Rotor Winding Tooling

Use of the term “fine tune” in relation to XS650 engine vibration is NOT approved.

Tee hee!
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Last bit of tooling.... I swear...

OK... this bit isn't really necessary, but I did it anyway. I picked up a 12V 5A power supply. Fastened it to the timing mark checker....

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On the side of it I attached a .010" feeler gauge....

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Rigged up a probe of sorts and when you touch the probe to the two slip rings, it pulls the feeler onto the rotor. Voila... magnetism. These are actually pretty strong little rotors. I held an 11/16" combination wrench (that weighs a half a pound) about an inch away from it and it snatched it out of my hand. Kinda startled me... :yikes:

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I'm gonna make a proper probe for it and add a switch. The main reason I did this so I can try to get an idea of the longevity. I'm going to take the out of round rotor and run it along the lines of 2 hrs. on... 15 min. off and then back on again.... simulate a cross country. 100 miles, stop for gas and a pee, 100 miles... gas and pee.... 100 miles.... We'll see how it does.
 
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When you switch off the current to the rotor there will be an induced reverse current. My experience with energizing my rotor last year showed that the power should be switched off rather than remove the contacts from the slip rings. Removing the wires from the rings caused small arc burns on the copper. Also, you may need to fit a diode across the power supply to protect against induced voltage spikes. But .....

.... I am guessing you have though off this because you mention about adding a switch.
 
I can now....
15 bucks at Amazon. Gets great reviews.

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Jim I wish I could remember what the company I worked for paid for the non-contact thermometer many years ago! I have to think it was somewhere north of $500.00 maybe closer to $1,000.00. I have though about one like your's or the ones Harbor Fright sells for around that same price. At those prices if it only works for a couple projects it would be worth the price.

How about a link to that one so we can get one too?
 
.....aaaaannnnnddddddd.....<drum roll please>............coming soon to a cranky old 1976 XS650C near you.....

TA DA!!! one of the very first production JimRotors.

I received the rotor, very carefully packaged, the other day and have finally unboxed it. All I can say is - wow - this is craftsmanship.
What a beautifully re-made part. Every surface is clean as a whistle, the epoxy potting is neat and tidy and the tiny winding connections are perfect.

I can't wait to get out into the DCW and install it on Lucille. I will report once that task is at-hand with photos and a description of the install.
Thanks Jim!
Pete

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How about a link to that one so we can get one too?
Here ya go Ken.

I'm writing up the ad for the rewinds right now. Just went through this thread to see if I missed anything, so.... a few clarifications....
I'm using JB Weld to epoxy the coils in. At a 500° rating, it should work just fine. The original epoxy I wanted to use turned out to be more like a potting compound... more of a rubbery substance. I decided not to risk it at the centrifugal forces we'll be pulling with these rotors.

Also not mentioned yet, when all testing is done, I give the rotor 2 coats of hi-temp clear paint. Of course.... my OCD affliction forced me to make a special tool to protect the rotors taper....:rolleyes:

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Here ya go Ken.

I'm writing up the ad for the rewinds right now. Just went through this thread to see if I missed anything, so.... a few clarifications....
I'm using JB Weld to epoxy the coils in. At a 500° rating, it should work just fine. The original epoxy I wanted to use turned out to be more like a potting compound... more of a rubbery substance. I decided not to risk it at the centrifugal forces we'll be pulling with these rotors.

Also not mentioned yet, when all testing is done, I give the rotor 2 coats of hi-temp clear paint. Of course.... my OCD affliction forced me to make a special tool to protect the rotors taper....:rolleyes:

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YUP - and that OCD approach to every single teeny tiny thing is evident everywhere on the actual part folks.

If you need an alternator rotor to get / keep your XS650 running.....see Jim about it.

Pete
 
Hey now! That’s super nice! Pete you lucky duck!
Great work Jim, after all the effort you put into this, it’s nice to see you going into production.
Pete, does yours have the Band of Brothers logo? :cool:
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Oh yes - its right there but its very teeny tiny.....;)
 
Jim what was the temperature of the rotor after full fielding it for 2 hours?
Just a thought you might want to use a power supply that can be adjusted to 15 volts and see what the temp is then. Something else that might be interesting is to check amp flow on yours compared to OEM.
 
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