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Thread: The Next Nerobro's HowTo: Doing the Stator Dance

  1. #71
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    Quote Originally Posted by posplayr View Post
    The epoxy also stops the windings from flexing as the electromotive force pushes on the winding as the stator generates power.

    If left to flex, they would wear through the insulation and short.

    Interesting Nerobro did not use any; it suggests that the stators doesn't create that much power or he did a really good job winding and securing all the windings.

    250 watts is about 1/3 of Hp
    Lots and lots of electric motors don't have fixed windings. :-) I did take a lot effort to make sure the windings were very tight. wow, this is a really old thread... 10/2006... I'll note that my stator still works.
    Last edited by Nerobro; 04-25-2015 at 01:59 AM.
    You'd have to be crazy to be sane in this world -Nero
    If you love it, let it go. If it comes back....... You probably highsided.
    1980 GS550E (I swear it's a 550...)
    1982 GS650E (really, it's a 650)
    1983 GS550ES (42mpg again)
    1996 Yamaha WR250 (No, it's not a 4 stroke.)
    1971 Yamaha LT2 (9 horsepower of FURY.)

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    Quote Originally Posted by Gorminrider View Post
    Grimly..if it's not too late to mention this, also be careful with the three sheathed wires (yellow ones) that come out to Regulator/Rectifier.

    A lot of wirevinyl sheathing is only good to 100C and I've seen several stators where the sheathing is shrunken, hard and cracked where it passes into the engine
    Yes, I have used hi-temp resistant fly leads as connecting wires. Allied with heat-proof sleeving it works well enough, so far.
    The original heat-proof wiring lasted a long time, but as you say, it's variable and depends a lot on running conditions I suspect. Might also have been improved by Suzuki over the model lifetime.
    ---- Dave
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  3. #73
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    bump......

    1980 GS1000GT (Daily rider with a 1983 1100G engine)
    1998 Honda ST1100 (Daily long distance rider)
    1982 GS850GLZ (Daily rider when the weather is crap)

    Darn, with so many daily riders it's hard to decide which one to jump on next.

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  4. #74
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    I'm still around. The stator is still around. :-) We can probally say this thread is gospel by now.
    You'd have to be crazy to be sane in this world -Nero
    If you love it, let it go. If it comes back....... You probably highsided.
    1980 GS550E (I swear it's a 550...)
    1982 GS650E (really, it's a 650)
    1983 GS550ES (42mpg again)
    1996 Yamaha WR250 (No, it's not a 4 stroke.)
    1971 Yamaha LT2 (9 horsepower of FURY.)

  5. #75
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    Quote Originally Posted by Nerobro View Post
    I'm still around. The stator is still around. :-) We can probally say this thread is gospel by now.
    Could you indicate what bike the stator is on and what R/R you have used with how much mileage.
    I would presume if there is any amount of mileage with a Shunt R/R that it has started to at least discolor from heat.
    To determine how much damage has occurred so far, would need have photos of physical inspection.
    Alternatively doing the stator tests at 5K RPM and comparing to previous results when new might provide additional information without pulling the cover.

    As I recall, you had repeated stator failures causing you to start doing your own rewinds. I don't know if you have specifically posted this, but are you seeing that your newly wound stator is lasting much longer under the same condition as before when stators were failing?
    Read about Charging Quick Test GS Charging Health GS Stator

    "The smallest giant of mankind, is he who stands on the shoulders of a larger giant who himself stands on the shoulders of yet a larger giant, and therefore sees the most light from GOD." Posplayr 2017 adapted from : Bernard of Chartres


  6. #76
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    He did indicate which model it is in. First post.
    “We are all atheists about most of the gods that humanity has ever believed in. Some of us just go one god further.” ~Richard Dawkins

    1984 1150ES

  7. #77
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    Quote Originally Posted by GS1150Pilot View Post
    He did indicate which model it is in. First post.
    So you think he put an 550 rotor into that 1150 frame?
    Read about Charging Quick Test GS Charging Health GS Stator

    "The smallest giant of mankind, is he who stands on the shoulders of a larger giant who himself stands on the shoulders of yet a larger giant, and therefore sees the most light from GOD." Posplayr 2017 adapted from : Bernard of Chartres


  8. #78
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    No, I don't. He rides a 550.
    “We are all atheists about most of the gods that humanity has ever believed in. Some of us just go one god further.” ~Richard Dawkins

    1984 1150ES

  9. #79
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    Quote Originally Posted by posplayr View Post
    Could you indicate what bike the stator is on and what R/R you have used with how much mileage.
    I would presume if there is any amount of mileage with a Shunt R/R that it has started to at least discolor from heat.
    To determine how much damage has occurred so far, would need have photos of physical inspection.
    Alternatively doing the stator tests at 5K RPM and comparing to previous results when new might provide additional information without pulling the cover.

