Hughs Handbuilt XS650 PMA CDI Kit How To Installation

Installing a Hughs Handbuilt XS650 PMA or CDI kit? Here's a step-by-step how-to installation video to walk you through it! This is the best kit on the market for adding a modern permanent magnet charging system and digital electronic ignition system to your classic Yamaha XS650!

[@chuckpeters6877]

This is very useful and well done. Was extremely helpful during the CDI install on my 1977 XS650. Wish it was a bit longer and included even more details. So good. Thanks so much for doing this.

[@OctaneElectrons]

Glad it helped!

[@marcuscrabtree]

Very helpful!! Thanks!

[@OctaneElectrons]

You're welcome!

[@williamknutson6163]

Very nice, now do a video on removing all the junk you no longer need. like the electric starter and all the cogs to remove all that excess weight from your motor.

[@OctaneElectrons]

Good idea!

[@BigChopperPoppa]

Nice! My instruction manual said to set the pickup in the middle of the slots, but now I'm thinking my timing might be slightly advanced as I'm getting excessive top end heat. Ill slide it forward like you did with the brass shim and tighten er down. Any chance you know the actual length of the brass piece? Not sure if I'll be able to find mine... Thanks for the vid!

[@OctaneElectrons]

I had a notification of a comment that seems to have disappeared. For whoever asked, the feeler gauge is .015" thick for setting the pickup coil to flywheel trigger gap.

[@jimmypopp2695]

What is the value on that capacitor? I have been toying with the possibility of using a capacitor that I am able to build using a new method I have been working on.Not only that but also a better coil plate along with a magnetic flywheel. Please let me know and I will get back to you about what I have been developing. I am on Facebook. Are you?

[@mattaragon7346]

Have you ever had an issue with it not charging? I have one on my 650, kick start only with capacitor. I got stranded. It turned off in the middle of the intersection. I was able to get it push started a few times but nothing after that. Now I don’t have spark and can’t seem to figure out what the issue might be.

[@OctaneElectrons]

No, the system charges very well. I don't love using them with a capacitor though, always prefer a battery.

[@matthewaragon3641]

@@OctaneElectrons Thank you. I'm in the process of testing all the components. the capacitor is good. I need to test the stator and rectifier

[@robertahlholm6412]

good vid but, you should really show how to connect wires with or w/o battery/ capacitor-using relay or not- took me a good while to figure it out. would be very helpful to other non electrical dyi's out there. also should show how to properly time it

[@OctaneElectrons]

The video shows the way I was installing it to test things on that particular bike, it's not meant to account for every possible way to hook up this system. If you're not using a battery, then you connect output of the regulator-rectifier to your capacitor (making sure to get the polarity correct). Your lighting and ignition system is connected to the capacitor as well. If you're not using the relay harness to allow a stock/OEM handlebar kill switch to kill spark from the CDI system, you simply need to run the kill wire from the CDI to a switch to ground. When the wire is grounded (switch closed), spark is killed. When the wire is not grounded (switch open), spark. Your timing adjustment on this system is slight movement of the pulser coil trigger. You can loosen the mounting screws and adjust it side to side slightly. Hugh's instructions are detailed and thorough and cover these topics well, make sure you have read them in detail before your installation.

[@jordoncarlson6871]

What did you do with all the old wiring and harnesses? Towards the end of the video they were just hanging out, are they useless at this point and does one just get rid of them? Great video by the way, will be using it upon purchase!! Thank you

[@OctaneElectrons]

The original wiring harness was tied back up on the frame. Most of it is still used, just some changes to how the ignition and kill switch tap in. Glad the video helped!

[@dannyceja85]

I took off the stock stator already but the Woodrow key is facing down and i already have TDC. Can i just spin it until i find TDC or do i need to put on stock components back on before spinning it to find TDC so that the Woodrow key slot facing up ???

[@OctaneElectrons]

I would spin it until you confirm TDC at the cylinder. Make sure #1 is at top of piston travel with compression, then you know you're good.

[@benjamintran8507]

Do you know the length of the feeler guage? The previous owner installed this kit but the timing is off and didn’t include the feeler guage.

[@OctaneElectrons]

No sorry, contact HHB!

[@evan2827]

Couple years later now how is it running? I have an 81' (TCI) that recently stopped charging and could use some newer electronics so this system has been in my sights for a while

[@OctaneElectrons]

Still working perfectly. This really is the best kit out there for charging & ignition system upgrade on an XS650.

