[onewizard]

Stator / OEM vs Rick's Stator/ China Star...

How was it with the OEM stator? I ask because I too have Gerbing gloves and jacket liner. This is my first season with a Versys (2015 - 650). Thank you Part 1-OEM is Delta wound, has approximately 42 turns of #18 magnet wire per pole, final connection is two 18 gauge wires connected to each...

www.kawasakiversys.com

 

[onewizard]

2010 Mk2 stator burnt out and I need to replace it
There was an option to rewind it for £200 or get a new one for £140. I went with buying a new one. To my surprise when I got one that it seems it has no coating on the coils. I am sure the current burn out one has some coating on top of the coils

So I am slightly concerned if I am not wasting my time and effort on my new purchase

I also seem to have overspent it - on US ebay basically exactly looking stators is going for three times less but... options are limited here in uk

For reference, I was looking at something more of Rebuild Your Bike's Expensive Stator

First, that stator is not equal to OEM, pay attention. Note at the very top of the stator, a rivet exists, directly above you see 3 magnet wires passing into a piece of black sleeving. That is the Y or Star connection ( 60% of the copper of OEM)
OEM is Delta wound.
The only place to buy equal to OEM is Electrosport.
My thread Stator / OEM vs Rick's Stator/ China Star...
is copied below


Discussion Starter · #26 · Aug 5, 2019 (Edited)




ElectroSport Delta Wound / Info

This was sent to me as a Email message. My comment is the OEM states it as 330 Watts. At one time I considered rewinding a core I have, one consideration was to drop some turns per phase, which would produce a lower impedance and also a lower output voltage, in turn this would produce a higher current. It is hard to say if ElectroSport did this, also I looked at increasing the wire gauge to a single 14 gauge wire Star wound, or a 17 gauge Delta wound ,this would be extremely difficult to hand wind, and there is insufficient room for 17 gauge unless you drop turns Delta wound. Presently the OEM is one 18 gauge wire per phase.

I also have a link and last time I checked it was around $140 USD
https://www.electrosport.com/collec.../products/esg638-stator-kawasaki-zx-6r-zx-6rr


This is from a PM sent to me;
from: Info - ElectroSport <info@electrosport.com>
date: Aug 5, 2019, 9:24 AM
subject: Re: Versys 650 stator tech question

ESG638 is delta wound. The power output is 330w by out measurement, the OEM was 300w, so ESG638 is about 10% more powerful.

The reg/rect we sell for this bike, ESR444, is a shunt unit like OEM.

Kyle Wood - Sales Manager

-------------------------------------
Procom Engineering / ElectroSport
21 Brookline, Aliso Viejo, CA 92656
PH: (949) 305-4200
www.electrosport.com

 

[onewizard]

2010 Mk2 stator burnt out and I need to replace it
There was an option to rewind it for £200 or get a new one for £140. I went with buying a new one. To my surprise when I got one that it seems it has no coating on the coils. I am sure the current burn out one has some coating on top of the coils

So I am slightly concerned if I am not wasting my time and effort on my new purchase

I also seem to have overspent it - on US ebay basically exactly looking stators is going for three times less but... options are limited here in uk

For reference, I was looking at something more of Rebuild Your Bike's Expensive Stator

As to the lack, of a coating, wrong again, I worked in a motorshop for 9 years, the varnish or encapsulation prevents the magnet wire from vibrating, that magnet wire has a .003 of a inch coating, without the coating it will fail prematurely

If you get bored you can read the following by me:
Stator / OEM vs Rick's Stator/ China Star...

Regulator & Editing / Series / Shunt / Star / Delta...

April 2020 I will be editing anything to do with series regulators and Polaris installs .If someone has a question post in this thread or related threads of Technical. Regulator / Shunt verses Series I got a couple questionable looks today when I mentioned I am replacing my brand new 2015...

www.kawasakiversys.com

Burnt Stator / Versys 650 / Stator Testing/ Stator...

I checked the manual before posting, not very informative if you don't know anything about it. The most accurate test is what you have already done, and it sounds like you have shorted turns, however it wouldn't hurt to try this again. What you need to realize is this is a 3 phase power source...

www.kawasakiversys.com

latest winding info;

Stator replacement

It looks like the stator on my 2011 V650 is going. It's already the second one on this bike - first one was replaced under warranty by the previous owner at 18,000 miles. I'm now just north of 40,000 miles. A month ago, I replaced the original regulator with a Polaris 941 series regulator using...

www.kawasakiversys.com

Stator?

Have a 2009 650. Battery tested and confirmed good. With a fully charged battery and bike running multimeter only shows 11.92 volts @idle. Revving the engine doesn't really move the meter. Maybe 11.94@ 6000rpm? If bad recommended source for replacement?

www.kawasakiversys.com

Monitoring the charging system

I'm not sure why but some of my favorite motorcycles have weak charging systems. My 2019 Versys 650 LT is the latest addition to this list. I just installed a voltage monitoring system consisting of only one LED. I mounted it next to the left accessory port in the factory console. Here is a...

www.kawasakiversys.com

 

[onewizard]

Doesn't the stator get splash with oil?
I would think you need it varnish coated so particles in oil don't over time wear down the thin layer of coating on the wires and short things.

