Well, I feel really annoyed at myself.
When I took the bike out and it was spluttering originally the first thing I checked was the powervalve, I took the cover off and put the exhaust back on and revved the bike and the powervalve opened fine, I checked the nut on the stud that keeps the arm onto the plate and it seemed ok, I gave it a little turn and it seemed tight and not loose so I guessed the weld I had previously done was still working.
My buddy was certain it was powervalve related so we had another look today and instantly I could see a lot of play in the plate, I turned the nut and it was just turning - the weld had come off! Previously when it happened though I lost the powerband completely and it just felt different so I didn't think it was the issue but took it to be re-welded again. Put it back on and the bike runs perfect again.
Time to order a new plate since I don't trust the weld!
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