stator re-winding

Discussion in 'The Garage' started by knybanjo, Dec 14, 2007.

  1. knybanjo

    knybanjo kinda slow

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    Has anyone of you ever re-wound your own stator/magneto coil? or know of somebody who has?

    If so do you have any advice or instruction to go by? Or where might I find more info on that subject?

    Also does anybody know of anyone that still does that sort of thing?
    (or has that art gone the way of all other disposable chinese electronics?)

    It seems like a simpe thing to do....but I'm not sure if there are any special tricks invovled...or just what may make a coil weaker or stronger.
    #1
  2. KevinMTB

    KevinMTB Been here awhile

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    Depending on your bike, I'm pretty sure that BajaDesigns can rewind your stator. If you search ThumperTalk you can find more info regarding people rewinding their own. Seems to be straight forward. Good luck.
    #2
  3. VStromTom

    VStromTom Long timer

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    I saw sometime in the last year a post detailing how to rewind a stator. Think it was on a KLR website, don't remember which one. Addressed making beefier, etc. Search. If I come across the link I'll post back.
    #3
  4. mark1305

    mark1305 Old Enough To Know Better

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    Check around locally for either an older established auto electric shop, or electric motor shop. They may be able to do it or give you some basics on how to calculate the number of windings and wire guage that you need for a specific output (by comparison to original windings and output).
    #4
  5. DaveF-

    DaveF- Adventurer

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    See this writeup.

    Several proven stator re-winders are listed near the end.
    #5
  6. Donkey_Kong

    Donkey_Kong Banned

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    Worked around motor rewind shop in the Navy. I also have a friend that makes transformers but most of them weigh tons. They build some of them on Rail Road flat cars so they can be shipped, the tracks go into their building. A motor rewind shop can do a stator because it's about the same thing.

    You can do most of it if you're good with wire but you may find it frustrating. If the old one is in good enough shape so you can count the number of turns and measure the wire that's where you start. You have to find out if you have a delta, a Y or single phase winding.

    You then need to source that size of wire that's varnish covered. You then need to source some fiber glass or glass reinforced mylar tape. Not impossible to find but not easy either.

    You then clean all the old stuff off the iron cores. Then you put the insulating material on, wind on the wire as tight as possible without damaging the insulation. Then connect the coils. This is the easy part.

    After you wind up the stator you need to dip it in a varnish insulating material. After that it needs to air dry and drip for a bit. Then it has to be baked to finish the set on the varnish. This is the part that will give you the most trouble without experience.

    After all of this it would be cheaper to get a new one or find someone to do it for you that does it every day and has all the stuff on hand.
    #6
  7. knybanjo

    knybanjo kinda slow

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    :thumb
    I copied the list and thought I'd post it up here too....Thanks.

    Stator Rewinding
    If and when the need arises in the future to have a stator replaced, my plans are to have a Honda stator rewound by a competent and reputable company specializing in rewinding stators. Several such sources are listed below.
    Custom Rewind
    Custom Rewind in Birmingham, Alabama has earned an excellent reputation among CX/GL owners for their high quality work in rewinding stators. I've heard nothing but praise for their work.
    Their website appears to be new but they have been in business for quite a while. The preferred method of communication with them is by phone at 205-798-7282 or toll free at 800-798-7282.
    Their mailing address is:

    Custom Rewind
    2014 Pratt Highway
    Birmingham, AL 35214
    West Country Windings
    West Country Windings is another company that has earned the praise of many customers for their excellent quality rewinds. Many UK CX/GL owners have used their rewound stators with absolutely no problems.
    They can be reached at West Country Windings, 79 City Business Park, Somerset Place, Stoke, Plymouth, Devon PL3 4BB UK. Telephone 01752 560906.
    Rick's Motorsport Electrics
    Rick's Motorsport Electrics is another source for quality rewinds.
    Rick's rewound a stator for another bike I've been working on. The work appears to be of high quality as can be seen in the photos below. Unfortunately the bike has not had enough miles put on it yet to make any kind of reliability assessment/endorsement, but I very much like what I've seen.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    #7
  8. VStromTom

    VStromTom Long timer

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    I looked but couldn't find the specific link I have seen before, but I will keep looking. I did run a search for "how to rewind a Stator" and a lot of links came up, a couple of which looked pretty detailed. Hope this helps.
    #8
  9. knybanjo

    knybanjo kinda slow

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    OK,
    I took the cover off and re-tested next to the coil and checked the wiring. Ignition stator still shows no continuity. Wiring harness tests OK.

    This article http://www.justxr.com/jaw/stator.html on rewinding the ignition stator makes it look easy and the DR has a single pole for the ignition just like the XR.

    So......I'm now at the point of no return......

    PLEASE FEEL FREE TO MAKE SUGGESTIONS

    My first view of the stator shows that it looks physically OK and that the ignition is on a single pole. (the big one)
    [​IMG]

    [​IMG]

    After removing it (good luck) I scratched the insulation next to the coil to retest it and the harness wires.
    [​IMG]

    The problem may have been where the wires connect to the coil as they both came loose while unwrapping. I could NOT find the ends of the coil to retest again or reconnect. [​IMG]
    [​IMG]

    [​IMG]

    So this is where the decision is made :evil no turning back now!
    [​IMG]
    there was something wrapped around the pole.....what do you think I should rewrap/coat it with? [​IMG]

    Unfortunately I managed to break off the lower guide tab on one side.....I may have to reattach it at least temporarily to help me rewind it.
    [​IMG]

    ONCE AGAIN PLEASE FEEL FREE TO COMMENT AND OFFER ADVISE AS THIS IS MY FIRST TRY!!

