1986 xt600 diy stator rewind
 

Hey ya’ll so recently my ratty xt600’s source coil burnt out. I was getting like 35 ohms instead of the correct ~130.

As you guys know those stators are kind of unobtainium, or at least here in the states. So instead of shelling out $400 for another used one I went ahead and rewound it with some magnet I had lying around.

This is actually my second time doing it since the first time I used 36 gauge wire and it worked for a couple miles but I guess it couldn’t handle the current and burnt out too.

This time I used some stuff I had lying around. Not sure what gauge it is, but it’s thicker. I’d guess 34 gauge.

To make the whole process go faster I threaded the wire through a small tube (I used a ball point pen with its innards taken out) and used that to guide the wire around the stator pole.

Here are some pics:

I totally forgot to get some pics of when it was done but it looked like a bunch of thin wires wrapped around the stator pole :smartass:

My meter read 131 ohms out of the red and brown wires. I wrapped a good amount and checked it and did that a couple times until I got about 140 ohms, then I unwrapped it until I got 131.

I am not sure if the polarity matters or if I just got lucky both times I did this. I’m thinking it doesn’t/shouldn’t.

Rewinding a stator should not be rocket-science...
 

For the most part, rewinding a stator should simply be a matter of the correct resistance of wire in each coil, and the coils wired together and wound (clockwise / counter-clockwise) correctly so that the your alternator is not producing alternating positive/negative peaks.

As you unwound the old stator, could it be possible to quantify the original winding by counting or weighing the removed coils, and then replacing with same? If the factory stator is wound, then formed and glued, it won't unwind nicely to count turns, and weighing it would need to account for the glue.

With automotive alternators, they use a machine to wind the coils, and then another machine presses, forms, and glues/molds together the coils with some sort of plastic so they never come apart. Remanufacturing that at home is almost impossible, given the forming and molding that needs to be done with a high degree of precision. By your pictures, the XT600 stator does not use any fancy coil-forming.

I've never looked at my XT600 stator, I hope I never have to, but in the event that I do a home rewind will be preferable to a $500 cdn outlay.

looks like a fun project, but any point in doing it when decent stators are so cheap?
cant believe that a DIY stator is going to be better than this 90$ one.


https://www.electrexworld.co.uk/cgi-...2ehtml#SID=200



who pays 500$ for a stator? :)

I think your stator will fail again quite quickly.


You only pay $500 for a stator if you walk into your main dealer with a target painted onto your chest.

:cool4:

The one linked to doenst fit his model, I hope he didnt buy it.
The kick only model stator are getting rare.

Several companies offer to rewind them, which is great unless the pickup is faulty.

Your spot on Jens, ive had them on my watch list for years as they are so rare now, i even posted a LINK to one i spotted a while ago in the USA (best place to find them) not sure if any member understood the importance of my find? if you own one of the old kicker XT`s you should have a good used one standing by for when your one eventually dies.

And yes the pickup coils are often the fault.

Mezo.