Stator rewind

This job is not that hard to do.  I read all the forum topics on this I could find at the time, settling on - as I recall now, 2 years later - 4 wraps around each 10 poles, with 18g wire.  The wire was absolutely 18g, I'm just not sure about the 4 wraps.

Removing the original wire off the few poles that had it was very easy, just a serious mess of tangled wire


The spool of wire


The spindle I set it up on to reel off the wire nice and smoothly


And now, to wrap it up









Finished with winding wire


Epoxy mess

It took a while to find an epoxy that was oil resistant (I know the XR's stator is out of the oil, but another buddy rewound his CRF450X stator at the same time, and it runs wet, and we bought materials that met both our needs), adequately temp resistant, plus available in a reasonable quantity at a reasonable price.  We still had to buy 10 tubes of the stuff.

Mounted up in the stator cover


The stator never failed in 1000's of miles.  I have since sold the bikes I rewound stators for (I did two at once), but they worked fine.
Also, I never ran a giga-watt light setup, so I don't really know how much power this setup was capable of.  120W plus is my guess.  I can tell you that at idle it'd power a 60w halogen bulb, a tailight bulb with running and brake filaments lit up, plus LED turn signals flashing, all running just as bright as if the engine was revved up.

Super easy to do, the hardest part is tracking down the wire and epoxy.
We got the wire from a local electric motor repair shop.  I found the epoxy online from some obscure place.

Total time to do the entire job, from removing the stator cover, to putting the epoxy on everything, was 6 hours.  That was the 1st one.  The second took about 4 hours, since I already had it all figured out.

Good write up, shame you didn't show the electrical connections inside the stator to make it perfectly clear how and where to terminate the 2 ends of the new windings .......or do you have some more pictures tucked away ?

I can't find more pics, or more specifically, a detail pic of connecting the newly wound wire to the wire harness.  But, the ends of the wire connect to the stator end of the green and white wires from the wire harness.  This is how I mated the wires together before soldering them together
(pic robbed from http://www.xr650r.us/stator/)


You just have to leave the wire harness' original wires as long as you can.  When you connect to them with the new stator wires it makes packaging everything as Honda originally made it much easier.

If I were to do this all over again, and I think will get the chance on a buddy's XR this winter, I would just add wires on the empty poles (US stator), and run that winding as a floated ground, and put it through a reg/rectifier to charge a battery and run the DC stuff.  The stock AC winding and regulator would be fine for the little bit of stuff that can run on AC power.

Also, after thinking about it a bit more, each pole had 4 wraps of 11 windings on each pole (so, the wire went around each pole 44 times - 11 times around up, 11 times around down, 11 times around up, and 11 times around down, then on to the next pole).  I'm 100% certain of that.