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Progress has been a little slow lately, but I have managed to take care of some details. I got my 520 sprockets from Sprocket Specialists. Went with 17/32 gearing to help keep the RPM's down a bit on the highway. I made a rear chain guide work off a MX bike with a little modification. I used a front guide off an XT350 cut down some to fit. Also mounted a roller just under the swingarm pivot to keep consistent tension on the chain.
Finally done with the wiring. Everything seems to work. I eliminated much of the XS's BS. I did a Banshee PMA conversion along with a Pamco Ign. W/elec. advance. A more modern Fuse box, starter relay and turn signal relay. I used 09 Yamaha R6 switches that were a little bit of a challenge to wire ,but I made it all work. Since I eliminated the XS starter safety switch I added a clutch starter safety switch into the system for a some added protection. Decided to go with a 8 cell lithium battery to save space. I made a tray under the seat for some of the electrics and battery.
Just need to take care of some details and to some final welding before tear down.
Gettin' closer to the finish.
I checked out your build, looks good! The banshee swap is is pretty common. I hunted down all the parts on E-Bay. There are complete kits out there for about $300. You can piece it together yourself a little cheaper.
In conjunction with the PMA swap using an ignition (Such as PAMCO) that eliminates the points is a good upgrade.
Here is a link on how to do the Banshee swap.
http://www.xs650chopper.com/2011/01/xs650-banshee-charging-system-swap/
This bike is all kinds of awesome, and you sound like you really did your homework with all the modifications. Looking forward to seeing it all wrapped up.
Making some progress. I tore the bike down and cut off all the unnecessary BS off the frame. Sent everything off to powder-coat. Luckily my PC guy rides and always needs someone to work on his bikes so I cashed in. Already got all my Gloss black parts back. Going to have him ceramic coat the exhaust system for me. Should have my wheels laced up soon, just waiting on spokes from Buchanon. Some pics of the PC stuff.
Painted the motor black although both engine covers, points covers and rocker covers are powder coated. Took care of some details like painting the YAMAHA logo's and installing mesh behind the flywheel cover. Really happy with the way it came out.
I also laced and trued my wheels. Still waiting on a couple of things from PC. Also need to get my paint work done, but I'm gettin close.
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