Dave wrote on 09/19/12 at 06:44:05:... Does more windings mean more amperage....or more voltage......or both? For every 10% increase in windings do you get more voltage....or more amps? At some point you will run out of room to wind unless you use smaller wire......then you run the risk of having wire that is too small. ..
More windings say more voltage. Thicker wire means more amperage.
I just inspected a destroyed stator and made following measurements.
The stator is wound with 1mm enamelled copper wire, this equals AWG 18 quite good (=1.0236mm) and each of the "teeth" has 45 windings.
Assuming you want more electrical power for additional load (heated grips and jacket) you best should go both ways: Thicker wire and some more windings. As much as you can get on.
But the space for the windings is very limited. AWG 17 may work but then it will be an artwork to get on 45 windings on all of the "teeth". Each layer will then carry only 11 windings instead of 13 as before.
Even with the economiest and perfect rewinding work (which is not easy and means some good training in that matter) you will fill a bit more than four layers (before: 3 1/2 layers) and each layer is thicker. I assume, there's very little or at least no space for more windings then.
Taking the same wire (AWG18) and putting on more windings may work, but the effort could be only marginal because you do two things at one time: Adding more ohmic losses (longer wire) and adding some tenth of a Volt under load. Considering all effects, that could be the way one should try
The stator is wound in "Y" pattern, so a change to a "Delta" pattern does not make sense at all, because you would need much more rpm to get the same voltage. Remember old techniques for three-phase electric motors. They sometimes have a switch to start with "Y"-pattern (low rpm, more thrust) and then to switch to "Delta" for high rpm in use.
Another way (very theoretical!) could be the permanent magnets in the rotor. There are only 12 and they do not have much power.
Changing that system to 24 magnets N52 and make the gap between stator and rotor as small as possible. But... no chance without further research and a garage full of finest machinery.
My opinion on that subject at all: Save your electric power as much as you can (led's instead of bulbs) and savingful use of heated gear...