Hey Guys...
I have issue with Charging Battery (new Gel type 5Ma) Seems the best I can get is 11.4-8 VDC, until 4500 RPM then I get 12.4VDC. Same with or without Battery connected. Issue is bike is used for city rides, has Electric Start (new coil and starter too) so not to many stops and have to use "Old Faithful...(Kick Starter)"

I have spare (complete stator and coils) Ignition coil is OK. Charging/Lighting coil is Smoked! My stupidity... left yellow connected in harness to ACV when changing to total DCV for all components. Actually couldn't find it ... Got sidetracked by Cat and ...Smoked! See Picture... You can also see room left on coil to add wire...

Now... All 12VAC goes only to R/R, So Stator coil only needs to consentrate on the issue of "Charging".

Can I rewrap Coil as is done in Suzuki 650?  3 coils all connected at one end (common point) and the other 3 ends going to new 7 wire R/R? (Yellow leads) Then connecting 1 of the 2 red (+) wires to original red wire. The other 1 going to Red (power feed) @ Starter relay. Then the remaining 2 Ground wires 1 to common harness ground wire lead and the other to Battery frame ground Connection.

??? Will it work?

Originally coil is wrapped as 2.
Lighting coil is from earth to yellow lead (40.5' of 20ga wire)
Charging coil is from Yellow lead to White/Red stripe lead (23' of 20ga wire)

I have plenty of room on coil frame to add (I did already to check...Insure I was correct. Agin see picture) additional wire I was able to safly add 75' and still clear magnetic wheel and base plate (1/4'3/8" clearance)

So if I wrap 3 coils and connect as 650 Suzuki does... (Can't seem to be able to add a second picture here, I will add a post explaining...

Question

1. can I wrap as layered as original was done here?
or
2. do I need to wrap side/by/side ? (Example: XX|XX|XX) I have room to do either.

Thus making all 3 coils 46.6'

Now last question I know to use 7 wire R/R. But is common connection on coils... Grounded? or is it floated?

This point will make a difference in how I start wrap!

Help Please!!

What is that?... it looks nothing like my stator... ...

Nope....not Savage.  When you start talking lighting coil and charging coil.....you are talking Old School Enduro stuff.

You probably are just better off buying a used one......for whatever it fits if it is a common bike.  If it is from something rare.....then maybe it is worth rewinding - but I know nothing about how to do that.

I know for sure we have had threads on re-winding the savage (consensus- not worth it).

I don't recall who was the expert. I do remember them saying that the Suzuki did all they could with the space allotted. So for a savage, going to a larger gauge, meant fewer windings, which equaled a zero-sum game.  Of course I have no clue how that translates to your bike.

Good luck, its a great looking bike.  

Pine wrote on 08/29/13 at 13:37:24:



Thanks for the compliment on the Bike! Issue was here for years that bikes found here were under 150cc, then it gained to 200 and 250 as they were built here. Import tax on anything else to get here is 300% . Asean being afiliated here with all SE Asia Country and a few over Seas will eliminate this issue, alot of us can't wait! The only way arround this tax was to prove ownership for the last 5 years and show current title/license and Insurance. Then they look at you and ask "And... Why are you here then?" Most Immigration and Customs Officers don't have a clue...

I answer... "I have a Wife and Family here, Anything more?" I ask in Thai and get suprised look on their face... Otherwise they still try to find issue to level a Bill (Fine) to collect more money (Duty) to "Save Face" with their superiors...

I love this Country......

If you find Big Bike you can take USA Price x 2.5 or even 3 and get close to asking price here in Thailand. Example: If I bought Chopper from Orange County for $40,000 USD, here price would be equiv. to $110,000- $120,000 USD! Because they can, not Dealership.. They qwn Bikes They Imported them.. Crazy! So waiting 5 years, paying each year to get required tags. Leaves Money $$$ in your Pocket!



So in the meantime I recycled and created my own!
David

This seems to be an issue at time with everyone, including myself. Someone explain how to boost Amperage and Voltage at lower RPM?

I hve rewrapped My Lighting/Charing coil, going from a single phase rotor to 3 phase. Originally coil was wrapped with 2 coils. Lighting coil was 40.5' in length and Charging coil was 25'. I eliminated the use for the lighting coil as I switched everything to 12VDC. 12VAC only goes to rectifier.

I wrapped coil with 3 seperate coils 35' each. Wrapped them the same as original was done layering them and switching direction of each layer. Now I have a 3-phase stator coil.(3 outputs, all tied together and floated at other ends.) Why is voltage higher (also went from 20ga to 18ga wire)? and Amp gauge now shows 12.5VDC @ 1500 rpm? before I hd to be @ 4000rpm to get even 12.4VDC.

What did I do that corrected my issue, "Charging battery intown driving" Before Voltage was 11.8VDC from idle to 4000 RPM...?

Maybe someone can explain so others having this issue or simular can hve some insight.

I posted a picture of original coils on Stator... Oh... I also went to a 7 wire R/R it has dual red leads and dual ground leads / 3 yellow wire connections...
David

I scorched my insulation just reading that..

davidstipek wrote on 08/29/13 at 00:37:59:


I ended up doing this:
3 coils layered

     />>>>35'>>>>Yellow lead
Soldered   X[/s]<<<<35'<<<<=Yellow lead
               \ >>>>35'>>>>=Yellow lead
Seems to be working great now! Wonder why wasn't strung-up this way in beginning? Maybe Technology not here yet? I can't believe that as Production is always 4-6 years behind development!
David