From:  Paul Gortmaker <penguin@m...>
Date:  Tue Oct 22, 2002  4:24 am
Subject:  Re: [XR650R] Stator Rewind
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I've done both setups; a 55/60 on a high output stator with BD
wiring, and a 90/100 on a super high output stator with custom
wiring. Both had the same BD headlight mask and headlight lens.

_From a simplicity point of view, going with a 55/60 setup wins
hands down. You have approximately half of the electric current
to deal with, which means the smaller wires from the stator and
in the BD harness can be used as is. Same goes for the headlight
switch. Buy a quality bulb such as the Sylvania Cool Blue (which
isn't really blue at all, but rather white) and the difference
between that and a std. 90/100 in the same lens isn't that overwhelming.

Winding the lower power stator is easier as well - you simply
strip off all the original wire (comes of real easy) and wind
on three wraps deep per pole, over all 10 poles of #18 wire.
There are usually 11 turns per wrap, giving about 330 turns total.
Should take less than 50' of wire. Final output is slightly above
the 100W mark. This works well with the BD kit, (60W headlight,
10W of taillights, 5W DRL; leaves 25W for charging/brake/turn.)

** NOTE: ** You may see that others have wrapped the previously
empty 6 poles with 5 wraps of #18 wire and then connected that to
the end of the stock 4 poles. This takes essentially the same
length of #18 wire as the above, but has less output (approx 70W)
and is less efficient (generates more heat in the engine).

The high power stator (well in excess of 100W) requires you to
make two groups of 330 turns #18 connected in parallel, or to
wind 300+ turns with the heavier #16. Then you should replace
the wires from the stator core to up under the seat with heavier
ones as well. Next, you start wondering about the size of the
rest of the wires, and the load capacity of the headlight switch...

I meant to tidy up some of the documentation on the little stator
simulation program I wrote before unleashing it here, but didn't
get around to it yet (hey, given the choice, you'd have gone riding
instead too!) I'll try to do that b4 the end of the week...

Paul.

greggstrode wrote:
>
> I'm thinking about rewinding my stator so I can go to a 55/60w or
> 90/100w setup and also have my battery remain charged.
>
> I've read most of the posts regarding the rewind and was wondering
> if any of you who have tried it are happy with the results and what
> you learned in the process.
>
> Is the dual output method the way to go with the BD kit?
>
> Any help is appreciated.
>
> Thanks
>
> Gregg