Hi there 'onewizard".... what my MC sparky said was the reason for the flairing was that in volume manufacturing when you by them from Internet sites etc.. what they use is a heavy guage wire to quickly make up the windings on each of the poles and it's cheaper to do and quicker to make hence the price to the customer... you'd think that the heavier guage is good - wrong! Carl said they use a much thinner guage copper wire so that they can get more windings on each of the poles (I think there are 5 or 6? around the unit) and when they soak them in the lacquer for a minium of 24 hours, it then creates a better soak and better quality product.... BETTA Bikes located here in Hackam (down south of the City of) Adelaide - South Australia and do most of the all Stator rewindings here in Australia for the Motorcycle dealerships for their customers... They have never had one ever fail or returned and guarantee them for the life of the bike! Carl said to me that if you think we Versysirians are kinda not happy.... they have done HEAPS from the Trium** Triples!!! (so their owners aren't too happy too!) they charge $300 to do up mine and if this one fails that I have now - I'll get it done by them.. just ashame I didn't know that they did them other than panicing and buying off the net because of the price my daughter quoted me..... thanks hope this helps somehow.... catchya.. Andreas
First, unless you know for sure that Kawasaki made a mistake in the number of turns, you don't increase or decrease the turns.
Next, the heavier the gauge the less resistance and less voltage drop = lost energy. You can use different temperature ratings of magnet wire, the higher the temp usually means thicker insulation. I prefer class H (180'C), and heavy , which is the coating thickness( around .0015 to .003 of a inch).
The next thing I use to do was preheat the finished stator, this removes any moisture trapped in the laminations, insulation etc., most rewind shops won't do this because it thins the dip and also cause the solvent to evaporate.
The more professional rewind shops have a vacuum dip tank, and my preference would be a epoxy dip, keep in mind you want the thinnest coat for heat transfer,and strongest coat to prevent the magnet wire from vibrating and breaking down.
A couple things happen when you increase wire size, one , with exactly the same number of turns, the outside turns are going to be further from the core. Second, you reach a point were there isn't enough room to get all the turns onto the pole piece.
You mention smaller wire size, what can be done is wind with as a example a equivalent to a single 10 gauge , would be two 14 gauge wires ( which would be harder than a 14 gauge), several problems come up with this method, say you had 20 turns of the 10 gauge, using the 14 gauge you will have 40 wires, and since you have 20 additional wires, you have added the insulation thickness of the 20, the second problem is when winding two in hand, there is a increased risk of cross overs between turns ( potential spots for shorted turns)
I said it before, if time permits I may try and find out what the output voltage is AC , compared to the actual DC current load and DC voltage output voltage.
As to how long it soaks, isn't as important as how it is wound. I use to preheat for 1 hour at 200'F, then dip it and soak for 1 hour in epoxy varnish, take it out and let it drip for 10 minutes then bake it for I think 6 hours--------been a long time about 35 years, they have some really good magnet wire available now.
$300 , are they saying once they do it , that it will never fail?
Bottom line, were you live it costs almost as much to ship as it does to rewind, so local is good.