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Old 05-12-2012, 10:22 AM   #439
Indy Unlimited
Beastly Adventurer
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Joined: Jan 2007
Location: Parker, CO
Oddometer: 1,479
I think we need the epoxy coating to keep the wires from vibrating and thus breaking at the bends.
Many manufactures make thermally conductive but electrically insulative epoxies that are rated to 500F for potting and dipping.
The aftermarket stators get away without the epoxy but fail a lot sooner than the stock unit. Most people epoxy coat the aftermarket stators for long term reliability.
It is difficult to evaluate the reason for stator failure but most are due to the copper wire breaking and raising the resistance to the point of frying. I would not put a stator in there without the binding force of an epoxy resin.
Current Stable:

2013 Ducati Hypermotard SP, 2011 Husaberg FE570S, 2011 BMW S1000RR, 2010 BMW F800GS
2007 Husqvarna TE610 , 2003 KTM 525 MXC
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