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Here's where I ended for the day, I fabricated some new side cover brackets that conceal the battery tray nicely. I had to wait overnight for a gasket to set before I fill her up with oil and see how it all functions. Ill post an update soon.

I decided to use a stock size battery, got the starter hooked up and fabbed up a battery box, there wasn't too many options on where to put it. I'm one step closer. Next is headlight/tailight and swap gas tanks( I've been soaking it in white vinegar, looking for a new petcock at the moment.

Update I got the wiring figured out and got her to run with the new jets. Every thing seemed all good until the next day. Battery was dead. Guess I have a short/ground issue or just a bad battery. Since its kick start only right now, I am looking for the smallest battery possible. I saw xschris...

Thanks Cafe! I am currently stuck at the rewiring phase. I completely removed the hacked wiring that was on the 1980 that I am working on and used the factory harness from the 1981 parts bike. I haven't been able to get spark now. In assuming the wiring harness will be compatible despite the...

Thank you for the help and advice, I was able to remove the flywheel using a bolt behind the puller. Here's a pic, got the original flywheel and starter system hooked back up, on to the next step... Rewiring with the factory harness I have and rejetting the carbs. Then front caliper and...

Not sure what you are referencing Specdog, I found out after more research this is one off those wacky attempts to reinvent the wheel of this bike. Called PMA or Permanent Magnet Alternator.. Not sure I'm on board. I feel the stock charging system would have been more than adequate for this bike.

I will keep my eyes out for stock h pipe. The big issue right now is removing the after market flywheel. The puller tool I have isn't long enough. I'm trying to find a longer bolt with the same thread.

Thanks for the info Chris, I would not of known to check that. If I have any issues I will definately order new ones from Jetsareus.com Can you give me a rough estimate of jet size for pod filters and aftermarket exhaust. I will need a set for both Florida and Colorado. The elevation change will...

I ordered the Gasket set for 54.12$ I realize now that MikesXs is in Tampa, only a few hours from me. Made it convenient. Hoping to get her fired up early next week.

https://www.mikesxs.net/yamaha-xs650-xs400-standard-overhaul-gasket-set.html Edit: ordered my jets from Mikes and they got here so fast. Is getting the whole gasket set my best bet? Thanks for the help Chris, I appreciate the knowledge. I would really like to keep the Motor stock, I don't need...

Any suggestions on timing the motor after the flywheel swap? Will it need to adjusted when I bolt the stock one on?

Found my issue, previous owner left me quite the project. Someone installed an afternmarket flywheel and it grenaded. Sprocket chain shredded the wires that connect to the stator, neutral switch and oil pressure sensor.. There's a plate with timing marks on it that is free spinning behind the...

I cleaned the plugs and tried two others, no spark at plug electrode. Ill try again. I would like to just rewire this motor for basic mechanical function, no accessory lights whatsoever. Like a dirtbike..

Tried using the spare bikes ignition module, no luck. Still not getting spark. The previous owner boogered the Phillips head screws on the pick up coil on the spare bike so I haven't removed that one to see if it will work. Not sure what else could have just suddenly quit. Maybe the ignition...

Honestly, there is a quite a bit of homebrew wiring I'm not happy about, ill post more pics soon.

Battery was 12.7 volts on the meter and I tried two other plugs to see if those would spark and notta.. I haven't checked the spare parts bike I have for a module or points yet. Maybe those ones will be functional.

I haven't been able to get spark after she died yesterday. I checked all the wiring, I'm thinking its a points or ignition module problem. I definately got a project, it was so much fun to ride.. For all 2 minutes, so I know it will be worth it in the end,

Thanks for the help Chris! Here is a picture of where the brake line runs from the m/c to a (?) I would like to figure out what fork this off of. And a picture of the pods.

Calipers say Japan and have a 8823 in white stamped under where the piston is and a 87r stamped into the metal. They do work good when I press the brake lever, I'm just worried they are going to lock up or not disengage when I need them too. The pods font seem to have a brand. What do you...

Another photo of caliper, I got two 1980 xs and one had disk front and the other has drum in front. Is this the factory disk brake and fork?