    [​IMG]
    #9
  10. Frank Warner

    Frank Warner Traveller

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    You need to provide some protection to the wires where they wrap around the coners of the central pole..
    Plumbers teflon tape should do ...

    On the wire .. measure the diameter - and get the 'wire guage' from that

    Then measure the lengths of what you took off .. you'll need a bit more than that (wasteage) .. I'd not bother counting the turns .. the lenght will give about the same number (and I usually loose count anyway) if you wind in a style similar to the original .. was it 'neat' (1st one row then another or all over the place?) Do the same style of winding ... most small wire is 'untidy' where as larger stuff is 'neat'.

    When you get to the top .. be carfull and put some tubing over the ends .. then glue it in place.. the starting end should also get a bit of tubing .. helps with the insulation .. and stress relief on the end. You should be able to reuse the original tuding.


    Price one from a wrecker, and having it rewound.. just in case.


    Try not to break off any more bits, ok? :evil

    Hummm .. it could be 'polorised' .. making what end gose where and the direction of the wind important .. (clockwise or andticlockwise) ...

    Let us know how you get on.


    The tape over the top is just protection .. and to stop it coming undone. You could seal it with aralidite .. provided it withstands the heat and oil.
    edit for spelling, and a bit more info
    #10
  11. valvecrusher

    valvecrusher tractus pro pensioâ„¢

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  12. Cosmic_Jumper

    Cosmic_Jumper Been here awhile

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    #12
  13. CodyY

    CodyY ADVenture Capitalist

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  14. knybanjo

    knybanjo kinda slow

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    I've been assembling the parts needed and may have a present from "Brown Santa" tomorrow.:thumb

    So far I've patched the places where I took off a bit of insulator to test at the coil. I 1st dabbed a bit of this liquid electrical tape over the exposed wire then after that dried it was covered with shrink tubing.
    [​IMG]

    I decided to go with Devcon 2 ton epoxy as another article said it was easy to find.(this is what the coil gets coated with after it's finished)
    [​IMG]

    I however, could NOT find anybody that had any in stock....but Motion was very helpfull in getting me some overnight!:thumb They even waived the shipping fees! total cost $5.43....when I stopped by to pick it up I saw they had a sign that said $25 minimum counter sale....but they made NO mention of it!:thumb
    [​IMG]

    :deal
    I decided to re-coat the iron pole with a thin coat of this epoxy as well as use it to re-attach the broken bit.
    [​IMG]

    [​IMG]

    I hope to have the wire tomorrow...btw...it turned out to be a hair thin 34g.:eek1 so I might know by this weekend if this little project will be a success.:lurk
    #14
  15. scooteraug02

    scooteraug02 Dog Rancher

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  16. Cauldron

    Cauldron Now in DESMODROMIC!

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    Oh man. Good luck to you. I hope this turn out.:clap
    #16
  17. mel brooks

    mel brooks Dirt Chick

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    This is better than a movie.


    :wave Kev!
    #17
  18. knybanjo

    knybanjo kinda slow

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    Me too!!:lol3

    Are you planning on Kamp Kraut again this year?:ear

    :wave
    Hi Mel!!
    I hope this works so I'll get the chance to chase that new KDX:ricky
    #18
  19. knybanjo

    knybanjo kinda slow

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    The wire arrived today but I have to work a double shift tomorrow then it's the Holiday weekend so.....who knows when I'll get to the actual winding..

    :dealThanks to Express Wire Services Inc in Charlotte for mic-ing my old wire and upon realizing it was smaller than what they dealt with put me on their phone direct with BAE Wire & Insulation in Florida!!

    Both were stand up guys that were willing to go out of their way for the little guy!:clap

    The smallest spool they had in 34g was a2lb spool at $9.69lb so I have way more than I need. You may be able to shop around for a better deal but the customer service I received won my business....as small as it is anyway.:D

    Look close and you can see how thin the wire is(look at tip of my index finger)
    [​IMG]

    How big a 2lb spool of 34g is...(you can see how thin where it crosses my thumb)
    [​IMG]

    New wire vs. old wire
    [​IMG]
    #19
  20. knybanjo

    knybanjo kinda slow

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    I just spent a couple of hours out in the shed....here's what I got so far.

    1st I re-used these little blocks of scrap plywood to hold it in the vice without damaging the other wires and windings. (same as I did on tear down)
    [​IMG]

    Then I rigged up a spool holder under the shelf behind the vice.
    [​IMG]

    Here's a look at the whole set-up, my shed/shop really is a disaster.:lol3
    [​IMG]

    That thin coat of epoxy I put on the core earlier dried a little uneven so I thought maybe a wrap of teflon tape (it seems to handle heat well) might be a little extra insurance against chafing on that 1st row.
    [​IMG]

    Things are starting to look good.:thumb
    [​IMG]

    getting closer.....yes my fingers got tingly and needed a few breaks as they often do
    [​IMG]

    This looked big enough as it's starting to bulge beyond it's own spool.
    [​IMG]

    :dealYep, it's within spec.:thumb
    [​IMG]

    Although I was hoping for a reading above 300.....spec is 240-360 for the "power source" Honda calls it the "exciter"
    [​IMG]

    I stripped the enamel off the ends of the new wire with a lighter, then wrapped them around the harness wires and soldered them on. Next I dabbed on some of that liquid electrical tape and after that dried the connections were covered with shrink wrap.
    [​IMG]

    [​IMG]


    Putting on the 1st coat of epoxy....I'll add another after all the wires are zip tied back into place. (that's the way they were stock)
    [​IMG]

    My biggest concern right now is the durability of the coil wire between the winding and the harness wire. I'm going to try and get them all covered up real good with epoxy after things are tied down.....it's about time to head back out and get that done....
    #20