two wires come from your brushes that are in your stater one is pos/ and one neg..if you have not got a green wire from your reg then i would try and see if you have a spark,[ kick it over] if no spark then ground the green wire then try again….

Thanks Pete, the green comes from the rectifier in the old situation. The new regulater/rectifier doesn’t seem to have a green wire connection. Can I put it on the battery or together with the brown wire I have?
Or can I do without the green wire.

green wire goes to one of the brushes on the stater …..

Can anyone help me????

Thanx,
Willem – Holland

i agree, and i know i do not explain things well, my brush wires are green and brown there is no black wire. the other difference about my brush set up compared to the picture above is the 4 screws involved with the brushes my brown and green wires are kiddie corner from one another not on the same side as in the picture, it is a change that supposedly was done in 1980 and has something to do with the way they grounded the stator so i do not know if i should ground or unground this setup. i just googled to ground or unground stator wires for xs650 and found out about these changes thanks pete

Well i do have points, and my stator has a green & brown from the stator and those wires are in opposite corners(of the 4 screws) each holding down a separate metal strip (spring retainer) so if a 1980 is tci then someone must have put a 70-79 top end on a 80 btm. end (wont that stink) i guess i will keep trying to find answers

so i guess i start over a little, when i bought the bike i was told it was a 1978, upon further research in 1980 they changed the stator wiring which includes a brown and green wire at the stator brushes so now i need to find a schematic for the different stator configuration, i am so sorry for wasting your time, i will post my end results hopefully to save some one else some time, any thoughts?

Could you email me that wire diagram plear

as i had mentioned in an earlier post the illustration above shows the 2 stator wires next to each other (as does another motor i have) and one of those wires is blk.
the engine i am using has the 2 wires on opposite corners from one another each one is holding the springs down for the brushes so there is a wire on each brush (i hope that makes sense) this is my first yamaha project i was into the hondas but i have the 650 bug so i have 2 650s and 4 motors (1 for parts) but this is the best engine so i really would like to use it.
so i guess i have to try and figure out this odd ball with all of your wonderful help.
i do not have a shop manual for the 650s yet (but i will) i was going to see if the brn. off the stator goes to blk. after the connector. i do not have to much of the stock wiring harness so i do not have much to go by. thanks for all of your help

green is usually one of the brushes……..

Not sure. Figure out which one is connected to the stator brush grounds. Pop off the little stator cover and see which color wire is connected to the three brush ground screws.

thankyou so much for your input and suggestions , i think i will put the metal screws back in, put the fuses in and see if i can get some spark. i will post the results

Good luck.

thankyou kris connecting the blk stator ground to a red was puzzling to me to but i figured if the blk stator wire was ungrounded (nylon screw) it was ok (somehow)
so if i try it your way (do not worry i would NEVER cry to you if it did not work) i think we have all had setbacks building bikes, but it does leave another question, in the diagram the brown from the reg/rec splits, one going to blk stator and one to ign. if i run blk. stator wire straight to ground does the brown reg/rec just go to ign.? i REALLY appreciate all the input.
the wire color on my reg/rec match up with the connector coming off the motor
thanks for your time

Mike- there is no way for me to say if you should unground the stator or not. I think it depends on the way that reg/rec was designed. If the reg/rec has the same wires that a stock XS reg/rec or a modern XS reg/rec has, then (if it were me wiring it up) I’d wire it up with the brushes grounded and the ground wire from the stator going to your main ground. Make sure to wire in a 20 amp fuse between the positive battery terminal and the ignition switch and reg/rec. The fuse will save you if the wiring is wrong. Run the bike, put a voltage meter on it and see what your charging voltage is like at 3000 rpms or so– should be 13.2v-14.4v. If that setup doesn’t work, try this diagram with the brushes ungrounded.

Good luck.

I wired my ’78 XS with this diagram and a TC Bros reg/rec. With the brushes un-grounded, the charging system would not charge the bike. I had to push the bike home 30 blocks on four different occasions. I re-grounded the brushes and it worked fine after that.

I really think the stator brush ground discussion is based on your reg/rec, not your bike. I’ve heard people who un-ground their brushes mention using a reg/rec off of an older bike, which (I suspect) is the reason for the un-grounded brushes. If you’re using a modern reg/rec for the XS 650 (TC Bros, Mikes XS, Hugh’s Handbuilt, etc.), I’m fairly convinced you don’t need to un-ground the brushes.

I’ve since installed a Hugh’s Handbuilt PMA and don’t have to worry about this anymore.

Thanks for the quick response.

Nick

thanks pete, that makes sense, but the schematic shoes the green wire with a metal screw in it? is the illustration incorrect? thankyou for your response

I have a TC Bros reg/rec combo being installed on a ’78 with stock points ignition. I hooked everything up according to this diagram, and installed a 20 amp fuse between the + battery terminal and the power to the ignition switch and reg/rec. I did not unground the stator, at the instruction of someone at TC Bros. But, I’m still blowing the fuse whenever I flip the key. Any ideas? Is it possibly related to the grounded stator?

1970-79 Yamaha XS650 Chopper Wiring Harness (points ignition)

@ Wes – From what you have described You are definitely going in the right direction with testing each electrical component. Like I mentioned above, a meter is invaluable in diagnosing electrical issues. you can pick up a meager for $9. It sounds like you have 1. a failing charging-system or 2. electrical short or 3. failing battery. Pick up a meter and start testing each component starting at your charging system.

Here’s how to diagnose your charging system >
http://www.xs650chopper.com/2009/06/xs650-charging-system-how-to/

Mike did you ever get your charging system working for your 82′ xs650? That’s what I have as well and need to know. Thanks

@ EJ black gos to ground red goes to positive on battery terminal Brown goes to stator.

https://xs650chopper.com/wp-content/uploads/2009/09/noid-chopperwiringdiagram.jpg

Not sure what you’re really asking, but the best thing I can tell you is to take some pictures and post them up on http://xs650temp.proboards.com/index.cgi some of the guys on that site have been riding and working on the xs for over 30 years.

I can’t get them locally & I hate to buy a bag of 100 or more when all I need is 3.

Thanks

2nd question, the connections at the ignition switch? I dont have the stock iginition, what type would you recommend and connected how?

Thanks , Mig

Note
1.reg/ rec combo: dont connect Positive until you are done(prevents causing harm to the reg/rec).
2. 20 amp fuse is needed on the HOT going to ignition.

Thanks to Wayne for posting this. It’s a great, very simple diagram to get you started, and fairly easy to add some features from there. Starting with this basic schematic will help a lot of guys that feel overwhelmed by the seemingly incomprehensible maze that is the stock schematic.