On 4 August 2011 20:45, Electron wrote: > > PS: on a second thought, I'd like to repair it myself. I tried on some > workshop but they all told me that as the wire is thin, it would cost > me to ask them to repair it more than buying it (which is ~$150). > > Can you point me to a good IDY guide about how to repair/rewind stators? > > Any tips from your experience? > > Thank you! > > Mario > > PS: my stator is this and the only coil damaged is the one of the 8 with > the thin wire: > > http://www.trailtech.net/media/stators/stator_system_kits/S-8302_w450.jpg > > > >>Thank You (and Sean Breheny, who replied, and on the same lines). >>I guess the manufacturer should have potted it. :( >> >>Well, I know one more thing now! And when I buy next, I will pot it >>myself. >> >>Thank You, >>Mario >> >> >>At 21.03 2011.08.03, you wrote: >>>Electron infinito.it> writes: >>> >>>> >>>> >>>> Hi all, >>>> >>>> my bike (enduro KTM 300 EXC) stopped running for some seconds, >>>> then ran again. Some hours later it did it again, then again.. >>>> then stopped and never came back to life. >>>> >>>> No spark. >>>> >>>> I checked all the wires, they were OK, no short with each other, >>>> no opens, all was right. >>>> >>> >>><> >>> >>>> I had to give back the stator, I'd like to repair mine, the ohms >>>> are just right, only the mH and the voltage (as seen on the 'scope) >>>> dropped to about 1/4.. could anybody explain me how this magic has >>>> happened, and how to revert it please? It's just a wound wire, it >>>> shouldn't behave like this!! :-/ >>>> >>>> Thanks, >>>> Mario >>>> >>>Mario, >>>this could be a shorted turn. =A0You would not detect a significant resi= stance >>>change, but it will show as degraded transformer performance. =A0If >>it's a just a >>>wound wire, you can try to replace the winding ( a bit tricky though). >>> >>>Sergey Dryga >>>http://beaglerobotics.com >>> Mario A few comments that may help. If you can. remove the old wire turn by turn, count the turns and measure the wiresize. Replace with as near identical wire (or slightly smaller) as you can. If you have to cut the wire off, retain all of it and estimate how much replacement wire you need by weighing it. You can also get an estimate of wire length & number of turns by calculating from the wire resistance. Don't forget to correct for temperature. Make sure the insulation on the replacement wire is suitably temperature rated. You probably _don't_ want the stuff that melts with a soldering iron. Probably, the harder it is to scrape the insulation off, the better. It may be advisable to replace with a slightly smaller wiresize. You are unlikely to be able to get the same neatness / packing density as the original if winding by hand or simple machine. Make sure it is well insulated/protected against any metal parts, especially at corners etc. Try to avoid sharp bends and make sure the wire doesn't kink. Make sure that the completed winding is tight and doesn't touch the case etc where vibration could break through the insulation. Once complete, use glue or varnish to help hold the windings in place (or pot it if possible). At least as it's a a stator, you won't have to worry about centrifugal forces or balancing. The longer it takes and the more care you take, the better the result is likely to be, but be prepared to have to start over again. Hope this helps. RP --=20 http://www.piclist.com PIC/SX FAQ & list archive View/change your membership options at http://mailman.mit.edu/mailman/listinfo/piclist .