upgrade charging system?

madpressdog, the stator on the 400 is surrounded by oil, the stator conversion (pma) on a 650 is dry can u use a 650 pma for the conversion or will it being submurged in oil not work?
 
Don't suppose anyone has a drawing for the stator bracket/plate - thinking of just CNCing the bracket + the adapter plate out of one billet.

Pretty please!

When I end up machining one I'll post the drawings and the part file up here for the masses.
 
i did this same thing with the xs650 pma kit works amazing!!! ihad to machine the cover to fit the rotoe and drill and tap holes onto my cases to hold the stator plate i dont have cnc drawings but i do have an extra cover you could use to measure so you dont have any downtime with your bike
 
I just may try this - but I'll have to wait until I get my generator cover off.. Never serviced these motors before so I've got a lot to learn... Should I be draining the oil? Can I do this with the motor in the bike? What all do I have to take off?? Looks like the ignition timing cover, chain cover and then finally the generator cover can come off...

My current worry, the stator is measuring open circuit...

Couldn't the rotor be replaced with a permanent magnet type (maybe one of them rare earth mags), and so allow one to not have to do all the fancy mods here? Just thinking that since we've already got a brush-less 3-phase stator, putting a new one in seems redundant to me. If that worked, you would only need to make sure to buy a regulator that can handle the power!
 
I just may try this - but I'll have to wait until I get my generator cover off.. Never serviced these motors before so I've got a lot to learn... Should I be draining the oil? Can I do this with the motor in the bike? What all do I have to take off?? Looks like the ignition timing cover, chain cover and then finally the generator cover can come off...

My current worry, the stator is measuring open circuit...
Rob the ignition timing cover Pointer has to be removed the engine can stay in the bike drain go to the first part of this chat look at the pictures you can see how the timing cover is clearance for the new stater do a little legwork before you ask questions fast
 
So are we talking yamaha banshee atv flywheel here? I'm having a charging issue and am looking to upgrade, I'm just having difficulty finding good NEW parts.
 
ok, i read this whole thing and got the gist and really want to do this mod because batteries suck the butts. and mine is kick only with led tail light and small head light so i dont consume a lot anyways. so my question is this.. the parts list is the hughes rectifier, a banshee flywheel, and a banshee stator? are the banshee products all the same?? because i looked it up and were differently numbered items, so im just making positive i order the right stuff!
 
There's another thread the guy is using a battery but uses all this and says it works great with no modification the stator cover meaning you can keep your timing marks which personally im a fan of plus less modification the easier it should be to do and it the whole set up is about what a banshee stator and fly wheel will run you so overall the combination of both these can get us somewhere b/c I really want to get this battery off my bike....

heres the list of stuff he used

ZL600 Stator and Flywheel ---------- $25
Banshee Stator Plate ------------------ $15
3 Phase Regulator/Rectifier --------- $13
XS400 Gasket 1L9-15461-00-00 --- $12
M16x1.5 Bolt ------------------------------ $5
 
i did this same thing with the xs650 pma kit works amazing!!! ihad to machine the cover to fit the rotoe and drill and tap holes onto my cases to hold the stator plate i dont have cnc drawings but i do have an extra cover you could use to measure so you dont have any downtime with your bike


i was going over the thread to see if anyone had responded and missed this post before. A guy who said he successfully did the conversion with full kit that can be bought instead of hunting shit down with trial and error if it works or not and everyone ignored him.......why?

we probably can get the info on how it worked since he hasnt been on in over a year.......
 
Why? Over 2 years later and you are asking why people didn't question him? Most of the people who participated in this thread no longer participate here. You likely won't be getting any answers. It is rare for people to stick around here for more than a year or 2.

On the other hand, there are a few who have been here for many years and thousands of posts... :shootme:
 
Don't think there's been much serious interest in the PMA mod in the last few years.
 
Why? Over 2 years later and you are asking why people didn't question him? Most of the people who participated in this thread no longer participate here. You likely won't be getting any answers. It is rare for people to stick around here for more than a year or 2.

On the other hand, there are a few who have been here for many years and thousands of posts... :shootme:

kinda hoping since then somebody figured it out............but thanks
 
The banshee dose fix the shaft. You will need a new key way. The housing needs to be sanded down for clearance. I ran a motor with points didn't need a battery for kick start only. SO READ THE POSTS
 
Ok its charging like new:thumbsup: no even better. Now at idel reads 12.8v When reved ,sorry no tac jumps up to 14.7volts and the lights are nice and bright. Right now i still have a battery but plan to switch to a small capassitor.this banshee setup on the xs400 is eazy to do > I just followed the steps to XS650 SWAP trimming the cover down was the hard part.
the part list was
banshee flywheel----------$100
stator--------------------$ 20
3 phase ref/reg-----------$ 42 (hughs handbuilt)
this is better then sliced bread
the web page i got the most out of was choptemberhow to xs650 banshee charging sys. swap here are a fu pic's
Any updates on this? I've got an 81 XS400 with a similar charging issue and I'm looking to ditch the battery all together. Seems like the charging system in this model is a common cause of headaches. Do you have pics of it completed? or a forum of your step by step progress? would love to learn more!
 
it all sounds great the problem being I want some one on here to get my XS400 breathing again, no spark ? Its sat in a back yard for 15 years, I put a battery on her and wow it all works, other than no spark, I fitted working coil packs as I think the one's I took off were dead, I freed the engine lots of oil 2/3rd gear and rock back and forth easy.. Fitted a Kick starter on here got compression and everything sounds great but no spark? help please. Great thread and great web site gents, I just joined last night.
 
Hey guys thinks for all the in put . I been doing a little home work on banshee. The stator is used in alot of bikes. The plan is to go battery less. Find one guy xs400 banshee rotor and stator setup. Said it works find, that's all he says. I don't thank he tried to fit it in the stock cover but Im going to try.
Dose the rotor fit the crank?
Dose it fix in the stock cover?
How to mount the stator ?
I'm going to find out

doing that banshee conversion does that mean you got lights too so you are ok to ride at night long distances
ant
 
I love that your thinking of modding the charging system to make it better but are you sure your previous system was working correctly? Is your bike stock with all electronics still there? If so then I would keep a battery just so you have a reserve. If it's not stock and you have less accessories then you could probably save just as much space by building a mini 12v battery. The only reason I stress on having a battery is that if there is any electricity produced it must be used up, if not it could fry something. If you plan on going with no battery and your charging system spikes, or if your diodes in the rectifier decide to quit and produce AC voltage the battery will take those hits for you instead of your components. I say carry out your mod but think twice about going with no battery. Good luck! :thumbsup:

Wow! Campbell you sound like the guy I really need to talk to I lost my charging system I started to test things swap parts to isolate the problem no luck then I lost all ignition and now I am really stumped I am not good with electrics never been trying to self teach any ideas where to start. Oh one last thing. somebody removed the fuse box on the bike so it has wires going in all directions but she has run like that for years I put over twenty thousand miles on her with out a problem now I dont know what to do and I love my 1980 XS400!!!
 
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