Well once again my poor 1125r has another stator that is in need of replacement, this time it has only managed approx 700 miles since the last one had a custom rewind, The bike is currently with Steve and the crew at Black bear who are doing a fantastic job of looking after me and the bike however the company they used to rewind the stator (HARLEY UK RECOMMENDED) will no longer deal with us Buell owners as they have not had an awful lot of success with the stator. So I am now stuck with a situation where a new stator is over £800.
I was wondering if anyone has a company they have used and can recommend to rewind the stator as I really don’t want to pay all that money for a new one that is still going to fail, I would rather a rewind and the modified rotor, Steve has very kindly offered to post the stator to anyone who could do this whilst my bike is with them in the workshop.

Thanks for your help with this

H-D use West Country rewinds, who are one of the best in the business.......I've had them rewind 1125 stators, which didn't last long

_________________
Mithered ta death.
92 MB
96 S2T
98 S1W
00 M2
01 X1
03 P3
10 CR

And they did Foxy's last time but don't want to go near them now Although they worded it far more diplomatically than that

Steve

_________________
Back on the road again!

Was talking to a bloke on Saturday who has had 3 on his 1125R in 12,000 miles. I am amazed that this problem cannot be fixed. Who would want a 1125 if they possibly face an £800 bill for a stator that may last as little as 700 miles. Harley should be offering these at cost at the least.

_________________
Buell S1
Buell S3 (Topless for now)
Buell XB12S
Piaggio X8 400ie
Yamaha XTZ750 Super Tenere (x2)
Suzuki GSXR750WR
BSA B441VS
FJR1300

What about the oil hole? And the relay discussed the other day? And the different regulators? And the Twin Motorcycles solution? Why don't the 08s suffer? What happens if you pull two headlamp bulbs?

Surely we have an understanding of the cause by now, and hence can drive a solution in...

_________________
08 Specialized Langster

The answer is to switch to the 2008 stator and rotor.

The 08s don't seem to have this issue - typical knee jerk reaction by HD when they had a parasitic drain on the 08s due (apparently) to a faulty IC flash.

And a good reason to use the kill switch - my 2008 has had no problems except for the one time I forgot to use it, although AFAIK HD did subsequently upload new firmware ...

Maz -thanks for the reply....I agree with you they do seem to really know their stuff,i have spoke to Dan there and he advised me that they also make sure they use the biggest gauge wire with the minimum length for the winding to keep the heat down so I am going to use them again with a modified rotor that Black Bear get machined and see how it goes.

Pash is right its about time this was sorted for good.My 2009 1125r has over 11000 miles on the clock and still on the original stator.I have the harness fix on mine and change the relay often.It seems to me that we look for fixes instead of causes,Just why do some last much longer than others?Is it riding style or what?

As I don't own one of these, and I am not an electrical engineer, I don't really have that much of a clue how the system works, however if they are overheating, that can only be down to:

1. Too much current being drawn
2. Wire gauge too small for current being drawn
3. Insulation on the wire too thin or damaged
4. Insufficient cooling

I don't understand this relay thing either, surely you put all three phases through the rectifier/regulator and distribute the load equally.

So what is stopping one:
a. Increasing the resistance of the rectification to reduce the current flow?
b. If the battery fails to maintan charge, pulling two of the headlamp bulbs to reduce the load?

_________________
08 Specialized Langster

I don't understand the relay either,but the only time I had a low battery I found the relay pitted.Changed the relay and problem cured.The H-D relay comes in around a tenner but I found a Tyco one for under two quid on fleabay which is in at the moment.Lets see if this is up to the job.

From what I have read it appears to be heat that is the problem. I think that it is a design flaw by Rotax as I have also read that the Aprilia RSV Mille also suffered the same sort of problems.

I don't think that hiding the regulator under the seat helps either, eventually I will get around to putting mine somewhere in the air flow once I get working on my Lightning seat conversion. I have also considered some sort of "scoop" to try to direct more air flow over the stator part of the engine, although I'm not sure if that's possible. The whole idea of the oil way that EBR is now putting into the rotor is to help with cooling. Perhaps changing the oil more frequently than the scheduled service interval may help - it is easy enough to do after all, I try to do mine abou every 2,000 miles, hopefully it's cheap insurance ...

Scoop directed at outside of stator may not be worthwile,I think cooling the outside would be minimal.I have the Buell lower fairings on mine so surely my stator housing would be hotter.Does using a lighter oil help? I have always thought a thinner would circulate faster and stay cooler.I always use Castrol 10/40 synthetic racing.

My understanding Pash is that because it uses a shunt regulator the stator is always giving out it's maximum output regardless of electrical load (varying only due to engine revs) the regulator uses what is required to keep the battery topped up and dumps the excess to earth so varying the load by removing bulbs will make no difference at all.
The relay mod takes out some of the heat by basically turning it into a single phase alternator at certain times.
Some fit series regulators because they only draw the required current from the stator so reducing it's output to what is required by the system and doesn't dump excess like a shunt one does.

_________________
2001 X1 2009 1125CR 2006 Uly X3 2010 Uly a fully Maz'd S1 and a 1991 RS1200 Westwind.

So increase the resistance of the shunt and dump the silly relay

_________________
08 Specialized Langster

Thanks for all the replys guys,thats the great thing with this site,Kevmean and Pash I really think you are on to something there with the relay issue,i know there has been lots of talk about this over the pond on badweatherbikers forum.