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Discussion Starter #1
It's best to do it yourself, right? Happy holidays everyone, looking to do something a little bit different to remedy my charging problem. I've been through two cheap stators, and the first lasted a little while, the second was junk out of the box. Does anyone have any insight into rebuilding a stator at home? Recommendations on materials? Tips on technique? Any help will be appreciated. Cheers.
 

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Fully agree with your philosophy, but I'm no help on electrics.:frown

I hope you get it sorted.
 

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This guy @900rrHonda rewound his own stators. He had a thread about it here somewhere. Try and search it. I know he said he didn’t wind it as much as the stock one was so it wouldn’t generate as much heat and/or burn out quicker.

Good luck sir :smile
 

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I did see the thread on here a while ago when my stator and R/R failed in June this year but cannot remember and I didn't book mark it! I think it was fiddle and there was a certain way you have to wind, some are wound one way and some the other. Perhaps get one not from China and from a supplier in your country and at least then you might get some sort of guarantee?
 

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I've been through this nightmare myself, here's the thread : https://www.fireblades.org/forums/articles-honda-fireblade/76464-tutorial-how-rewind-smoked-charging-stator-6.html#post978542

But it is possible to permanently fix it - I rewound the stator on my 929 9 years ago, and it's still going strong (as is the voltage regulator I fitted at the time), no sign of overheating. But there is a compromise you have to make, and that is that you have to reduce the output of the stator. I believe Honda designed it to cover all eventualities, e.g. sitting for long periods in traffic with headlights on and cooling fan running while only at idle rpm. As soon as you reach normal rpm, it's generating much more than the system needs and all that extra energy has to be disposed of, and that's through heat in the windings and heat at the voltage regulator. Eventually either the voltage regulator goes pop, usually taking the stator with it, or the insulation of the windings in the stator breaks down, the windings short-circuit, and that's the end of the stator.

What I did was to rewind the stator with fewer windings (28 instead of 37) and fitted a flywheel with reduced-strength magnets. That manages to keep the bike charged under most circumstances, unless the fan comes on while idling. Acouple of years ago I also fitted a lithium-ion battery, and that makes the situation even better, those batteries charge up in no time. Because I am a control freak I also fitted a voltage meter, one of those cheap little LED things. Re-assuring at night when you're miles from anywhere.

source for wire here:

https://redirect.viglink.com/?format=go&jsonp=vglnk_157796058228111&key=df6d33a331f165273813f635b825e4ff&libId=k4wkuowu01015q1i000DAacb9zaw1&loc=https://www.fireblades.org/forums/articles-honda-fireblade/76464-tutorial-how-rewind-smoked-charging-stator-6.html&v=1&opt=true&out=http://wires.co.uk/acatalog/cu_enam.html&ref=https://www.fireblades.org/forums/gtsearch.php?q=stator%20rewind%20epoxy&title=Tutorial-How to Rewind a Smoked Charging Stator - Page 6 - Honda Motorcycles - FireBlades.org&txt=wires.co.uk : Enamelled Copper Wire
 

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Discussion Starter #10
Happy new year to all, and thanks for the replies. Apologies for not checking up on the thread a few days ago, I now have more to read. Once I build up enough research (and a little bit of confidence) I shall chronicle and post the results! There's also probably going to be a few more questions but so far this is much more thorough than I found anywhere else.
 
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