Maybe you can find a way to claim item is junk and return to seller for some credit.

First I am rarely on this forum due to many of my threads being partially duplicate and many valuable threads are MIA.

So I will explain something in this thread ( I am very sure if you spent 15 or 20 hours reading my posts, eventually you would find a thread with a post by me explaining it-And THAT 15 or 20 hours is also the problem I am having and administration turned me down to be able to correct it-I am at a point where I don't give a SH--T )

Explanation of magnet wire various classes of insulation, varnish dipped; epoxy coated; encapsulated, or nothing.

Induction; counter EMF; permanent magnetic field; time constant; applied force equal to and opposite that of the applied force -- all of these terms and words are related to both AC and DC motors and alternators/generators.

I am sure some of you have seen someone using a portable stick welder with long cables, every so often you see these cables jump-generally this happens when the person welding stricks the arc. The reason is the inrush current striking the arc produces a VERY STRONG MAGNETIC FIELD ( the strength of the magnetic field around each cable is directly proportional to the current through this cable)

Next , some of you have been around distribution transformers in small businesses, you may have noticed a loud humming and possibly felt a small vibration, that is in some cases the laminations ( LOOSE laminations, they are stacked and many times these laminations are already coated before the winding is installed) vibrating from the alternation 60 hertz frequency.
So what happens is in our permanent magnet rotor alternator, that rotor is moving a north and south magnetic field across the winding of our stator. This magnetic field produces a voltage and when we have current flow we get what is called counter EMF, equal to and opposite that of the applied force. And THAT IS THE PROBLEM, the magnet wire is pulled and pushed alternately each time the north or south pole crosses the winding. If you don't coat the winding with varnish or epoxy or encapsulate it, and LOOSE magnet wires will vibrate, this vibration will wear the .003 of a inch coating off the magnet wire--part of this problem is early stators brought the delta crossover connections from the poles across a winding from the back, weventually you got a line to phase short and joined the BURNT STATOR CLUB .

I helped a member here rewind a stator-hand wound and in all honesty ( with 9 years of me working in a motorshop - probably better than I could have done)-this guy was exceptional and he did coat the winding in the end and it was Delta wound! @fuse_X

Stator Rewinding

See also https://www.kawasakiversys.com/forums/74-how-forum/132250-12-2016-stator-failure.html It was a hot day, 8-year old battery in need of replacement and an extra load caused by a smarphone running a navigation app… my stator cooked! (30K kilometers on my 07 Versys) Where I live kawi...

www.kawasakiversys.com

 

[onewizard]

Pretty NICE having "onewizard" back in the fold, isn't it...?

Honestly, Ed-"And THAT 15 or 20 hours is also the problem I am having and administration turned me down to be able to correct it-I am at a point where I don't give a SH--T ) "

I

may not post again for another 8 months and the longer I am away, the harder it is to come back here. Until management reaches out to me I see no solution. Made myself laugh-the chances of management reaching out to me--- is like me giving Putin a call and asking him to stop the war

 

[onewizard]

Stator coating can be beneficial for protecting the windings from moisture, dust, and other contaminants, especially in harsh environments. It helps improve insulation resistance and prevents corrosion, ultimately extending the lifespan of the stator. Whether it's necessary depends on factors like the operating conditions and the level of protection required. In some cases, the stator may already come with a factory-applied coating that provides sufficient protection. It's essential to consider the specific application and consult with professionals to determine if stator coating is necessary for your situation.

You sound like you are either in the industry or copied this from some web site.

https://www.kawasakiversys.com/threads/stator-coating-as-in-epoxy-or-varnish.231710/

I had a post I used every so often but hard to find, the comment was looking for a service manual. It would apply to your post in this thread. I would suggest using my link here and introduce yourself . I would be REALLY interested if this was YOUR knowledge. As very few fully understand what you just posted-
FYI read the bottom of each of my posts. To be clear, I rewound motors, changed windings from star to delta, some really special stuff, including R&D .

First you should post in https://www.kawasakiversys.com/forums/🖐new-member-introductions.5/
Please read the posts above-no link available directly from this site. You need many posts to allow private messaging. Asking in your first post for a PDF service manual, is like going to a grand opening of a bakery, where free donuts are offered, BUT -you won't be coming back and buying $$$ once they open for business.

 

[onewizard]

What product to coat these cheap Chinese? I am looking now as I just bought one.

Take a close up on both sides of the stator and post it. It isn't the coating that is the problem, it is the wire size and 66% of OEM copper, and the fact it is Y connected instead of Delta.
A better investment would be switching to a series regulator!

 

[onewizard]

I might also add, keeping your oil level just above the high mark, as the oil is what cools the stator, this was proven on a UK Versys site years ago.