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Old 05-02-2012, 05:40 AM   #376
JRWooden
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One option is a rewind of your stator, but wire insulation rated at 200C or better is needed...
From what I have read most shops don't have something that exotic....

I have not checked out any of the sources below, so consider them "leads":

http://www.electrosport.com/street-b...phase-102.html



https://www.rmstator.com/en/motorcyc...categories.htm


http://www.ricksmotorsportelectrics.com/stators.php

I think Indy ordered one of these:
http://www.regulatorrectifier.com/catalog/2007-2011-BMW-F800S-F-800S-Stator

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Old 05-02-2012, 05:43 AM   #377
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Circling back: Why don't stators burn up on the F800S ?

Circling back:

Why don't stators burn up on the F800S / F800ST?

Did Rotax/BMS "re-design" the flywheel when they came out with the F800GS and screw it up?

JRWooden screwed with this post 05-02-2012 at 05:50 AM
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Old 05-02-2012, 07:41 AM   #378
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Quote:
Originally Posted by JRWooden View Post
Circling back:

Why don't stators burn up on the F800S / F800ST?

Did Rotax/BMS "re-design" the flywheel when they came out with the F800GS and screw it up?
They do.. Read the BMW ON's magazine from a couple of months ago, there's an article on Voni Glaves' 800ST having "battery trouble" and her hubby went thru all the diagnostics, changed battery, (i knew all along it's the stator thanks to this great forum / site) which eventually he figured it out. He's got a big pictorial article detailing all he did to diagnose and then fix the problem. Trouble started for them when riding thru Alaska.
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Old 05-02-2012, 10:43 AM   #379
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Originally Posted by GB View Post
They do.. Read the BMW ON's magazine from a couple of months ago, there's an article on Voni Glaves' 800ST having "battery trouble" and her hubby went thru all the diagnostics, changed battery, (i knew all along it's the stator thanks to this great forum / site) which eventually he figured it out. He's got a big pictorial article detailing all he did to diagnose and then fix the problem. Trouble started for them when riding thru Alaska.
Yeah, they do. I have also read about it on F800riders and the German F800 forum from S and ST owners.
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Old 05-02-2012, 12:45 PM   #380
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Thanks gents....

I saw Paul's article ... just for some reason "assumed" that the problem was not as serious on the non-GS bikes.

Sigh................ well I guess that makes me feel better -- misery loves company ?

I would REALLY like to see a picture of the new flywheel design....
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Old 05-02-2012, 01:00 PM   #381
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Me too. Will the new design allow more oil cooling? If you see it, please post it.
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Old 05-02-2012, 04:23 PM   #382
JRWooden
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Me too. Will the new design allow more oil cooling? If you see it, please post it.
The implication is that the design will allow for oil cooling, or possibly air cooling ... it's not clear ... at least to me ...

But yeah... whoever sees one first needs to snap pictures for the rest of us ... so that we can see if we think its a worthwhile $900 upgrade?
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Old 05-02-2012, 09:11 PM   #383
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I have a question.
Does anyone know whether the toasted look of the stator comes gradually, or is it a sudden thing?
What I'm getting at, can we pull the cover and say, hmmm, that's on the way out, better replace it before my 15,000km ride in August?
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Old 05-02-2012, 09:47 PM   #384
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It should darken the epoxy quickly within the first few thousand miles but once it cooks extra dark it it will start to show flaking and brittle failure. that is when it cant support the wires anymore and the violent forces of magnets ripping by the copper coils causes then to vibrate and break. Then we got a useless stator.
So the key is finding an epoxy we can apply to a new rewind that can take 200C. They are out there but usually include high tech mold and vacuum impregnation. I am still searching for something we can dip and cure that can handle 200C and protect the wires from violent vibrations.
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Old 05-02-2012, 10:04 PM   #385
JoelWisman
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That's not how these stators are failing in my experience.

I have held one in my hands that due to instrumentation and a customers watchful eye, and luck, was caught and the bike shut off within a mile of failure.

The magnet wire insulation failed and shorted while the epoxy was just fine. Dark, but still strong and not failing anywhere.

Ride a bike with a shorted stator and temperatures will exceed 500 C, so of course the epoxy will fail along with the magnet wire oxidizing or even melting, but that's all consequential.

It's the magnet wire insulation that fails from heat induced aging, not the epoxy dip.

You could tell a stator that wasn't likely to fail due to color, but by 10k miles you can't tell one from good for another 20k miles from one on deaths door because what causes the failure is internal to the epoxy dip.
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Old 05-02-2012, 10:15 PM   #386
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I found the superceeded stator assembly at San Fran BWM and pulled the trigger on it. I ride my bike every day and I can't wait for the new item to show up on our shores. Hopefully this one will last another 50K miles. I'm going to install one of the LED voltage monitors to keep an eye on it. It was a pretty straight forward swap. I think I knocked it out under two hours.

Here's a side by side comparo with the new part and the old, fried one.



Crispy bits were all inside cover. I'll be doing an oil change tomorrow.



Most of the epoxy coating got hot enough to melt away.



I'm hoping we can eventually find a vendor that can do rewinds that meet the spec of our bikes. It would be nice to have one for a spare since I've had both of my GSs stators fail and they've been replaced with superceeded parts.
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Old 05-02-2012, 10:53 PM   #387
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Quote:
Originally Posted by MonsterJ View Post
I found the superceeded stator assembly at San Fran BWM and pulled the trigger on it. I ride my bike every day and I can't wait for the new item to show up on our shores. Hopefully this one will last another 50K miles. I'm going to install one of the LED voltage monitors to keep an eye on it. It was a pretty straight forward swap. I think I knocked it out under two hours.

Here's a side by side comparo with the new part and the old, fried one.



Crispy bits were all inside cover. I'll be doing an oil change tomorrow.



Most of the epoxy coating got hot enough to melt away.



I'm hoping we can eventually find a vendor that can do rewinds that meet the spec of our bikes. It would be nice to have one for a spare since I've had both of my GSs stators fail and they've been replaced with superceeded parts.
Ride a lot! All parts over counter OR parts replaced in the shop after the bikes warranty expires carry at minimum a 2 year unlimited mileage warranty.

If you can't kill it in 1 year and 11 months, let be know and I can LOL, then you will get the updated part for free
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Old 05-03-2012, 05:02 AM   #388
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Just to throw reckless idea on the table. I haven't checked yet but would F650GS/Dakar stator fit/work? At least the spare part number is not the same as with F800.
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Old 05-03-2012, 05:14 AM   #389
JRWooden
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Quote:
Originally Posted by MonsterJ View Post
I found the superceeded stator assembly at San Fran BWM and pulled the trigger on it. I ride my bike every day and I can't wait for the new item to show up on our shores. Hopefully this one will last another 50K miles. I'm going to install one of the LED voltage monitors to keep an eye on it. It was a pretty straight forward swap. I think I knocked it out under two hours.
MonsterJ:
Looking at the parts catalog, I thought the stator was only available as part of a "kit" that included the flywheel....
Do you have the P/N handy for the superseded stator by it's self?
It sure does look different, I wonder how/if it's better?
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Old 05-03-2012, 05:16 AM   #390
JRWooden
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Originally Posted by JoelWisman View Post
Ride a lot! All parts over counter OR parts replaced in the shop after the bikes warranty expires carry at minimum a 2 year unlimited mileage warranty.

If you can't kill it in 1 year and 11 months, let be know and I can LOL, then you will get the updated part for free
No exclusion for "electrical" parts?

PS: It's a good thing you're no longer a "company man" ... or BMW would have to kick your ass for this kinda talk!
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