XR250 stator thingy

[sAsLEX]

Right after Nodman helped isolate the stator as the problem with my XR the thing was left for a while.

Work is a bit slow so today I started to unwind the thing, well 3000 turns later by hand I now only have to wind it back on.

All care was taken to count the turns off accuratly but there was some insulation on the outside which meant the first few layers of wire had become stuck to the crusty black stuff. I got a count of 1495 and 1460 for the two posts the faulty winding is on. Will it be advisable to just chuck 1500 on each??? And will I need to fully insulate it again??

Also does it sound right for one end to be grounded?? the stator has three wire coming off it two are from one winding and one from the problem one.

[Blakamin]

Right after Nodman helped isolate the stator as the problem with my XR the thing was left for a while.

Work is a bit slow so today I started to unwind the thing, well 3000 turns later by hand I now only have to wind it back on.

All care was taken to count the turns off accuratly but there was some insulation on the outside which meant the first few layers of wire had become stuck to the crusty black stuff. I got a count of 1495 and 1460 for the two posts the faulty winding is on. Will it be advisable to just chuck 1500 on each??? And will I need to fully insulate it again??

Also does it sound right for one end to be grounded?? the stator has three wire coming off it two are from one winding and one from the problem one.
Holy Shit!!!! ring an armature winder and see what they say... they DO have machines that do that y'know???

[k14]

Yeah but thats not as fun as doing it by yourself.

I would say it needs to be insulated cause without insulation the coil would be useless.

[Motu]

Good grief!! and I thought I was a tight arse! Do you dip your own matches by hand too? Were the windings on those poles thinner than the others? Usualy the thick windings are lighting or charging coils,the CDI coils are often many more turns of thinner wire.Insulation is not required.

When you wind them all back on,can I come and watch? - I'll bring my own beer and sleeping bag.

[sAsLEX]

Good grief!! and I thought I was a tight arse! Do you dip your own matches by hand too? Were the windings on those poles thinner than the others? Usualy the thick windings are lighting or charging coils,the CDI coils are often many more turns of thinner wire.Insulation is not required.

When you wind them all back on,can I come and watch? - I'll bring my own beer and sleeping bag.


yeah much thinner like 0.25mm enamel coated copper wire, this means the wire itself is insulated k14, the insulation I was talking about covers all the wires once full wound!

Yeah work at the mo is a bit boring so i am finishing a few projects that i have lying around!! oh and it was going to be 150 big ones to wind it, and with my brakes playing up and that being enough for about 100 beers.....

[Milky]

have rebuilt rotors for the BMs for years, but that is only one loop of wire, and they go off to some guy to be rewound by machine. I assume the stator will follow a similar procedure as that for the rotors... We get them coated in resin of sorts to insulate them, I assume it gives some extra support to the windings when the rotor rotates, but for your case this shouldnt be a problem.
You will need to get the right sort of wire for rewinding - same resistance (ohms/metre) hence diameter etc... I am sure you know all about that though. The number of turns should have some leeway in it - 5 turns on 1500 is 1/3 of a percent, ie just under half of bugger all...

[sAsLEX]

yeah should of checked wire a little more carefully before starting, inadvertantly used some wire with two strands within the enamel, hence less cross section =bad.

Since I found this out once I had wound all 3000 turns back on i whipped it in the bike and gave it a damn good kicking, to which it fired a few time ran a bit then died, got new proper wire from a rewind place instead of trying to save a few dollars by using what there was in the workshop and will rewind it tomoorw now that parts for my brakes wont be here for a few weeks, which means fine weather guarenteed since I cant go riding!!!!

[sAsLEX]

well after rewinding it twice, it now goes the mighty XR has been maruading the streets of Devonport, opps I mean MX park somewhere! Took a bit to get started, about an hour of persistant kicking, and was just starting running for a bit then dying. But after doing this for an age it eventually started to run for longer and longer until it constantly, but not smoothly on its old fuel! What is it you add to fuel to remove water?? put some more gas in tonight to dilute the old stuff which was below reserve anyway.

Anyways I found some problems, seems to be an exhaust leak near where the headers go into the engine, some exhaust sealent might fix this tomorow night. And generally its a loud mother of a 250, back firing and burbling off throttle.

There is also a small oil leak near the decompression thingo on the head, but that has always been there!

Anyways dark now and I have no light in the garge so will try remidy the other stuff tommorow.

[Blakamin]

well after rewinding it twice, it now goes the mighty XR has been maruading the streets of Devonport,
full points for persistance!!!! :niceone:

[StoneChucker]

By now, I'd have flung the stator whatyamacallit through the window of the opposite neighbours, plugged the hole in the exhaust with my foot, repeatedly, kicked the bike over and drained the fuel out by gravity and wound the wire around my neck 1495 then 1460 times and finally over the beam in the garage!

Top marks for persistance dude. However unlikely it sounds, I'd like to learn about what you're doing now. I just know if I buy a non-running 250, it'll stay that way, taking up space.

Where DO you find a stator in a bike? I'm guessing the charging system?
If you take apart an engine, as long as you don't introduce any dirt you should be able to put it back together and have it run as normal right?

[Motu]

How did you keep count? I could never do it,an old fart like me would wander off reminising about how fantastic a rider I was on an XR,and how I was gunna show these young buggers a thing or two when I got this thing running....damn! was that 677 or 687???....I better start again!

[sAsLEX]

How did you keep count? I could never do it,an old fart like me would wander off reminising about how fantastic a rider I was on an XR,and how I was gunna show these young buggers a thing or two when I got this thing running....damn! was that 677 or 687???....I better start again!

umm, well i only counted to 100 about 30 times and wrote down each small milestone!! The second time was infuriating to say the least!!!

[Wellyman]

I think you can unplug the fuel and drain in from the tube the goes from the tank to the carb just block it after you unpug in and then find a container and drain and refill with fresh fuel.

[sAsLEX]

I think you can unplug the fuel and drain in from the tube the goes from the tank to the carb just block it after you unpug in and then find a container and drain and refill with fresh fuel.

yeah forgot the container bit and some spilled but oh well, drained some so will take it for another blat tonight!

[sAsLEX]

Found why bike was running rough, the rubber thing in the pic, between the carbs and the cylinder is crap, might have to get a new one. Good trail wrecker anyone???

[NordieBoy]

Try EconoHonda, you may be surprised at the price.
Oh and it's the carb manifold.

[XTC]

Never forget to price a new one from a honda dealer.... Was going to buy aftermarket radiator shriuds for my DRZ once and thought I'd check genuine suzuki price. They were $24 each and after market were $80pair.......

What year is the XR?

[sAsLEX]

Never forget to price a new one from a honda dealer.... Was going to buy aftermarket radiator shriuds for my DRZ once and thought I'd check genuine suzuki price. They were $24 each and after market were $80pair.......

What year is the XR?

84 so dont know if any new parts would be around will check that out though