[@evan2827]

Great, thanks! From what I can tell in this video the CDI ignition replaces the TCI and you don't need to switch to points like you would if you were only installing a pma, correct?

[@shannonkaiser9592]

@@evan2827 I was wondering the same thing

[@shannonkaiser9592]

I have an 81 XS650 bobber what setup do I need to make it so it's Kickstarter only no battery

[@OctaneElectrons]

www.hughshandbuilt.com He has all the gear for you!

[@cewdulltooththebeardedbike9400]

If you have the original stock harness could you please send me a picture of it my stock harness was a birds nest and mikes xs doesn't seam to have an exact fit pleas and thank you

[@OctaneElectrons]

Sorry I don't have the bike around any longer. You can try and ask Hugh, or post on the XS650 Facebook group, I bet you'll get some help quick!

[@cewdulltooththebeardedbike9400]

Thank you

[@MrChipwich]

So what about your points and advances? Are they just not needed?

[@OctaneElectrons]

Correct, the CDI system completely eliminates the old points and advance mechanism.

[@miniordie]

The instructions say to set TDC but this puts my woodruff key on the crank on the bottom…for it to be on top of the crank I’m not at tdc…

[@OctaneElectrons]

That sounds strange... something wrong there. Was the motor running before the HHB swap?

[@fiveola]

This looks like a great system. Does this type of pma/CDI system tend to burn out the regulator? Thanks.

[@EvanGrist]

No, this system comes with a heavy duty MOSFET regulator, same as the one used on high output Harley Davidson single phase charging systems. It is very reliable and works great on the XS650.

[@robertahlholm6412]

@@EvanGrist since when? mine came with a 20 amo then had questions for hugh he sent me a 30 amp and when I turn on light volts drop drastically to 6.5, lights off and I'm only getting 12.5. - seems all other ststors are 3 phase not single phase to handle the draw of lighting- still confused 4 yrs later and I've tried it with both battery and capacitor

[@fiveola]

@@EvanGrist I finally got around to installing this kit. Pretty easy install and my TX650 runs great! No regrets. Thanks for this video. It has helped heaps!

[@EvanGrist]

@@fiveola that's awesome! Glad to hear it. I'm still a huge fan of this kit!

[@DannyC2345]

How much? I’m picking up a 1980xs650 tomorrow for 500 bucks. Plugs get no spark

[@OctaneElectrons]

$599! www.hughshandbuilt.com/product/complete-xs650-cdi-system/

[@markmanwaring3823]

solder all electrical connections and seal with heat shrink , much better mate

[@OctaneElectrons]

Always a good idea.

[@EricLawtonForbes]

What 2-into-1 exhaust is that?

[@OctaneElectrons]

I'm not sure sorry.

[@EricLawtonForbes]

@@OctaneElectrons ok

[@pjlucaschannelpatentes9455]

Wat is the prize pls.. And wer we can buy..

[@OctaneElectrons]

www.hughshandbuilt.com

[@skylarhemauer2761]

what year is this bike?

[@OctaneElectrons]

1978 I think, it's been awhile!

[@patrickscott1604]

What is the price on the kit

[@OctaneElectrons]

$599 www.hughshandbuilt.com/product/complete-xs650-cdi-system/

[@BloodNuke76]

does any company make a pma for the xs850?

[@OctaneElectrons]

Not that I know of. The XS750 and 850 triples do not use the same system as the 650 at all.

[@BloodNuke76]

@@OctaneElectrons how do they differ?

[@rickyrobinson3096]

I bought a 78 xs 650 the previous owner cut all the wires off except the ones for the coils and the ones coming from inside the motor. Im wanting to just wire the head light brake light and fire the bike up could i do this with this kit or something different

[@OctaneElectrons]

@@BloodNuke76 The XS750/850 use a fixed mounted field coil (it does not spin). The rotor is not permanently magnetic, and spins over the fixed field coil, with a ring stator around it. This is different from the XS650, which has a field coil embedded in the rotor, and the whole unit spins. I don't believe the taper on the crankshaft is the same between the 650 and 750. This would take some testing and investigation to see if a similar system could be used on the 750 motor. Almost for sure a new backing/mounting plate would need to be created.

[@OctaneElectrons]

@@rickyrobinson3096 No, this kit only affects ignition and battery charging. It will not provide any way to wire up lighting.