Honda CX500 & GL500 Forum

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02-16-2007, 10:43 PM HomerRod Joined on 07-21-2006 Posts 223 Stator rewinding....... Myself and others have touched on this subject before. Since our bikes are inherently stator failure prone, It may be worth a look at rewinding our stators with heavier wire, for longer life. Found this site, with good pictures.  I am printing this and adding it to my technical manual, along with sensor repairs,fuel pump upgrades,head milling, etc that I have added over the years. I'm always willing to share, so if you run into a snag, let me know.  Here is the website:  http://www.4strokes.com/tech/honda/brpstatr.asp    Report

02-17-2007, 9:55 AM Anonymous Re: Stator rewinding....... Information is always good. Knowledge is always the key....  Can you post or e-mail your info that you have accumulated?  Thanks   Pete

02-18-2007, 5:28 AM Phil in VT Joined on 03-02-2006 Lowgap,NC Posts 1,041 Re: Stator rewinding....... Having disected a CX500 stator to get an understanding of how it was made, I believe an individual, if He/She were very careful, could duplicate one.  As far as doing this with a heavier wire, I don't think there is enough space, UNLESS you can duplicate the original resistance by using less of the heavier wire.  eg.  #10 wire  = ? ohms per 10'  compared to # 8 wire = same ohms per 7'  In other words less turns of wire for each  post. Go for it, Whatcha got to lose.  I need to set my spare engine up in a test stand just for this reason, doing component replacement research without having to pull the engine from a bike all the time.  Then you guys can build your Alternate components and I can test them for you. Hmm... 06 Suzuki S 50 Boulevard Cruiser ANY WARM DAY ABOVE GROUND IS A GOOD ONE (unknown senior citizen) Springfield, VT    Report

04-08-2007, 2:42 PM coragyps Joined on 07-05-2006 Arvada, CO Posts 22 Re: Stator rewinding....... For what it's worth, resisitance in wire increases with length and decreases with cross section... i.e with a heavier gauge wire, you'd need a longer length to achieve the same resistance. But, I can't say what using however much of a heavier gauge wire would fit in the stator would actually do to the output. -Timothy 1981 CX500 + one 1982 parts bike 1983 GL650i Denver, CO    Report

04-08-2007, 2:54 PM Phil in VT Joined on 03-02-2006 Lowgap,NC Posts 1,041 Re: Stator rewinding....... And your point is? 06 Suzuki S 50 Boulevard Cruiser ANY WARM DAY ABOVE GROUND IS A GOOD ONE (unknown senior citizen) Springfield, VT    Report

04-10-2007, 4:41 AM JB in SC Joined on 03-02-2006 Irmo, SC Posts 306 Re: Stator rewinding....... Voltage is proportional to the number of turns. Thicker wire = fewer turns = less voltage. 2007 Burgman 650 1983 CX650C    Report

04-10-2007, 10:24 AM Fourcycle Joined on 03-28-2007 Michigan Posts 91 Re: Stator rewinding....... Another thing that needs to be taken into account is inductance.  As engine speed increases, the AC frequency also increases.  I wonder if the Honda engineers designed the stator such that the alternator’s power output gradually decreases as the R’s increase.  Since shunt regulation is used, this would make sense.  Others have mentioned that it’s an important consideration when getting into details of the alternator operation and shunt regulation, which IS how the CX  does voltage regulation.  I’ve never run the experiment on a permanent magnet motorcycle alternator but I have on another permanent magnet alternator that utilized shunt regulation.  On that unit, voltage out was proportional to speed with no load, just as one would expect.  However, once a load was applied, the voltage was not longer proportional to speed, there wasn’t even a linear relationship.  When I calculated the apparent resistance (reactance) I found that reactance WAS proportional to speed.  Clever.    Report

04-11-2007, 5:56 AM JB in SC Joined on 03-02-2006 Irmo, SC Posts 306 Re: Stator rewinding....... That reactance stuff just hurt my brain. 2007 Burgman 650 1983 CX650C    Report

04-11-2007, 2:02 PM Phil in VT Joined on 03-02-2006 Lowgap,NC Posts 1,041 Re: Stator rewinding....... Wait til we get to impedance 06 Suzuki S 50 Boulevard Cruiser ANY WARM DAY ABOVE GROUND IS A GOOD ONE (unknown senior citizen) Springfield, VT    Report

