Alternator Stator Repair

Previously neil_renwick wrote:

Hi All,

One of the 2 wires on the alternator stator on my 750 has broken off and the other looks like it will be break soon. (See photo). Also the wires/sleeving that connect the alternator to the electrics has gone solid due to age and possibly heat.

I have cut away some of the insulation to find the remainder of the wire on the stator and proposing to cut the other wire and then solder new wires onto the stator and then cover this with a shrink sleeving. Question is, has anyone else done this and if so, any guidance? Also views on, is this worth doing or should I just purchase a new stator? (£60)

If I proceed with the repair I going to use wires that are rated for 16.5 amps given that the Lucas alternator 2 wire (part No47205A) is rated at 10 amps so I understand from various web sites. Again, any views on this?

As always many thanks for any help/guidance provided.

Neil

neil,

buy a new one. spend the £60 and do the job once or you may be stuck by the roadside.

Previously anthony_williams wrote:

Previously neil_renwick wrote:

Hi All,

One of the 2 wires on the alternator stator on my 750 has broken off and the other looks like it will be break soon. (See photo). Also the wires/sleeving that connect the alternator to the electrics has gone solid due to age and possibly heat.

I have cut away some of the insulation to find the remainder of the wire on the stator and proposing to cut the other wire and then solder new wires onto the stator and then cover this with a shrink sleeving. Question is, has anyone else done this and if so, any guidance? Also views on, is this worth doing or should I just purchase a new stator? (£60)

If I proceed with the repair I going to use wires that are rated for 16.5 amps given that the Lucas alternator 2 wire (part No47205A) is rated at 10 amps so I understand from various web sites. Again, any views on this?

As always many thanks for any help/guidance provided.

Neil

neil,

buy a new one. spend the £60 and do the job once or you may be stuck by the roadside.

Neil

I did exactly as you describe to the stator on my 71 roadster probably 30 years ago, I dug a section of resin out until I reached the actual windings. Soldered on some decent sized wires, long enough to go all the way to the rectifier, & sealed in all in a length of tubing with Araldite. Been perfect but needs doing again now! I shall try to re-do it soon & have little doubt that it will be perfectly OK. It should outlive my need for it (there's a sad thought!)

Bob.

I have just done this repair to my 3 phase rotor. It is worth doing. The wires go right through the steel plates to the back side then split to attach to the winding wires. Cut down to the steel but go very close to the original sleeve wire. Do the same from the opposite side exactly opposite the hole in the steel plates. Remove all the original PVC insulated wire and solder in new PTFE insulated wire (as long as you want) Cover with 6mm heat resistant sleeving (from ebay) and seal the whole lot with resin and hardener. It's important not to go too far from the original sleeving as the windings are close. I used a dremmel type tool with a 3mm drill and ended up just drilling through the middle of the sleeve to the other side then enlarged the hole with a decent penknife. There is little point in replacing the PVC wire with the same stuff, PTFE is the way ahead. When you seal the new wire in resin you can put a bend in it where it comes out of the stator to point it towards the correct part of the back of the chain case. Better than new and cheaper too.

Here is my way to repair it:

I dug out the rest of the wires with a Dremel tool and soldered some new ones on.

Then I filled the gap with resin. I made a form out of tape:

Voila! I hope I saved the original stator, the bike is not running up to now.

Hi,

As long as you can make a repair that is mechanically sound I'd go for it. It is probably worth trying to get an idea as to the state of the enamelled insulation on the wire comprising the coil.

Good luck!

Keith

Neat Ulrich, A bit fiddly with three wires to take care of but do-able. worth steering clear of PVC wires and going for the teflon option. (ptfe)

http://www.hostingpics.net/viewer.php?id=530502Scan0001.jpg