fugazi Posted September 3, 2009 Report Share Posted September 3, 2009 Hi. Does anyone know which way the winding goes around the ignition coil on the stator and what exact diameter of wire to use for the ignition stator.... Am having a go at doing it myself before having to pay the Quote Link to comment Share on other sites More sharing options...
ronm Posted September 4, 2009 Report Share Posted September 4, 2009 Hi Phil, Depending on your abilities, this is a doable project. You need a spool of 30ga magnet wire. In the US, this is readily available from McMaster Carr. A 1/2 lb spool has 6150 ft and costs about $15.00. You will also need a roll of fiberglass cloth electrical tape (also available from McMaster Carr) and a container of epoxy cement. The stator has about 256 billion turns (or so it seems) so you will not be able to wind it properly by hand. Also, the stock windings are potted in epoxy so they are impossible to just unwind. When I did mine, I lost track of the direction and I am pretty certain I wound it backward. I made a fixture to hold the unit in my lathe. Due the shape of the laminations, it is tricky getting the windings all the way to the ends. I made a simple tool out of some 1/8" brass tubing to help place the wire. The wire is .006" in diameter including the enamel. This means it is not very strong. To make sure it did not break part way through the process, I made a ball bearing pay off mechanism by modifying a skate board wheel truck. I also added a spring steel strip that rubbed on the flange of the spool and acted as a brake so it would not coast and create a bird nest. I mounted the payoff and spool behind me and to the side. The wire passed through the tubing tool and I guided it by hand. I set the lathe to run about 150 rpm. At that speed, it took 15 minutes or so to lay on the wire. I had a very even job and I am certain that that part of the project was done ok. I had to use a magnifying glass to solder the connections. I coated the windings with epoxy to seal them from moisture. After that setup, I wrapped with the glass cloth tape and epoxied over that. I am certain that everything was done correctly with the exception of the winding direction. I could not get the bike to start, but as I was attempting to push start on a hill, I rolled it backward and if fired in the reverse direction. In the end, I got tired of messing with it and just bought a new coil. I think that I only paid about $150 or so from Beta USA. If you decide to do it, and want help, post back. I may have some pics of the set up in case my description is unclear. Good luck. Quote Link to comment Share on other sites More sharing options...
copemech Posted September 4, 2009 Report Share Posted September 4, 2009 Hi Phil,Depending on your abilities, this is a doable project. You need a spool of 30ga magnet wire. In the US, this is readily available from McMaster Carr. A 1/2 lb spool has 6150 ft and costs about $15.00. You will also need a roll of fiberglass cloth electrical tape (also available from McMaster Carr) and a container of epoxy cement. The stator has about 256 billion turns (or so it seems) so you will not be able to wind it properly by hand. Also, the stock windings are potted in epoxy so they are impossible to just unwind. When I did mine, I lost track of the direction and I am pretty certain I wound it backward. I made a fixture to hold the unit in my lathe. Due the shape of the laminations, it is tricky getting the windings all the way to the ends. I made a simple tool out of some 1/8" brass tubing to help place the wire. The wire is .006" in diameter including the enamel. This means it is not very strong. To make sure it did not break part way through the process, I made a ball bearing pay off mechanism by modifying a skate board wheel truck. I also added a spring steel strip that rubbed on the flange of the spool and acted as a brake so it would not coast and create a bird nest. I mounted the payoff and spool behind me and to the side. The wire passed through the tubing tool and I guided it by hand. I set the lathe to run about 150 rpm. At that speed, it took 15 minutes or so to lay on the wire. I had a very even job and I am certain that that part of the project was done ok. I had to use a magnifying glass to solder the connections. I coated the windings with epoxy to seal them from moisture. After that setup, I wrapped with the glass cloth tape and epoxied over that. I am certain that everything was done correctly with the exception of the winding direction. I could not get the bike to start, but as I was attempting to push start on a hill, I rolled it backward and if fired in the reverse direction. In the end, I got tired of messing with it and just bought a new coil. I think that I only paid about $150 or so from Beta USA. If you decide to do it, and want help, post back. I may have some pics of the set up in case my description is unclear. Good luck. Good one Ron! Quote Link to comment Share on other sites More sharing options...
fugazi Posted September 4, 2009 Author Report Share Posted September 4, 2009 Well, I got some .14mm wire, rewound the stator by hand, took about 90 mins, soldered it all up, put it in the bike and the spark came back.... I was buzzing thats its actually worked, but the bike still wont run, I have fuel and a spark, bizarre. The only thing i can think of is timing, but the stator is back in exactly as it came out.... If the wiring is in reverse, ie the ignition stator is generating -ve instead of +ve ,would that affect the timing ? Managed to snap the woodruff key and waiting for a replacement to come before I can carry on looking whats happening. Any ideas anyone ? Thanks Quote Link to comment Share on other sites More sharing options...
fugazi Posted September 7, 2009 Author Report Share Posted September 7, 2009 Sorted, was wound the wrong way, switched the wires over and its running. If anyone wants a go at winding there own stator, give it a go, takes about 90 mins to do ! better than the Quote Link to comment Share on other sites More sharing options...
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