    As I recall, you had repeated stator failures causing you to start doing your own rewinds. I don't know if you have specifically posted this, but are you seeing that your newly wound stator is lasting much longer under the same condition as before when stators were failing?
    1983 GS550ES. That was indicated somewhere along the line. It's got ~3000 miles on it since then. I think. I"d need to go look. I've checked the stator several times, and because I used larger diameter wire, it's always given 80+ volts instead of the 90+ we really want. But that's not changed over the years.... That said I haven't checked it in 3-4 years. It just works....

    I've only had two stator failures. One on a 1980 GS550. It came with a burnt out stator, and I replaced that with an OEM stator. I didn't have an OEM stator for my 83, and the cheapest method was rebuilding the one I had.

    From what I've experienced over the years, I think most stator failures start at the r/r. I've flipped 10 bikes? something like that. The vast majority have had charging issues. Since I tended to pick up bikes that had been given up on, because they wouldn't keep running, or had "carburetor issues". I didn't run into bikes that had been babied and were put on chargers all the time. If they had a bad r/r I'd replace those. They always seemed to have an ok stator. What this indicates to me, is that a failing R/R can leads to a toasted stator. Depending on the r/r's failure mode. I think "abuse" leads to a burnt stator, if you get the r/r when charging system fails.... well the stator never seems to go.

    There's really no way i'm going to be popping the stator cover to inspect the stator. The gasket isn't weeping, and it charges.
    You'd have to be crazy to be sane in this world -Nero
    If you love it, let it go. If it comes back....... You probably highsided.
    1980 GS550E (I swear it's a 550...)
    1982 GS650E (really, it's a 650)
    1983 GS550ES (42mpg again)
    1996 Yamaha WR250 (No, it's not a 4 stroke.)
    1971 Yamaha LT2 (9 horsepower of FURY.)

  10. #80
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    Quote Originally Posted by Nerobro View Post
    1983 GS550ES. That was indicated somewhere along the line. It's got ~3000 miles on it since then. I think. I"d need to go look. I've checked the stator several times, and because I used larger diameter wire, it's always given 80+ volts instead of the 90+ we really want. But that's not changed over the years.... That said I haven't checked it in 3-4 years. It just works....

    I've only had two stator failures. One on a 1980 GS550. It came with a burnt out stator, and I replaced that with an OEM stator. I didn't have an OEM stator for my 83, and the cheapest method was rebuilding the one I had.

    From what I've experienced over the years, I think most stator failures start at the r/r. I've flipped 10 bikes? something like that. The vast majority have had charging issues. Since I tended to pick up bikes that had been given up on, because they wouldn't keep running, or had "carburetor issues". I didn't run into bikes that had been babied and were put on chargers all the time. If they had a bad r/r I'd replace those. They always seemed to have an ok stator. What this indicates to me, is that a failing R/R can leads to a toasted stator. Depending on the r/r's failure mode. I think "abuse" leads to a burnt stator, if you get the r/r when charging system fails.... well the stator never seems to go.

    There's really no way i'm going to be popping the stator cover to inspect the stator. The gasket isn't weeping, and it charges.
    Thanks for the update. You are correct R/R's cause stator failures, but it is not (in general) R/R failures that cause stator Failures. It is SHUNT v.s. SERIES that has been discussed bow at length.

    As far as abuse, I'm not sure what you mean unless it is"neglect"of connection maintenance or thrashing of high RPMs in which case I agree.

    As far as 80V vs 90V, open loop voltage always goes up with RPM (it is basic physics), but power produced is limited by the magnetic flux paths which is a function of the rotor design no matter the stator.
    Read about Charging Quick Test GS Charging Health GS Stator

    "The smallest giant of mankind, is he who stands on the shoulders of a larger giant who himself stands on the shoulders of yet a larger giant, and therefore sees the most light from GOD." Posplayr 2017 adapted from : Bernard of Chartres


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