Rewinding stator by hand

[Mentacycle]

Hello folks, hope everyone is getting to enjoy the great weather today...

After a 2 week exhaustive search I cannot find a stator to fit my bike (yup the CPI Sprint 125), so Im considering rewinding my stator myself because only 2 of the 3 phases are producing current and testing to ground shows a dead short.

Im following this instructable https://www.instructables.com/id/Rebuild-your-bike-s-expensive-stator/

With the crude tools I have to hand (no verniers,calipers,etc - yet) Im unable to accurately measure the wire on the windings so would i be safe using 0.95 mm wire as in the instructable?

[Rogerborg]

Do you have an engine code? If you're extracting it anyway, a part number? Or a picture of the engine and/or stator?

I ask because it'll almost certainly be one of the Honda CG or CB or Suzuki GN/GS copy engines and you should be able to get a stator to fit.

Given that cmpo want £25.41 for (e.g.) a CG-copy stator I wouldn't give up the search just yet, unless your time is cheaper than that.
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Biking is 1/20th as dangerous as horse riding.
GONE: HN125-8, LF-250B, GPz 305, GPZ 500S, Burgman 400 // RIDING: F650GS (800 twin), Royal Enfield Bullet Electra 500 AVL, Ninja 250R because racebike

[WD Forte]

I've rewound a few and didn't sweat the exact wire gauge.
Near enough is good enough
I was in a hurry and had the materials to hand, but as Roger says the chances are its a common cheap item you'll get from Ebay or places like
CMPO. quite easily.
There are basically two types
generator only and generator with CDI source coil
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bikers smell of wee

[neptune8]

In the past I have rewound all sorts of devices including car alternators , relays and D.C. and A.C. electric motors. Your best answer is to buy the wire from your local electric motor rewind shop. Take a sample of the old wire with you. They will burn off the varnish, and measure the wires diameter with a micrometer. Take careful notes of how the old winding was applied and connected, e,g, number of turns per coil[ may differ from one coil to another] whether each coil was wound clockwise or anti clockwise as viewed from the outer end of each polepiece. Also the connections between coils and how the output leads are connected. Remove all the old coils and weigh the wire, as wire is sold by the kilogram. Carefully preserve all the insulation pieces. After the coils are rewound, the job needs dipping in winding varnish, and baking. The rewind shop may do that for you for a small fee[a drink]. A reasonable substitute is to paint the job with polyurethane varnish using a paint brush.[Do not Bake!] Hope this helps.
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[Fizzer Thou]

Try these people

https://www.westcountrywindings.co.uk/

They were at the London Docklands bike show earlier this year and their examples of their handywork was spot on
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[mentalboy]

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[331X2]

Funny thing is, welding the webs to the big end pins and centre shaft is seen as the only proper way to build a crank in high performance skis...

Of all the people telling me it's absolutely necessary, no-one ever seems to have had first hand experience of a crank shifting out of phase and the one I rebuilt (without welding) has been running for over two years now without issue.