Stator rewiring

[speedy231278]

Has anyone ever tried replacing the wires on the stator? I don't mean rewinding the thing, but changing the three output wires. Mine are really ropey at the connector end, and I won't be able to trim much more off to find anything any better without making them too short to be able to put the connector back through the mount on the fairing bracket.

I figure that new wire would help minimise losses in the charging circuit, although I appreciate that most loss will be between the reg/rec and the battery. Speaking of which, is there any reason why I couldn't or shouldn't forget about the connector above the clutch cover and just take the three wires directly to the reg/rec? Mine's already wired individually due to the death of the connector, so it's not an issue to disconnect the existing ones at that end.

[CMSMJ1]

I did when I fitted the GSXR statot

Chop them off, splice adn solder then heatshrink them. all good. Got me some connectors from an autoelectrics shop online

[thunderace]

Not too difficult a job. If you're not sure you're welcome to post it up to me and I'll get it done and posted back in a day or so in exchange for a beer token

[speedy231278]

Thanks for the offer, but I'm happy to do it myself. It's not utterly urgent, but I need to get a decent iron first. I'll probably acquire a spare just in case I screw up. If I can, I want to go from the terminals on the windings straight to the reg/rec. I figure splicing and connectors is just adding resistance. Haven't got the wiring diagram to hand, but there's nothing other than plain wire between the connector on the end of the stator wiring and the connector at the reg/rec is there?

[CMSMJ1]

Nope...

[lalalandrus]

Cammo is sending me a stator To do this exact thing. I will write a tutorial on how after i figure out the technical speca on the stock one.

[speedy231278]

I'm sure it's going to be pretty straightforward if you have a decent iron, decent solder and probably a bit of extra flux for good measure. I'm just not willing to do it with the single example I have (maybe unless you get the pics up and it's proved to be something even I couldn't screw up!) as I'll be buggered if I ruin it!

[Neosophist]

Dead easy job.

Cut the wires back to an apporpriate place where you have decent wires to work from.

Make sure your new wire is decent quality and appropriate thickness. 2.0mm sq will carry 200 watts at 12v so is more than enough for a single phase.

the wires MUST be soldered togheter to ensure a good connection.

I wont go into how to solder properly as there are a million guides on the net in books and pretty much everywhere. But a decent iron that will get warm enough, some good solder and a bit of flux. Heat shrink sleeve them when you are done, I added some PVC electrical tape over the heat shrink to offer extra rub protection.

Been fine ever since.

[lalalandrus]

just use the same guage wire as the stock, use the same number of turns. also need to make sure no sharp edges to cut the enamel coating

[Neosophist]

just use the same guage wire as the stock, use the same number of turns. also need to make sure no sharp edges to cut the enamel coating

Has anyone ever tried replacing the wires on the stator? I don't mean rewinding the thing, but changing the three output wires.