Choptember How-To XS650 Banshee Charging System Swap

Originally Posted by bonesxl1100

How did you make out with this? I started filing mine down today but ran outta time so i didnt finish. May get back to it tomorrow.

Got it done. It ended up smaller than I thought. Just short of a razor edge on one end to get the wheel all the way up.. Slides all the way up now like it should.

Cant wait for the rest of my motor parts.

Anyone ever do this on a motor rebuilt from a crate of parts. Should be pretty easy since TDC is easy to mark when its in pieces.

Originally Posted by chrroe

Got it done. It ended up smaller than I thought. Just short of a razor edge on one end to get the wheel all the way up.. Slides all the way up now like it should.

Cant wait for the rest of my motor parts.

Anyone ever do this on a motor rebuilt from a crate of parts. Should be pretty easy since TDC is easy to mark when its in pieces.

Got mine done too. It's a little bigger than what Hugh picture shows but the flywheel fit on so we'll see when it's time to start her up and do the timing.

I'm new here so I guess I should pick a fight with the baddest cat here (please identify yourself) and get it over with.

Anyone try the Mikes XS's PMA kit? He's got one for older and newer 650's and doesn't say anything about modifying the ignition (TCI) to get it to work. I know nothing about electrics, m'cycles or computers, but I rode a new 1980 special in 1980 and got a jones for one about 4 yrs ago. The charging sys doesn't work anymore (I changed the brushes). I keep it on a battery tender and ride once a season, but mostly stare at it on the way to my car. Last 2 times I rode it died much too soon, even with a new battery, so I've been toying with doing this mod for awhile now. I've got the time, but not the balls. Especially when I realized it didn't end there, but needed a pamco ign swap as well. My fear is that I'll buy the parts and find a loose wire that's causing the problem. Hell, it's only 31yrs old. I'm 68 and my parts are fine. Except for lower back, 2 knees, and a few other minor life threatening issues. Cheers all.

The pamco is for the ignition system. It replaces the points. You don't need it for the pma swap which is for the charging system. Although I'd recommend you do that swap too eventually. I got everything for the pma swap off eBay and it cost me a total of about 150 bucks. The most expensive part is the banshee flywheel. Also, get a adaptor bracket from Hugh.

Originally Posted by bonesxl1100

The pamco is for the ignition system. It replaces the points. You don't need it for the pma swap which is for the charging system. Although I'd recommend you do that swap too eventually. I got everything for the pma swap off eBay and it cost me a total of about 150 bucks. The most expensive part is the banshee flywheel. Also, get a adaptor bracket from Hugh.

From Hugh's slide show,

"NOTES: If you are using a TCI ignition, you'll need to change over to points or Pamcopete's awesome setup before doing this modification (PMA). You'll get the timing working first, get it all timed properly and use the timing marks from your setup to reinstall the timing tab on the side cover.

Whoops. I completely missed that you had a tci setup.

r u the baddest cat here....lol...


Btw, MikesXS just responded to my query with "checking on it."

Originally Posted by findingZzero

r u the baddest cat here....lol...


Btw, MikesXS just responded to my query with "checking on it."

haha, they have been telling customers to call me, or sending them the links to my How-To's instead...

thanks for all your support folks

Hugh
Hugh's HandBuilt

will this work on the xs400's?

So I acquired one of these banshee kits from a guy, I've read the install of this and the HHB kit, now my question is... Woodruff key? Do i need it?

Originally Posted by gypsyspit

So I acquired one of these banshee kits from a guy, I've read the install of this and the HHB kit, now my question is... Woodruff key? Do i need it?

Nope...

Awesome, thank you Hugh!

Originally Posted by Punkskalar

Nope...

Really?? I thought it was essential to the timing? I spent forever trying to keep it in place while putting on the flywheel. Damn magnet would slam and knock the key out of place all the time.

the taper holds the rotor in place, the key just locates it.

Sob. Oh well. Key is in. Ill remember that for next time i have it apart. Thanks