2002 fe400e stator repair?

JohnV · Jun 17, 2017

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

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

JohnV · Jun 17, 2017

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/prod...sqvarna-vertimati-some-models-european-models

bushmechanic · Jun 17, 2017

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?cl...0...1.1.64.mobile-gws-serp..2.0.0.2v9WK4mzSN4

Another popular idea is to put a spare stator in your back pack

JohnV · Jun 17, 2017

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.

bushmechanic · Jun 18, 2017

http://husaberg.org/electrical/17806-sem-kokusan-conversion.html

webmonstro · Jun 18, 2017

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

JohnV · Jun 18, 2017

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?

[/url]2017-06-18_09-19-55 by Chris Harris, on Flickr[/IMG]

bushmechanic · Jun 18, 2017

Pm zaga if he doesn't reply here

JohnV · Jun 18, 2017

For any that are interested.

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

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

IMAG0639 by Chris Harris, on Flickr

tourist · Jun 18, 2017

Wow. Some colors. Very modern art! Technically interesting too - thanks.

JohnV · Jun 20, 2017

Guys, will a 2004 fe501 system fit into my 2002 fe400e? As in stator cdi and coil?

Sent from my HTC 2PS6200 using Tapatalk

jampe · Jun 20, 2017

No.
Kokusan on 2004-2008

ede · Jun 20, 2017

Hi JohnV,

sorry to hear about your SEM trouble.

JohnV said:
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/prod...sqvarna-vertimati-some-models-european-models

I attached an ignition overview chart. I checked the specs for this replacement stator and it seems the one from your link fits pre 1999 models only!!! The resistance Black-Red is way to small.

I run a replacement SEM-replica by Electrex/HPI. The picture below shows the orientation since this thing has no ignition marks on it. Put the stator in fully retarted position and it should run. You may want to put the ignition a little advanced, then turn it slightly, about 1mm.

The replacement unit that should fit a 2002 FE 400e (same as my FE501) can be found here:
electrical parts for motorcycles manufactured by Electrex World - Combined Lighting/Ignition Stators for Husaberg | Electrex World Ltd

or here:

HPI | Horse Power Ignition

(same unit - different importeurs).

Good luck - hopefully you can make to your rally,
regards,
EDE

FCBerger · Jun 20, 2017

Small Coil Rewinds in Melbourne did my 99 FE501E last week, give then a ring. Ph 03 52788454. Address is 50 Edols St, North Geelong.....they do a great job, had a few done now. Hope it works out for you. Cheers John.

JohnV · Jun 20, 2017

ede said:
Hi JohnV,

sorry to hear about your SEM trouble.

I attached an ignition overview chart. I checked the specs for this replacement stator and it seems the one from your link fits pre 1999 models only!!! The resistance Black-Red is way to small.

I run a replacement SEM-replica by Electrex/HPI. The picture below shows the orientation since this thing has no ignition marks on it. Put the stator in fully retarted position and it should run. You may want to put the ignition a little advanced, then turn it slightly, about 1mm.

The replacement unit that should fit a 2002 FE 400e (same as my FE501) can be found here:
electrical parts for motorcycles manufactured by Electrex World - Combined Lighting/Ignition Stators for Husaberg | Electrex World Ltd

or here:

HPI | Horse Power Ignition

(same unit - different importeurs).

Good luck - hopefully you can make to your rally,
regards,
EDE

Thanks for all that info. That chart is very helpful. I will hopefully get my hands on the used fe501 stator today so I will be able to make the rally on the weekend!

Sent from my HTC 2PS6200 using Tapatalk

JohnV · Jun 20, 2017

FCBerger said:
Small Coil Rewinds in Melbourne did my 99 FE501E last week, give then a ring. Ph 03 52788454. Address is 50 Edols St, North Geelong.....they do a great job, had a few done now. Hope it works out for you. Cheers John.

Cheers mate.

Sent from my HTC 2PS6200 using Tapatalk

JohnV · Jun 26, 2017

Thanks for all the replies everyone. I made the rally and had a ball. First decent ride out I've had on the Berg. It's a little rocket ship, I love it

Sent from my HTC 2PS6200 using Tapatalk

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