KZ650- 81' Rotor+Stator fit in 77' Cover?

I'm doing a complete rewire on my 77' KZ650B and have recently focused on the non existent charging system.

I was lucky enough to have another builder supply me with an 81' KZ650H CSR Stator + Rotor and I purchased my own Shindengen MOSFET Reg/Rec based on the success of other members.

However, I purchased a lovely set of Black Powdercoated Side Covers without paying attention to the Alternator Cover which I see now has the 3 screws indicating it's a 77' Side Cover for the Field Excited Systems.

QUESTION:

Is there any possible way of making an 81' Stator+Rotor fit into the 77' Cover with some modifications?

I'd hate to lose the niceness of the matching black Covers.

Thank you

Nickolas

(PM replied to)

I think someone here could make an adapter if there is enough room in the cover.

You'd have to make some very careful depth measurements to see if it would work.

Reply to PM:

Maybe someone can take a very accurate measurement of how deep the stator sits inside the alternator cover from the cover mating surface. It would only take a straight edge and a ruler (or depth gauge).

Or you could just order a later cover, make the measurements, fabricate your adapter, then re-sell the later cover. I think I would choose this route in order to be able to re-measure as necessary. You can get any cover from 1978 and later.

To be honest, it seems that you're going about this sort of backwards. Rather than trying to modify things even further why not simply buy and install the correct generator, rectifier, and regulator and sell the wrong stuff that you bought? This approach would make things much easier than trying to modify the cover so you can install the incorrect charging system on the bike. Unlike some later charging systems, the original 1977 KZ650 charging system works extremely well. I bought my KZ650 new in 1977 (62,000+ miles ago), and other than replacing the rectifier when it was 35+ years old the system has always worked great without any problems. Ed

That's a good point. It'll definitely be easier, and I agree, the 77 system, while being more complicated, has better output efficiency and overall output at idle. It will cost a bit to get the regulator and other parts if you don't already have them. I guess it's a time vs money issue... or some people just like to find out if it can be done.