Subject: Re: Stator rewind Date: Mon, 02 Apr 2001 09:18:55 -0000 From: growl62@yahoo.com To: Eric J Foster www.xr650r.us --- In XR650R@y..., Eric J Foster wrote: > Let me start off by thanking Eric for sharing his efforts with the group, especially the work he put into his directions on his web-site! Thanks Eric! I decided that winding three more coils would be sufficient to run a 100 watt halogen. I based this on the fact that our stock 4 coil system is rated at 80 watts (20 watts per coil) Baja Designs strips the original 4 and rewinds all 10. They wind them larger and then grind the case cover out for clearance. This gives them 250 watts total (25 watts per coil), but they make their system a dual output system (2 x 125). So, winding three more and running all 7 in series should make the stator capable of 140 watts output. The stock system.... I didn't do any baseline readings on my bike before the rewind, but my brother has the same bike and I did baseline his. At idle, the 35 watt incandesant was drawing about 2.6 amps at around 12.3 volts. Apply Ohms law of P (power or watts) = V (voltage) x I (current) and you get about 32 watts. However, when reved up, the current draw dropped to around 2.1 and the voltage to 11.6! This would mean the light would dim while riding! This sucks! When we installed the Baja Designs Light Improvement Kit (Older XR light housing with a glass lense and 55 watt halogen), the current was right at about 3.6A. The current didn't drop off when reved with the 55 watt bulb, insted it increased to about 3.9A with the output voltage right around 14. This equates to 54.6 watts. *********Note**************** I need to point out a problem with Honda's wiring of the stator coils. On Eric's bike, as well as my brothers, the first coil is wound clockwise and is tied to the "green" wire and the last coil wound counter clockwise is tied to the yellow/white wire. My bike had the the yellow/white to the first coil and the green to the last! Honda wouldn't do something like this would they? This may seem like an insignificant detail until you tie your new coils to the old and get clockwise to clockwise, or counter clockwise to counter clockwise coils in series. This would subtract the induced voltages instead of adding. Verify yours before before breaking and making the new connections. To make a long story short, both bikes have been rewired and draw close to 7 A@ 14.xx volts (bike reved) for the expected 100 watts. I just remembered. The stock stator output was 60 vac maximum. The rewound stator with all 7 coils in series produced close to 130 vac. Light is damn bright, but haven't got to do a mega night ride yet. Mike