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Rotor Winding Tooling

Discussion in 'The Garage' started by Jim, Jul 22, 2018.

  1. kshansen

    kshansen XS650 Junkie Top Contributor

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    Nice guy !:mad: You must have bought the last one. "Not in Stock: is what I get with that link. They do have a "Let me know when next box shows up" option on that page so I put in my email address!
     
    gggGary and Jim like this.
  2. Jim

    Jim The thrill of victory and da agony of da feet. Top Contributor XS650.com Supporter

    Sorry.... :(
     
    gggGary likes this.
  3. kshansen

    kshansen XS650 Junkie Top Contributor

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    That's OK at least I should be getting a fresh off the presses one not a day old one!
     
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  4. gggGary

    gggGary Stop that! Top Contributor XS650.com Supporter

    Seems like some sort of Canadian affection going on here... a bit odd??
     
    MaxPete and Jim like this.
  5. Superjet

    Superjet XS650 Junkie Top Contributor XS650.com Supporter

    Great work Jim with all your tooling, hard work and dedication to the XS community! :cheers:
     
    TwoManyXS1Bs, MaxPete and Jim like this.
  6. Jim

    Jim The thrill of victory and da agony of da feet. Top Contributor XS650.com Supporter

    At the1hr. mark I stopped the test to do a quick video. Was at 137° F when I stopped. Power sup. maxes out at 14v. Amps on test rotor was about 2.5..... right about where Ohms Law says it should be. Here's the video...

     
    Last edited: Mar 15, 2019
    GLJ, TwoManyXS1Bs, MaxPete and 2 others like this.
  7. Superjet

    Superjet XS650 Junkie Top Contributor XS650.com Supporter

    Nice info on the copper rings and tci magnet!
     
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  8. Jim

    Jim The thrill of victory and da agony of da feet. Top Contributor XS650.com Supporter

    OK... so first 2hr. run at 14v.... 160°F on the sides and 139° on the slip rings. It pretty much stabilized after a little over an hour.
    15 min. gas and pee cool down temp is 135° on the sides and 116° on the rings.
    Back on the road for another 100mi.
    Read the directions on the temp gun. :rolleyes: Temp in video is prolly not accurate.:confused:
     
  9. MaxPete

    MaxPete Life with Lucille...I suggest, she decides. Top Contributor XS650.com Supporter

    Very cool....errrr, I mean warm.
     
    Jim likes this.
  10. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Good on the heat test, Jim.
    Thinkin' out loud here.

    From ambient to full heat, about a 100°F differential.
    That's in an open environment.

    On the bike, enclosed environment, summertime, somewhere about 230°F.
    Add the 100°F differential, gets 330°F.
    (Not an exact science, just diddlin')
    It's within temp range for the epoxy.

    Calculate the increased resistance of the coil.
    I think you can add the resistance differential, plus a bit of fudge.
    What was that? 5.2 ohms up to 6.5 ohms? Added 1.3 ohms?
    Fudge it up to 1.5 ohms, add to that 6.5 ohms, gets 8.0 ohms?
    At 14v, 8.0 ohms, gets 25 watts,
    down from initial cold values of 14v, 5.2 ohms, 38 watts.
    25/38 = 65% of cold value?

    Worst case stuff.
    If charging system isn't fully taxed, expect lower temps, lower resistance...
     
    Jim and MaxPete like this.
  11. kshansen

    kshansen XS650 Junkie Top Contributor

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    I'm thinking that unless your battery is almost dead when you start the ride the load on the rotor windings should start dropping off after a few miles. Or at least if I'm thinking right this morning!
     
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  12. GLJ

    GLJ Ran through life like my hair was on fire 650 time Top Contributor

    You are correct. He's testing worst case scenario.
     
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  13. kshansen

    kshansen XS650 Junkie Top Contributor

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    You mean just on the chance I was to buy one of those rotors?

    But then the xs650 I used to pull the sidecar I rode to work for many years ran as a total loss electrical system! Had a small car battery in the sidecar and when signals started getting slow I'd put it on the charger over night and be good a several more weeks!
     
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  14. MaxPete

    MaxPete Life with Lucille...I suggest, she decides. Top Contributor XS650.com Supporter

    But Ken, that would be risky if you went out with a lady on a dark rainy night in the country....:rolleyes:;)

    DAMHIK.
     
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  15. kshansen

    kshansen XS650 Junkie Top Contributor

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    That's what I have the Sportster with a sidecar for! The 650 with sidecar was just to go back and forth to work about a one mile run one way.
     
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  16. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Dunno why, but I have this image in my head of a special button on the handlebar, a bottle of liquid nitrogen, and a nozzle aimed at the rotor.

    "Jim's booster mod"...
     
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  17. MaxPete

    MaxPete Life with Lucille...I suggest, she decides. Top Contributor XS650.com Supporter

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  18. Jim

    Jim The thrill of victory and da agony of da feet. Top Contributor XS650.com Supporter

    Just finished a 10hr. continuous burn on the rotor. Started this morning at 67° and 5.1 ohms.... Rose to 157° in about an hr. Never changed after that. As soon as I terminated the test, coil was at 6.7 ohms. I think the only way for an honest longevity test.... is to just use the damn things.
     
  19. GLJ

    GLJ Ran through life like my hair was on fire 650 time Top Contributor

    Yes time is the final judge.
    Now quite whining about the weather and go out and put a few thousand miles on one.;)
     
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  20. kshansen

    kshansen XS650 Junkie Top Contributor

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    Well as the last new one Yamaha installed is about 36 years old so we'll be checking back in 2055 to see how it's holding up.
    That only make me 105 so just maybe?????
     
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