Saturday, October 8, 2011

Swapping the xs650 charging system

The xs charging system never worked properly, so I opted to do the yamaha banshee swap (permanent magnet), both for reliability and the option to go batteryless in the future. Not to mention being able to kickstart the bike on a dead battery. I had to fabricate an adaptor plate on the lathe (to attach the banshee timing plate to the crankcase), but other than trimming some of the timing plate, thats all the fabrication that was required. Instead of buying used parts, I opted for brand new ones from rmstator.com, a fantastic Canadian company. Parts required: homemade adaptor plate, Banshee timing plate, Banshee upgraded flywheel, and a Honda Hurricane stator.
It looks stock, and it went together super easy. At least once I got the stock rotor pulled it did! I didnt have the proper puller, or even the right sized die or bolt to make one, so after a lot of swearing and failed attempts with various 2 and 3 jaw pullers, I finally got it off with a straight leg puller from Princess Auto. First time Ive ever seen or used one!







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