PMA conversion.

I've done a number of mods for this bike, this is the permanent magnet alternator conversion I did.
You can buy a kit from one of the many XS650 parts outlets, but the $$$ are frightening in Oz. I hunted around on ebay for stators and rotors that would fit and found a new stator and reg/rec for an XV and a rotor for a Banshee all for $130, then turned up a mount to fit the stator to the XS crankcase.
In fitting the new PMA alternator it's important to fit the stator in the correct position, ie, central to the rotor's magnetic field. So, I mounted the stator inside the rotor and attached the rotor to the crankshaft and took some measurements. Then I spun up a mount to fit. I didn't have a slab of aluminium thick enough to make it from one piece, so, turned up a two piece mount to get the correct height, about 40mm from memory.
To make the lektrisity flow better I polished the mount.
While the rotor fits the tapered XS crank, the woodruff keys are a different thickness, 6mm for the Banshee rotor and 5mm for the XS650 crank shaft. I stepped a standard 6mm woodruff down to 5mm only to find the diameter of the woodruff didn't match the keyway in the crank, so I turned up some stock to the required diameter, cut it in half, stepped it and then shaved the top off the key until the rotor fitted.
There were marks on the original rotor for timing purposes, however, the Banshee rotor didn't have any. The original alternator was fitted again, the engine timed, then removed and the PMA fitted again. I then made a curved timing plate, fitted it to the left side cover and scribed lines on the rotor and plate.
All that remained to be done was fit the rec/reg, behind the battery carrier on an aluminium bracket I made up. That done, I routed the wires through, fitted modular plugs to the regulator and alternator leads and snapped them together.
The stock XS 650 alternator is a brushed unit, so similar to a car's alternator. However, it has a very low output: zero at idle, rising with the RPMs, resulting in a flat battery with all the stopping and starting you do when building a bike. The new PMA has a 14.4 volt output from idle right through to max revs.
74 TX650, lots and. Lots of mods.

 

AKA, THE SHAKER. I am building a soft tail chopper with xs650. Have you ever done a rephase on one?

 

Nope. There are plenty of 180 degree and 270 degree bikes out there, don't see the point in changing a 360 degree twin to something else.