackets that I removed from this xs650 don't seem to fit either the original headlight bucket I removed or the new chrome one I have ready to install. The brackets appear to be approx. 6" apart when oriented straight forward. The...

After rebuilding 2 previous XS650s (a 1977 and a 1981), I'm back with my third project. This is another 1981 that a friend of mine purchased from a buddy who bought an old house in Madison, WI to flip, and this bike was in the garage under a pile of junk. From the license plate, it appears to...

I was able to finish the headlight and new instrument wiring today. I took it for a short shakedown spin. Need to address a few more items: Front brakes are still mushy - more bleeding? Left front signal stopped working Clutch needs adjustment, grabs too quickly Check front fork oil -...

The smoke you see coming from the exhaust was the burnoff of oil we squirted in the spark plug holes before we started 'er up! It has since cleared up. I am truly amazed at how well this bike runs right off the bat! I was not expecting that. Today, I plan to complete the front bucket and...

Well, a significant milestone was reached tonight. The XS650S project bike runs for the first time since 2002! I applied a little choke (first click) and it started right up. Then I adjusted the idle screw and it ran like this! My friend Harrison is very happy, because he's buying this bike!

OK, I *think* I have discovered the main front brake problem. When I rebuilt the master cylinder, I put the spring and rubber end cap in the wrong way (inexperience). Now that I have corrected that, I seem to be generating some hydraulic pressure, and I will continue bleeding all the air out of...