Stator rewind

mm193 said:

I see that you rewound your stator. Last weekend the stator on my 97 fe600 went bad. I have rewound a couple of Japanese stators in the past and use my lathe with a counter on it to get the number of turns correct. What I have a question with is how the 4 coils were connected. There is also a diode in the circuit. I suspect the diode is just used for half wave rectification. If you have any notes on what you did I would appreciate the information.

Regards

Mike

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BundyBear said:

Mike
Good to see some other bugger keen to have a go at a rewind. Good luck.

The actual one I wound came off my cousin's '92 TE610 Husky and went onto my '92 TE350. I believe it was identical to KTM LC4's of the time (except the base plate is different) as my cousin had previously replaced his stator with a KTM one. I still have the crook one off my TE350 at home with the notes I took at the time strapped to it.

The reason I'm assuming it was the same as what is on my '98 FE600E 'berg is that both the flywheel & CDI/coil unit the look the same as SEM ones that were fitted to the Husky. I have not yet pulled the flywheel from my 'berg to compare stators directly. You mention, however, a diode in the 'berg stator. This was definitely NOT present in the one I did. It had a printed circuit board inside it purely as a termination point for the magneto coils, but when I rebuilt it I left that out and terminated the coils directly to new leads.

The 4 coils were connected in series but the windings turn in opposite directions between coils. The north & south poles in the flywheel are set at the same pitch as the four coils. This means that for any output cycle two coils see a north, two see a south. The sequential reversing of the turns on the coils puts the voltage generated by each in the same direction - ie they add together.

As best I could make out, the magneto charging coils each had 3500 turns of wire. When I rewound it I put on 3600 & it seemed to work well. I don't think I rewound the trigger coil. The stator was still running the bike a couple of years later when the cops caught the arsehole who stole it riding it through town. It had been completly wrecked by then.

I'll dig out the notes I took & try to get you a copy. I don't know if they will be much help though.

Also, please indicate if you wish me to put this in as a discussion thread instead as PM's. It may be helpful to others.

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mm193 said:

Please put this in as a discussion thread. Any information would be greatly appreciated. I worked on fabricating some new bobbins to wind the coils on and will rewind some time later this week. I am new to using chat rooms and message forums, but I would like to share my results with anyone who is interested.

mm193

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