XJ Stator Swap Complete

[81xsproject]

While not my most technical conversion (EFI, GM-DIS, Hydo-Clutch, LED,...), the XJ stator swap is a success. For me, it was a necessary project as the XS stator was barely making 12 volts at 5k RPM and as low as 11.3 volts near idle. Even with all LED's, my busa fuel pump was eating to much juice. So, I decided to give the XJ stator a try. The most difficult part of swap was getting the XS stator rotor off of the crank. I bought a set of pullers and had zero luck. Then I came back to the trusty forum, did some research, and found that I needed a M16 with 1.5 fine pitch thread to pop the rotor off. THIS was the hardest part. The hardware store had M16 with standard 2.00 pitch and all the way up to M14 with fine pitch. BOO! So, I called all over hell's half acre (on a Saturday). I got 10 no's and one very useful recommendation to check out a place called Specialty Supply once they opened on during the week. The big shock wasn't that he had a M16, fine pitch, ~3" long bolt in stock, but that it was $0.78. That would have been about a $4 bolt at the local hardware store.

Anyways, after that, I just bolted on the XJ rotor and stator, and the wire connections were a direct fit for my '81. I had read that some wires needed to be swapped around, but I had no such issue.

The final result; the bike makes high 12 volts at idle and mid 13's at 4k. One of these days, I hope to pop for Geezer's Regulator. And, my biggest worry turned out okay...the YICS sticker peeled right off.

[skids]

Nice job! (PS, I am sure that you had a decimal out of place on the bolts cost)

Anyways, after that, I just bolted on the XJ rotor and stator, and the wire connections were a direct fit for my '81. I had read that some wires needed to be swapped around, but I had no such issue.

The final result; the bike makes high 12 volts at idle and mid 13's at 4k. One of these days, I hope to pop for Geezer's Regulator. And, my biggest worry turned out okay...the YICS sticker peeled right off.

[81xsproject]

I know, I couldn't believe it either. I know where I'll be getting all my hardware from.

[trbig]

You guys need to know that this won't work on your bikes and you need to leave MY XJ parts alone!!

Man.. the pickens are getting slimmer.. lol. Maybe some day you'll be cool enough to leave that YICS badge on there..


Tod

[DiverRay]

Maybe some day you'll be cool enough to leave that YICS badge on there..

No Tod, We'll just try and grab the good parts from you bike!!
But then, maybe we can get you to do the "first ride" on some of these things we are putting together!

[Crazcnuk]

Ok, so it works better than your cruddy one, but how does the XJ system stack up against a good working XS one?

Does it give us more watts/amps?

[81xsproject]

There was nothing wrong with my old one. Both brand new, the XJ's brushed alternator put out significantly more amps. The only down side is that parts'n'more no longs carries the brushes.

[trbig]

TC has the actual stats on the alternator differences, but yeah, the XJ's is better... but as stated, Partsnmore quit stocking the brushes. I even contacted them about them buying one more order if I would buy them all... and heard nothing back from them. They can still be bought, but at a much higher price. I've got @ 30k miles since last year on a used set, and they still look good. The manual wants you to change them a lot more frequently than you need to, but it's not like something you'll have to change with the oil.


Tod

[TopCatGr58]

The XS makes 20 amps, the XJ makes 26 amps!

Hey Tod, I thought I had checked PNM after you had posted about them not carrying the brushes, and found this, it looks different than what I remember before, but then I might have been thinking about the starter brushes, but do these look right??

ALTERNATOR BRUSH
For 3-phase alternator systems
Must reuse old terminals
Fits XJ1100

$5.00US EA. Part#24-2050

T.C.


Okay, more research, the Yamaha fiche site revealed these #'s for the brushes, for the XJ11, and the XJ 750, and the XJ550

4G0-81611-10-00 XJ11
4G0-81612-10-00

4Gx-81611-10-00 XJ 750
4G0-81612-10-00

4G0-8L6LL-L0-00 XJ550 showed the 4Gx/superceeded with this number,
think it's typos "L" for 1's!?

The XJ 650 shows the same 4Gx prefix for the #1 brush, but with the 550 info, I'm pretty sure it's the same, and then rechecked PNM, and they list the same part # for the XJ650 brushes as for the XJ11, so looks like they either got them back in stock or such, because they haven't removed them from their listings, and they have them on both the 11 and the 650 sections!
T.C.

[81xsproject]

The last contact I had with partsnmore, they emailed me and said that they were out and would no longer be carrying them. Mikes has some for the 650's but my research (probably short winded) found that the ones on Mikes wouldn't work. Keep digging, TC! I would love to find another source that was less than $50.

[81xsproject]

This is what Mikes sells.

[Crazcnuk]

heh, sorry, but

"XS stator was barely making 12 volts at 5k RPM and as low as 11.3 volts near idle"

didn't sound like your old one was working very well.

20 to 26 amps is a decent boost. Hopefully you can solve the brush issue. Easiest is probably to find out who actually made the stators. They often try to standardize as much as possible, and other charging systems may use the same brushes.

[CatatonicBug]

This thread really has my attention! With all the added lights I've put on mine (running lights on the fairing/trunk, brake lights on the trunk), my turn signals are having trouble drawing enough current to blink while at idle! I don't want to loose the auto-cancel feature, so I'm not switching to LEDs on the signals, but I may on the trunk. However, it would be nice if I could boost the power output of the generator a bit to allow me to use the radio too! I know where there is an XJ just waiting to have it's stator stripped out, so if you guys can locate a source for brushes, I would love to use this mod!

[Ivan]

So, on an XS would rewinding the field coil (the part in the middle) with finer wire and more wraps make it charge harder, since it would effectively make a stronger electro-magnet? I have a coil that is burnt up and woudln't be that hard to find a source for winding wire, but i wonder if it will be worth the trouble and expense.

[DiverRay]

For new brushes, go to your local electric motor shop. The shop in Santa Cruz, the closes one to me, carries a TON of brushes. You should be able to come really close, and just file down the brushes if need be. I've also found the brushes there are MUCH cheaper than the "OEM" source.