Another alternator hits the dust and not under warranty

Discussion in 'Parallel Universe' started by C5!, Jul 11, 2011.

  1. theborv

    theborv Been here awhile

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    What does it mean to rewind the alternator? Sorry to ask a noob question :ear
  2. JRWooden

    JRWooden Long timer

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    The stationary stator is the part that gets rewound.
    If you look at some of the pictures: http://www.electrosport.com/products/stators/
    You see that wire is wound around the laminated steel core.
    There are permanent magnets in the flywheel and as it spins around the stationary stator the magnetic flux induces the current in the stator wire/windings. When the stator burns up it is the wire windings that are destroyed.
    By working carefully you can remove the dead windings and "rewind" with new wire.
    Make sense?
  3. JRWooden

    JRWooden Long timer

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    At one point in my career I worked at a place that made small industrial transformers.
    After being wound the transformer cores were submerged in a tank of some sort of epoxy resin which was then placed in a vacuum chamber and theey pulled a vacuum on it ... this made sure the epoxy resin saturated all of the windings leaving no air voids (much better than dipping ... and much more expensive as a mfg. process).
    After the transformer was "saturated" with epoxy they were hung on a moving chain so that the excess could drip off and then the epoxy cured in an oven. Good stuff but ... not real cheap.... :lol3
  4. theborv

    theborv Been here awhile

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    Yes, perfectly, thanks! :)
  5. ebrabaek

    ebrabaek Long timer

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    Ahhhh... I see.... Well I can do that.....except for the vacuum..... Ohhhhh well......:thumb:thumb

    Erling
  6. MonsterJ

    MonsterJ I have motopsychosis

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    Nope. The new stuff wasn't available and I couldn't wait. Nothing like a $800 temp fix. :becca
  7. JRWooden

    JRWooden Long timer

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    Yours needs to burn out within (what I believe) is the 2-year warranty period ... then you can get the good stuff.... :wink:
    Pack on the miles....
  8. JRWooden

    JRWooden Long timer

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    I got to a human being quickly, and the guy I talked to was very nice ... he was unable to answer the above question.
    If anyone else would like to give it a go with whoever answers the phone at the time, the number is: (888) 327-4236
  9. hardbern

    hardbern n00b

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    Please!
    Everybody who has experienced this failure needs to log a complaint with the NHTSA as has been suggested here by wiser people (thank you by the way!).
    https://www-odi.nhtsa.dot.gov/VehicleComplaint/index.xhtml

    don't wait, do it now. They cannot rely on forum complaints to initiate investigations.
    and if you have stalled while in traffic because your battery was completely drained and your alternator toasted, SAY SO!

    please.
  10. JRWooden

    JRWooden Long timer

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    Nobody ever found a source for the wiring harness plugs did they?

    I'd like to make a "detuning" adapter for my stator but not have to cut up the harness to do it,
    so a male/female pair of the 3-wire plug coming out of the stator would be really nice to have ..........
  11. C5!

    C5! Been here awhile

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    Your Complaint Information has been successfully submitted.

    Your Confirmation Number (ODI Number) is: 10458740.
  12. WayneC

    WayneC Long timer

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    JRWooden

    BMW use AMP, Kostal & one or two others for plugs/sockets, Wurth supply a lot of them to the dealer network, in addition on the online fiche under various plugs & sockets you may find they are available (at BMW pricing of course)

    If you can look at the plug & socket & locate all numbers from them & post them here I could look up some catalogues I have access to. You should find 2 sets of numbers. A BMW No & a manufacturer No, plus possibly a logo

    Re the NHTSA complaints, people should post the ODI Number so that each subsequent creport can refer to the previous one's lodged. With the F650 single we found key entry mistakes at NHTSA could hide reports under other models & with the confusion BMW created with the "F" designation that is likely to occur with your reports
  13. JRWooden

    JRWooden Long timer

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    Thanks Wayne!

    I am on the road for a while, but when I get home I'll disassemble harness and capture the numbers.
    THANKS for your help!
  14. kokni

    kokni n00b

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    Sorry if it has been answered elsewhere, but there are now more than one threads open:

    Is there any, just any kind of official response from bmw regarding the alternator/stator issue?

    I am planning a long trip and want to proactively deal with this issue.

    Replacing the part with one of the newer batches (if any) solves the problem?

    Sent from my GT-I9000 using Tapatalk 2
  15. JoelWisman

    JoelWisman Long timer

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    BMW does not officially respond to forums or customer inquires, EVER.

    Occasionaly they post a service buliten for internal franchise staff, and quite often, in cooperation with the NHTSA, they issue recalls.

    Neither of the above has occurred to date, and personally I don't expect either to occur in regards to this issue.

    The new flywheel looks like it will improve stator longevety but it will be years before we know for sure.
  16. JRWooden

    JRWooden Long timer

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    I may have posted this to a different thread, or not posted it at all .... sorry I've been on the road and out of the loop...

    But as a status update, ElectroSport has prototype stator assemblies on order and they will be testing their proposed design on arrival ... availability is not known yet since a design iteration may be required.

    I asked about the design point and got this reply ... which sounds like it could be good news for use:

    "The insulation should be good up to about 350 degrees, which might sound a bit low for the BMW. But we are hoping that a different winding configuration plus a much higher quality copper wire with lower internal resistance will allow our stator to operate well below 350."

    For the record, I have no affiliation with ElectroSport other than that of a potential customer ... :lol3
  17. Indy Unlimited

    Indy Unlimited Long timer

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    Great news! Thanks for keeping us posted. I hope we can get a durable aftermarket solution soon!
  18. bxr140

    bxr140 Flame Bait

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    Since I'm lazy (and my rudimentary half assed search didn't provide results), what is the failure mode? Its it a more binary "it doesn't work now", or do they die an analog death? I'm having starting problems at ~30k and with the bike running I'm getting around 12.5-12.6 across the battery leads.
  19. ebrabaek

    ebrabaek Long timer

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    Analog death..... melted insulation...partial/full short of one or all phases.....
  20. JRWooden

    JRWooden Long timer

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    Wayne:

    Thanks --- I am finally back from my trip .......... they all seem to run over........

    The MALE 3-prong plug shows the following:

    1-962658-1
    PA66
    Tyco 1-963470-1
    BMW 8 352 337


    The FEMALE 3-prong plug shows the following:

    AMP 1-828817-1
    PA66
    BMW 1 378 114


    I should have written it down, but I think it was the female side that had a little molded clip on one side to secure it to a metal mounting bracket, this would not be required ... as we do have zip ties :lol3 and there might be a "generic" equal that did not have the mounting boss/clip?

    The plugs are not sealed against moisture like some of the connectors on the bike but I guess BMW figure that since this was a "power connector" it didn't need to be sealed against the elements. I could not help myself and put a dab of dielectric grease on each prong for "insurance" :lol3

    http://www.permatex.com/products/au...e/auto_Permatex_Dielectric_Tune-Up_Grease.htm