Buell 1125 charging issues

I am currently repairing a 2009 Buell 1125 that has charging issues.
The fried culprit which I have had rewound. I will post some more photos soon.

Yum! Looks toasty!

At least it isn't buried in the frame.

No but it is behind two stupid quick disconnect oil lines ( lousy GM style spring clips) and the stator wires must be lead through a flex conduit that if you stuff up takes about 2 hours to rectify :beg:

sheesh stator cookin looks well done

Mmmmmm...deep fried copper! Who's hungry?!?!

Rewound stator and the green mouse wire to get the stator leads back up through the conduit.

Seems fairly painless so far.

How much did rewind cost?

Much less than the $300+ to ship out a Ricks one from the states and incredible turnaround time. Dropped off on Friday and picked up on Sunday :good:

That's a TINY lil thing! :shock:

Stator wires are now through conduit, need some grey sealant to finish up cover install

Use some pretty pink sealant so everyone knows that work has been done in there. :smilie_happy: :beer:

the winding on that stator looks like its not tight enough ... my Uncle-in-law who passed in June , wound one for me , and told me some facts about it , them things are PICKY . opcorn:

[url=https://classicgoldwings.com/forum/viewtopic.php?p=138355#p138355:2wlrvgoa said:

sledge » Tue Dec 30, 2014 9:09 pm[/url]":2wlrvgoa]
the winding on that stator looks like its not tight enough ... my Uncle-in-law who passed in June , wound one for me , and told me some facts about it , them things are PICKY . opcorn:

Click to expand...

tell more sledge i can see its wound a bit loose ? opcorn:

I have seen loose windings rub off the insulation so the wires short out instead of using "all of the windings".
It is difficult to see if the stator in question is too loose or not. Luckily Buell's don't vibrate :whistling:

At Miller Electric (welding manufacture) we wrapped them very tight and they were dipped in varnish afterward to keep them from vibrating. I've included a picture of a very nice wind to show those who are unfamiliar what we're talking about.

Neater looking windings would be nice but I have been using this rewinder for over 15 years without any problems. You might notice that he power coats the core with a blue insulation before winding then dips the whole finished product in varnish. I also know that these Buell ones are a pita to do.

Finally got my sealant which was high temp red 300c+. Which hopefully can stand the high heat in a Buell/ Rotax.
Aviation sealant for the damaged cover gasket

With all those posts spaced tightly together I'd imagine it would be difficult to wind.
I was not suggesting it would fail, but trying to explain why that would be a concern (for those who don't know).

Dipping in varnish is smart, and I see less and less of the aftermarket stators being done that way.

Original Buell regulator/rectifier that charged 13.5-13.8 and jumped around with revs
Cut off the original wires and attached them to my second hand Mofset regulator that I carted around in the Rats Nest in case the original one failed ( one of these days I will finally do the conversion). True regulated charging 14.5v no matter what revs or load this should hopefully alleviate the overheating stator issues that Buell/Rotax have.

[url=https://www.classicgoldwings.com/forum/viewtopic.php?p=138434#p138434:1fdq2op6 said:

C5Performance » Thu Jan 01, 2015 4:58 pm[/url]":1fdq2op6]
With all those posts spaced tightly together I'd imagine it would be difficult to wind.
I was not suggesting it would fail, but trying to explain why that would be a concern (for those who don't know).

Dipping in varnish is smart, and I see less and less of the aftermarket stators being done that way.

Click to expand...

My rewinder used to work for General Electric doing massive jobs and when he was retrenched about 20 years ago he started specialising in Motorcycle windings. The powder coating insulation material he uses he imports directly from Germany and is the key to the reliability of his rewinds.