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Stator re-wind?
Topic Started: Dec 9 2014, 11:08 AM (588 Views)
rossonza
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Supermoto Mad
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HI guys,

Does anyone know of a company, or an individual who can re-wind my stator for improved output? the Yamaha WR400 99' only has a 55w stator, i need about 80 to run my indicators and dash and lights all together.

There is the option to upgrade to a 2nd hand stator off a newer wr, but they are close to £200.....id rather spend a lot less haha


Thanks
Ross.
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Rob 110
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God
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http://www.westcountrywindings.co.uk/
CLICK HERE TO DONATE TO THE FORUM

DIRTY R30 644 '03 TPS done, gubbins gone, GSXR can, 150 main, 27.5 pilot, needle 2nd position, K&N no lid
FILTHY 404DS '04: 152 main, 70 pilot air jet, 38 pilot, emm needle 4th clip, Quill T3. Sold :(
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rossonza
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Supermoto Mad
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Rob 110
Dec 9 2014, 12:08 PM
thanks mate, i emailed them earlier and they have advised they can do ~20% rewind, but im still waiting on a cost.

Cheers!
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Speedshop
Knight
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I'm glad you have found someone who can add 20% output to a generator without burning it out!

I would ask them if they have actually run the generator after and mapped the new output with regard to RPM, power and temperature it runs at. I'd want to see the before and after results of a proof run if spending my own money.

I say this as we design generators and anyone who can up a well designed generator's output by 20% using the stock laminates and the same RPM range is doing (extremely) well.

We are testing the output of this generator, changing the number of turns by as few as 100 and the wire size by 0.01 mm dropped the running temperature from 175 to 64 degrees C - without engine heat. Run it at 175 and it'll burn out in 6 miles on the road.

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This test bed will run the generator off the bike so you can see exactly whats going on. Shown is a XT generator - the sheets behind are electric steel from which we cut laminates for generator windings. The rig will swing the Rotax 604 generator to 11,000 RPM and any other of similar size - we use it to prove generator output and ignition systems. I've yet to see a 20% change in power output by simply changing the amount of turns or 'heavy duty' wire added to a generator. Japanese generators are so well designed that getting more from them is very, very difficult.

If someone is simply adding 20% more turns of copper they won't be getting 20% more power! Often this results in less power at high RPM as the generator is outside of its optimal configuration.

It would be a worthwhile exercise to compare a stock and one that's been 'improved'
Edited by Speedshop, Dec 9 2014, 08:11 PM.
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rossonza
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Hi speed shop. Sadly I've no idea how anything electric works on the bike. I'm colourblind so have always avoided electronics....

They said upto 20% but they've not got back to me on a price.

I've been advised I can fit a later model wr stator and they come standard 130 watts opposed to my 55. Any ideas what the main difference would be? As it's a straight swap. Just a bit much at £160 2nd hand. I'm more tempted to stay indicator less and save myself £160.

Thanks
Ross
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Speedshop
Knight
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I'd say the swap for a later generator would be the way to go.

Generators are normally designed to give 100% of the possible output. They have a fixed magnetic strength, amount of iron inside the winding and a certain amount of copper that works well with that combination. All these things have to be balanced.

Think of it like the carburettor; If you fitted a filter that flowed 20% more but did not change the jetting, you'd find the engine wouldn't make more power and invariably the result would be worse then before you made changes.

Changing only one thing in the generator is the same thing as just removing an air filter. If you add more copper you'll need to change the magnetic field or the amount of iron inside the copper to compensate - neither of these is possible unless you change the stator or flywheel.

The only exception to this is if one generator was de-rated with missing windings. It could be restored to full power by adding the missing windings. But to be honest the cost of doing this is going to be similar to getting a generator that already makes the full power.

It'll be cheaper in the long run to bite the bullet and do the job properly rather then trying a half measure that hasn't been proved.
Edited by Speedshop, Dec 10 2014, 08:38 AM.
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rossonza
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Speedshop
Dec 10 2014, 08:24 AM
I'd say the swap for a later generator would be the way to go.

Generators are normally designed to give 100% of the possible output. They have a fixed magnetic strength, amount of iron inside the winding and a certain amount of copper that works well with that combination. All these things have to be balanced.

Think of it like the carburettor; If you fitted a filter that flowed 20% more but did not change the jetting, you'd find the engine wouldn't make more power and invariably the result would be worse then before you made changes.

Changing only one thing in the generator is the same thing as just removing an air filter. If you add more copper you'll need to change the magnetic field or the amount of iron inside the copper to compensate - neither of these is possible unless you change the stator or flywheel.

The only exception to this is if one generator was de-rated with missing windings. It could be restored to full power by adding the missing windings. But to be honest the cost of doing this is going to be similar to getting a generator that already makes the full power.

It'll be cheaper in the long run to bite the bullet and do the job properly rather then trying a half measure that hasn't been proved.
Ok that makes sense, thank you for explaining it to me.

Guess i had best get saving then!


Cheers!
:dirtbike:
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