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June 17th, 2017, 02:37 PM   #1
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2002 fe400e stator repair?

Hi all,

My stator has failed, the red black circuit resistance value is way off and only giving me about 10-11 VAC under crank condition.

It's Sunday here in Australia and I'm meant to be leaving for a three day rally this coming Friday. I don't think I have any chance of getting a rebuilt one shipped to me by then.

I'm a mechanic and auto electrician by trade, so I'm going to have a crack at repairing it myself. Maybe I'll be able to patch it up enough to get me through the weekend until a rebuilt one arrives.

From the looks of mine it's been repaired already at least once.

Has anyone managed to repair/rewind one of these sem stators at home?

How did you remove the plastic material around the windings?

Any other advice or tips would be greatly appreciated, the ticket for this rally wasn't cheap and I've been planning it for about 3 months hence I'm willing to give anything a go (anything within my budget)

Cheers

Chris

[IMG]2017-06-18_06-15-09 by Chris Harris, on Flickr[/IMG]

Last edited by JohnV; June 18th, 2017 at 03:18 AM.
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June 17th, 2017, 02:49 PM   #2
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Has anyone tried a stator from these guys?

Also, the quoted resistance doesn't seem the line up with what I've read on here from this year model...

https://www.rmstator.com/en_ww/produ...uropean-models
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June 17th, 2017, 03:38 PM   #3
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Gday John yes a few people have done it. I'm not sure where the threads are but here's a start

https://www.google.com.au/search?cli....0.2v9WK4mzSN4


Another popular idea is to put a spare stator in your back pack
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June 17th, 2017, 04:35 PM   #4
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Cheers Bushy.

Hopefully I can repair this one, then I'll order a replacement and carry this one spare.

My challenge is the time constraint.

This really seams like a major issue the more I research it. I'm seriously considering buying a complete system that is more reliable and retrofitting it to the bike.
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June 17th, 2017, 11:14 PM   #5
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SEM KOKUSAN Conversion
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June 17th, 2017, 11:17 PM   #6
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Hi . I've never messed with a sem stator , but some years ago I sucefully repaired a Kawasaki stator. A friend of mine worked in a shop that did electrical repair to big motors and generators . They had a machine to do the rewinds but it was too big for the tiny stator winding so wee glued a adaptor to hold it . We also counted the number of times the wire was wound around and measured the thickness of the wire and I bought a spool of it . (cost 6)
You also need to wind it in the correct direction and cover it every few turns with clear coat to protect it . The Kawasaki one I did had two windings with 1100 turns each , but we're naked coils , I have no idea how to remove the coating on the sem stator
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June 18th, 2017, 03:29 AM   #7
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Thanks for the replies.

I've managed to remove most of the blue compound and removed the trigger/cdi charge coils from the battery/lighting coils.

It really doesn't look all that complicated to rewind it, albeit very time consuming.

I know the coil wire is 41 AWG, can anyone help me out with how many turns are on each bobbin?

I'm guessing that each coil needs to to have approximately 700-750 ohms resistance and they are wound in series?

[IMG]2017-06-18_09-19-55 by Chris Harris, on Flickr[/IMG]
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June 18th, 2017, 04:05 AM   #8
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Pm zaga if he doesn't reply here
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June 18th, 2017, 04:47 AM   #9
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For any that are interested.

Here's the ignition coils separated from the lighting coils.

[IMG]IMAG0638 by Chris Harris, on Flickr[/IMG]


IMAG0639 by Chris Harris, on Flickr
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June 18th, 2017, 07:50 AM   #10
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Wow. Some colors. Very modern art! Technically interesting too - thanks.
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