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upgrade charging system?

Discussion in 'The Garage' started by madpressdog, Jan 15, 2011.

  1. bcXS400-81

    bcXS400-81 XS400 Enthusiast

    I'm pretty excited to hear that this system works on our bikes. I can't remember where I heard it, but I was always under the impression that you couldn't do this swap and run a capacitor on our bikes. My bike has issues with the charging system that I haven't looked into too much yet, but this seems like a way better solution than trying to track down the problem and replace crappy components with more crappy components.

    A write-up for this would be epic, if you can spare the time.
  2. drewpy

    drewpy Excess twin Top Contributor

    fantastic, might/wil be a future upgrade for the tracker after it's been used a bit! :thumbsup:

    pikkies, where's the pikkies?
  3. ahale2772

    ahale2772 XS400 Addict

    agreed, a writeup would be "Epic" :D
  4. madpressdog

    madpressdog XS400 Member

    Hey guys ! Bike is running good !!I have been having so much fun ride i forgot i have a few pics to post

    Attached Files:

  5. drewpy

    drewpy Excess twin Top Contributor

    cool, is that mag not covered then?

    suppose you could get a cage or fab something via those screw holes
  6. HoughMade

    HoughMade XS400 Guru Top Contributor

    I'm glad to hear you've found a solution and more proven mods are a good thing. I would note, however, that your previous charging system must have had something really wrong with it. It may not be the most robust system, but when it is in good repair, it makes plenty of juice. I found my lights brightened and I had no issues whatsoever after I took apart each and every electrical connection and cleaned them with a Q-tip and mineral spirits and rebuilt the fuse box. I run all stock turn and brake lights and had a 55w/60w headlight (I put a 35w/35w in because I thought I may have an idle issue due to discharging, but it turned out to be something else- will be going back to the 55w/60w).

    Good luck with the mod!
  7. madpressdog

    madpressdog XS400 Member

    Thank y'all ! When I got the bike it had been pick apart over 20 years of mud . Sorry drewpy the mag fits nicely in side the cover. But it did cross my mind to try there is oil sloshing everywhere. It would be cool!
  8. larsbar

    larsbar XS400 Member

    Wow, that is great to see. My last bike, a DRZ400, had no battery, just a capacitor, and a 70 watt headlight. It never had any trouble starting or powering that light. I had a hidden switch that disconnected everything except the engine and computer during starting, then once it was running I switched on the lights. The only issue I had was when riding at night if it stalled or died all the lights went out immediately, making it a little dangerous if it wasn't running well.

    Ps. I am new and have been lurking for a couple weeks and thought it was time to contribute. Love this forum, I will get my first 81 xs400 later this month
    Last edited: Aug 26, 2011
    Anthony T DiMarzio likes this.
  9. Just wondering how this mod is panning out? Have you installed a capacitor yet? If so, what size did you use?
  10. striker85

    striker85 XS400 Member

    The electro-magnetic systems that were common on older jap bikes work fine. The key is to have everything clean and tight. All connections need to be gone over and replace any connectors that are bad. Also, check resistance on the rotor and stator. If all checks out, it is usually a bad rectifier. These guys make a good product and I have not heard one bad story about them.


    However, this mod is interesting. I'd like to see an update on the running with no battery part.
  11. drifter

    drifter XS400 Member


    I am considering this mod and have some questions

    first is will this full kit from Hughes hand built work ? its for a xs650?

    second is

    will the stock cover fit over the whole works or does it need to be modified or is the mod always exposed ?
    /edit *seems after re reading the thread you state the cover does fit over the whole she bang.. wasn't apparent in the pictures :) how much did you have to trim?

    /edit2 ok i am having trouble seeing how the cover would fit over :confused:

    new question would a aluminum mounting plate work ? instead of steel ?

    thank you

    Last edited: Jan 27, 2012
  12. madpressdog

    madpressdog XS400 Member

    Hey Drifter yes some of Hugh's handmade rectiffe/voltage regulater about $42. The stator is samwitch on a thin steel behind the cover that is hone out alot. Look at the pic the weight on the flywheel is clocked to fit on the crank and the keyway. The edge of the cover is honed too. Now the flywheel can be pushed flush to the cover to look stock. I all so had to add a small hole at the bottom of the backing plate so oil can flo back in to the crank case there is a pic of that too.
  13. madpressdog

    madpressdog XS400 Member

    O this mod is kick only no starter on this one.
  14. iglehart332

    iglehart332 XS400 Member

  15. FlyingAnvil

    FlyingAnvil XS400 Addict

    I like all this crafty stuff, just good info.
  16. 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!
  17. madpressdog

    madpressdog XS400 Member

    Iglehart332- the mod is very similar. The outer case will need to be clearanced for the flywheel to fit in. See pics above of my case. Everything will fit inside the stock cover.
  18. iglehart332

    iglehart332 XS400 Member

    Sweet. So let me get this right. You used a banshee flywheel, a banshee stator and hughs 3 phase regulator? And your saying you had to hone out the cover? How did you do that? Sorry just starting to dabble in this stuff.. Thanks
  19. OleDoc

    OleDoc FREEBIRDS MC Central NY

    me too.my girl needs a diet
  20. madpressdog

    madpressdog XS400 Member

    ok here is a pic of the stock cover and the cover after i cut and honed,filed sanded. I cuth the outside timing marks out smooth to the edge with a jig saw with a meatal blade.I smooth out all the edges inside useing a grimal tool.just to make room for the flywheel,to spin free and not rub.

    Attached Files:

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