Generator has died again

[Cyclingbiker]

Losing my patience with my CG, my replacement generator, which I bought after my old one died on me leaving me with dim lights, has itself gone and done the same thing

This just after spending money painting the engine panels and buying a new exhaust to replace the rotted one with a snapped stud. Over £200 I've spent since September keeping this thing on the road and now this.

Output directly from the generator is approximately 4.5 to 6v AC on idle and 1/3 throttle respectively. Result is lights are impossibly dim, do not brighten significantly with increased revs and I suspect the battery will no charge with this.

I guess my only options are either to get another generator from a breakers or get my stator rewound. I am leaning towards the latter after my experience of 2nd hand stators so far...
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Honda CB500s (1999) - Honda CG 125 BR-J (1991)

Mod 1 - Passed - 12/11/12 --- Mod 2 - Passed - 26/11/12

[CaNsA]

[kramdra]

I suspect the time spent is a lot more significant than money.


External generator get a pully welded onto front sprocket. use a small 3ph brushless mounted above gearbox.

Example
https://www.ebay.co.uk/itm/181100615068

Decent output while moving. It'll use battery for lights when your stopped.

[Cyclingbiker]

Calling around I found Pitstop Motorcycles in Warrington and they seem to have a good reputation for coil rewindings, better than West Country so I've heard. They have quoted me £45 + £5 return postage for my generator with a 12 month guarantee on the work done.

Honda want £478 for the same part, not at all shocking...

My search for a pattern part has come up with nothing except for replacement coils for around the £60 mark. I will get it rewound, it seems the most attractive and cost-effective route to take at this moment in time. I will get it posted off tomorrow
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Honda CB500s (1999) - Honda CG 125 BR-J (1991)

Mod 1 - Passed - 12/11/12 --- Mod 2 - Passed - 26/11/12

[Cyclingbiker]

I have sent off my stator in the post today to Pitstop for them to rewind it. At less than £4 recorded it wasn't too bad but mine is a very small, lightweight and admittedly feeble generator so it weighs only 450 grams packaged up with plenty of bubblewrap.

I have high hopes of them being able to fix it for the price they said. It seems many people hold them in high regard as West Country Windings have apparently gone downhill in recent years for various reasons. A week turnaround is what I have told to expect by them but I am prepared if it takes a little longer than first said.

I did casually inspect the coils before I packaged it up and saw a larger burnt-out section on the uppermost of the two coils which is encased in some sort of wax or resin. I take to mean that it has shorted out and overheated at this point and means the coils produce less voltage than required. The bike still runs which means the ignition portion of the coil is still in good nick but the dim lights suggests the charging and light coils is fucked. Hopefully when it returns I will have a fully-functioning generator that will go for 1000's more miles without another thought or failure.
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Honda CB500s (1999) - Honda CG 125 BR-J (1991)

Mod 1 - Passed - 12/11/12 --- Mod 2 - Passed - 26/11/12

[smegballs]

[Vincent]

Did you try Electrexworld? Not known for being cheap but they've been good whenever I've rang them for help.
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Space Is Deep

[moonzoomer]

[Cyclingbiker]

[moonzoomer]

The stator was 2nd hand when I bought it, it was from a bike that was being broken for spares so had an unknown amount of usage beforehand and did have a slight blackening of the top coil already so it is not that surprising that it has gone again. The rectifier is fairly new, bought from Wemoto in October.

still worth a check though, you do not want to pay good money for bottom coils only to find the fault returning due to an external fault possibly reg/rec related. Hope you get it sorted but a few simple checks could save you a few quid.

[smegballs]

Maybe worth looking at a rewinding as opposed to getting another potential unknown quantity with 2nd hand stators?

It's not beyond the realm of imagination that several years of heat and vibration start to fuck up the insulation of the windings and eventually result in an internal shorting. Then the heat from the short makes even more insulation break down and have a cascading sort of effect.

No idea how much rewinds are, if it was me I'd be tempted to have a go myself depending on how complicated the stator looks.

https://laurencecrew.com/getmybikeback/stator%20plate.jpg

On an rxs the lighting coil is the one on the right, I'm quite tempted to rewind it with twice the turns to convert it to 12v, and leave 6V hell.

[Cyclingbiker]

The stator is on its way back from Pitstop Motorcycles after being rewound. They have redone one of the two coils, I'm assuming it is the upper coil which I believe is the charging/lighting coil and which had the burn marks visible on the insulation.

Hopefully it will be with me tomorrow and I can get it back on the bike and be riding it after the weekend once the snowy weather is out of the way.

I do not know whether or not to change the Reg/Rec or leave it. I will check the charging voltage as per this thread to be sure once I start the thing up for the first time and if I suspect anything is wrong I'll replace with a spare unit that I have lying around in my toolbox, it is a pattern part (same as the one fitted but from eBay not Wemoto) so we'll see. Fuck paying in excess of £100 for a Honda one.

https://www.ixxra.co.uk/v-web/phpBB3/viewtopic.php?f=3&t=22743
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Honda CB500s (1999) - Honda CG 125 BR-J (1991)

Mod 1 - Passed - 12/11/12 --- Mod 2 - Passed - 26/11/12

[uberkron]

I reckon your regulator-rectifier is faulty. Its more likely that selenium/silicon has broken down than copper wire and magnets.
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i ride a zip 50 2smoke. It overtakes a hundred times a day.

[unitynotsocri...]

if interested you could wind your own coils as they are pretty simple...........one thing to consider is the ballast resistor .what it does is burns iff excess current from the genny, problems with these can lead to constantly blowing bulbs,as voltage rises too high and errattic charging
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nearly a normal tax paying tosser.......with ferrileness suzi100,cg125,cb125scb100n,cb175,cd100,cj250t,kh250,c15,125 bantam,super 6,rickman gs750,xt500,250rs,dt175,lifan125,dolomite1850,metro,Morris220ld,morrisfg,leyland princess,range rover,corsa,vw camper .now struggling with legs. MORE ORDER = MORE CHAOS

[Cyclingbiker]

[Cyclingbiker]