DIY Stator wrapping

[POWER-TRIPP]

A while back I re-wrapped my own stater after giving the one on my bike to a friend in need.
With all the the stator failures on S3s, I have been asked to share the details of how to perform this simple task for USD $20-50 in place of having to purchase a new stator.

I will soon supply detailed photos and step by step instructions, but a few links should get you started in the mean time.

http://www.thegsresources.com/garage...atorrewind.htm

http://chromegnomes.com/documents/ho...re_stator.html

I highly suggest using USA or European spec 17ga-18ga magnet wire, and not cheap Chinese wire of unknown purity.
I particularly like Essex brand wire, and it can be found on Ebay in smaller spools to wrap a couple of stators for around USD $9.00 - http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=170398399436

You will also need epoxy to cover the stator core before wrapping, and then again to cover the wrapped wire. Most sources will tell you to use specific epoxies that hold up well at high temps. FWIW, most epoxies will hold up beyond 250° F - even cheap tubes available at Walmart. Just do not use quick drying epoxy. You need something thin, that will leave a smooth layer, and not set up too quickly... before you finish. I have even used colored epoxy paint made for engines or brake calipers.

Pay attention to the number of windings on the legs of the stator core. I like to add a wrap or two to increase the voltage output slightly. On high revving engines, I like to reduce the number of windings by a wrap or two. This gives a very sligh HP increase, but requires that the engine rev a little higher for full output.
Using slightly thicker gauge wire will increase the amperage output as well. Most stators are wrapped with a metric sized wire that is between 17ga and 18ga. Either will work.

For those of you in the metric world, or using Euro spec wire, you need 1mm-1.15mm wire - http://www.engineeringtoolbox.com/aw...uge-d_731.html

Once you are done with the windings, you can use the stock wires from the stator to the regulator, or you can use heavier gauge wire (recommended) and the stock harness plug (or a replacement). On the S3, the wiring from the stator to the regulator is LONG. This can be cut shorter (recommended) before soldering to the stator windings.

Let the epoxy over the windings dry for 24 hours before installing.

On the stator cover, place a small amount of high temp black or gray silicone around the wires that go through the cover.
You can use a new paper gasket from Triumph on the cover, or clean off the old gasket and use anaerobic gasket sealer, or the gray Permatex/Yamabond #4/Hondabond - the choice is yours. Torque all bolts to spec.

I hope this helps.

[crashmasterd]

Good stuff.

I was just reading a similar post about rewinding the stator of my DR. The process is slightly different for the ignition coil though. Not an issue for the S3 of course.

[protege83]

Thanks Wayne! The info is always appreciated.

[mjay]

waitng on the pics and step by step

[POWER-TRIPP]

The photos are done... except one. I Just need to sit down and do the writeup.
Not happening today, I have a few headlight harnesses to build, a couple of pipes to cut and weld, and a new under-tail exhaust silencer housing mold to finish so I can lay up a few in carbon.

[dr_gallup]

Nice tech info Wayne. We use mostly Essex wire at work but I actually like Elektrisola better. The one suggestion I have is to see if you can find a higher temperature rating than 155°C. At least 180°C but I always specify 200°C temp rating wire insulation for fuel injectors and you can find 220°C rated insulation. Both Essex & Elektrisola offer it. I've not tried to find either in small quantities, might be difficult. The only downside to the higher ratings is you can't solder through them, you must mechanically strip the insulation or else weld the connection. Sandpaper will easily strip the insulation. Wire welding is not for the do-it-your-selfer but that is all we do for any newly designed coil.

[POWER-TRIPP]

Good info Doc.

Do you know of ANY source for 50-200 feet of the Electrisola magnet wire?
I've only been able to find full rolls - 1000 ft.





If anyone has a bad stator laying around, I would like to get it from you.
I want to try wrapping slightly differently and use less windings on the S3 to see if there is much of a HP difference - like I see on the 600cc suporsports.

[dr_gallup]

We always buy direct, most of our winders take 70 lb spools although the fine wires (35 AWG) us 35 lb spools. There are miles of wire on those.

[rnexussix]

An old thread. I know. The chances of PowerTripp posting them, how-to pics of stator rewinding, are pretty slim at this point.

I'd like to experiment with stator rewinding. Unfortunately I threw away my old burned OEM stator. Anyone kept their OEM (2005 - early 2006) OEM stator core ? If yes, I'd pay shipping if you could send it to me (about $5 for USPS priority flat fee box CONUS). Will post a how-to and pics in case of a successful experiment.