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Had a bad battery. Replaced it and the bike runs great. The starter gear is still slipping but not as much. About 50/50. I might try and tackle that project again when the bike needs a fresh oil change. Thanks for everyone’s help.

I’ll check the battery this weekend. The bike stays on a battery tender too. What CCA is recommended for a bike that has a big bore of 750?

The starter gear was slipping so I replaced it with an OEM clip. I was getting 7 pounds of tension with the new one. I put the bike back together and now it’s acting like the tension is too tight. I’m able to kick the bike over and it rides great. Shifts great too. But when I use the starter...

Shockingly my local Yamaha dealership had a replacement clip. It’s reading about 7 pounds of tension. Isn’t the sweet spot around 8-9? I tried the starter with the bike disassembled and it was 50/50 at getting the gear to engage. I hoping not to have to put the vice to this new part. I also have...

I was changing the oil on the 82 xs650 and decided to try and fix the tension clip. Well I broke it. What are my options in replacing it? Here is what I’ve found so far. https://www.mikesxs.net/yamaha-xs650-starter-gear-repair-kit-fits-72-84-oem-447-15516-00-90468-29062-90501-15409.html I hate...

The starter works but slips. I know there is a tensioner spring or something that needs to be adjusted. I'll get around to it next time I change the oil.

I installed the new rotor from Jim and cleaned all the connections in the headlight assembly. I'll continue to work on the other connections. Here are my voltage recordings. I never once used the electric starter. I think with the 750cc kit the starter is working to hard which is killing the...

Big shout out to Jim. He got my rotor back to me and it looks perfect. I wish I had a before and after picture. I’ll post the finished product anyway. The plan is to work on the loom, reinstall the original rotor and run a few test Melnic suggested over the weekend. Thanks guys.

Thanks Jim

Fuses, battery and headlight.

Jpdevol. I tried the multimeter and got 0. I’ll have to dive further in on how to test the rectifier. Most of this electrical stuff is Chinese to me. Everywhere I look wires have been spliced and wrapped with electrical tape. I might just have to start from scratch. Save what parts I can and...

No plans for highway riding, Marty. I also did the test light and got nothing.

I checked the battery and it came back good for the second time in 6 months. So I‘m still at a loss as to what is causing me all the electrical problems. Guess it could be the wiring harness. Is there a way to check the stator and rectifier? I checked the battery two days ago and it was showing...

Update Marty I tested the electrical system with a battery testing light. I got no light connecting the ground terminal to the battery ground. I pulled the battery and will be taking it to O’Reilly for testing tomorrow. Wingedwheel I took the chain roller off and checked to see if that part...

I'll try and add a few more pictures. You guys think I can just take it off? I googled "chain roller" and found some generic parts. I might just replace it.

Got your message, Jim. Thank you. Got another question. My drive chain is rubbing on some kind of pin that sits under the sprocket. The pin has two bearing that look like they once were covered in a rubber. The rubber is gone and now the pin and bearings are exposed. Can you fellas point me in...

Ill pull the battery and get a hold of a test light ASAP and report back. Marty, Ill catch back up to you after Thanksgiving. Thanks again. Jim, I sent you a message about getting the original rotor rewound. Let me know if you got it.

Update on the bike. I purchased the UNI air filters and installed them. The bike was on a float charger for several days. The starter did not want to turn the bike over. Not a real surprise considering I have not ridden the bike in days. I went to kick on it and it turned over no problem. Nice...

Thanks 5twins on the TCI timing recommendation. I'll put it on the "to do" list.

Any recommendations on air filters for those BS38 that won't restrict the ports?