04-19-2007, 4:35 PM TurboDan Joined on 03-06-2006 Griffin, GA Posts 92 Re: Stator rewinding....... Resistance is the opposition to electron flow through a conductor. The symbol for resistance is Omega. The tool used to measure it is called an Ohmmeter. Resistance creates heat in a conductor. Reluctance is the opposition to the magnetic field force created around a conductor, or within a coil of wire. Even though no parts touch, it will still build a lot of heat in relation to the amount of work opposing magnetic fields perform. This is why alternators and generators need to be cooled by a combination of fins and fans. The CXT stator is mounted inside the spinning permanent magnetic flywheel where it cannot be cooled by air or oil. The faster the flywheel spins, the more magnetic force fields push electrons in the stator wiring creating electrical current and LOTS more heat. More RPM = more current = LOTS of heat. In the CXT stator, the problem has nothing to do with the wiring, it has everything to do with the ability of the insulating varnish to prevent the wiring to ground out to the stator metal body or in between wiring coils wires. The extreme operational temps of the stator causes the varnish insulation to degrade and fail, turn black and crusty, and totally fail. The only thing that will increase the service life of the CXT stator is to use a wiring insulating varnish that will not break down due to the extreme heat. At one time I had a military electrical engineer working towards building a stator made from military grade flat wiring using a teflon varnish type of wiring insulation which would withstand temperatures up to 750 degrees. Our military's current efforts in the middle east has called the engineer away from our project for the foreseeable future. The design and placement of the CXT stator was intended to survive for just a few years. Honda never intended the bikes to be around this long. Dan Topping Diesel Tech Program Coordinator Griffin Technical College Griffin, GA owner CXTC's Parts & Accessories, Inc    Report

05-28-2010, 5:54 AM RAGBrian Joined on 10-23-2009 Wildwood, MO Posts 76 Re: Stator rewinding....... Now that I have my Maggie running, I have discovered my stator is not up to snuff any more. 2 of the windings put out just about 12 VAC, and one is about 5 VAC. So, for the time being, I have switched off the headlight for day riding and use a smart charger to keep the battery topped off. If I don't start it too many times, it is working OK for the moment. I too have a spare engine and another stator (it's an '82 version, so I don't have the ignition windings on it) to use to setup my own test bench for stators. Have sourced some wire that has 200 degree Celcius insulation on fleabay and will end up purchasing some, since it runs about $9.00 US per pound and about 2#'s would be needed (per other web page guides). Interesting about the flat wire project - since this was over 3 years ago, has anyone followed up on this? RAGBrian 1978 CX500 Standard (Running...) | 1982 CX500C (donor) | CB360T (NOT running) | CB350G (donor?)    Report

05-28-2010, 8:29 AM Timothy_D Joined on 04-22-2006 Santa Rosa, CA Posts 1,585 Re: Stator rewinding....... On my last triple bypass, I bought a stator from custom rewinds that is using a new resin coating on the stator wires. Instead of the usual clear resin, they are using a high temp green resin.  According to the owner, this green resin has been used successfully on Triumph motors that have a tendency to fry stators quickly. In his words, "I have never had a stator with this resin come back." Unfortunately, they weren't using this stuff when I put a stator in my 500T, but it is in my 650E right now, and I have had no charging issues so far. CX500 Turbo, GL650I, Two CX650E's, and one Crown Jewel of the CX line- CX650T. Why do I own five CX/GL bikes? Ask an alcoholic why he drinks. Donating Member. Sold: 1981 CX500D, 2- 1982 CX500T's, 1983 CX650C.    Report

06-17-2010, 9:40 AM TurboDan Joined on 03-06-2006 Griffin, GA Posts 92 Re: Stator rewinding....... The electrex G08 stator will provide up to 32,000 verified mileage in the CXT. For the price it is a good value for the service life. Not too many CXT owners will exceed that useage. They can be bought from Dennsi Kirk for about $135. Some minor mods make it a drop-in. Dan Topping Diesel Tech Program Coordinator Griffin Technical College Griffin, GA owner CXTC's Parts & Accessories, Inc    Report

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