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Discussion Starter #1 (Edited)
Ok so i was driving home and thinking.....what is the biggest flaw on our bike.... the charging system. and yes, frankenstator is here, but its nothing but a bandaid.

What if there was a way that the electrical system could be modified to produce more then enough juice (looking in the 60amp range, and no idle issues), and what if it was as reliable as your cars?

how much would it be worth to you.... i havent put this past just being a thought, but i think i may be able to pull it off. it will be a at least 60% revamp of the charging system, and maybe a complete replacement. i am thinking it may sit around the 500-1000 mark. there will need to be quite a bit of machining. which btw i would like to talk to someone one with access to these tools. i think i may have a permanet solution.

not making this sound like i am trying to milk ya'll, i am asking to decide if i should persue it cause it would cost quite a bit in R&D
 

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personal i havent had a problem with the charging system in 18years of use exept when the +ve terminal on my r/r coroded out early on, I had an r/r from a z750 so replaced it with that, no problem since. but I had also relaced the std. exhaust for straight throughs so this could have helped to(less heat). also on the uk model the headlight is only on when you want it(seporate switch) so less load.(or would that make the r/r get hotter)?
 

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Ok so i was driving home and thinking.....what is the biggest flaw on our bike.... the charging system. and yes, frankenstator is here, but its nothing but a bandaid.

What if there was a way that the electrical system could be modified to produce more then enough juice (looking in the 60amp range, and no idle issues), and what if it was as reliable as your cars?

how much would it be worth to you.... i havent put this past just being a thought, but i think i may be able to pull it off. it will be a at least 60% revamp of the charging system, and maybe a complete replacement. i am thinking it may sit around the 500-1000 mark. there will need to be quite a bit of machining. which btw i would like to talk to someone one with access to these tools. i think i may have a permanet solution.

not making this sound like i am trying to milk ya'll, i am asking to decide if i should persue it cause it would cost quite a bit in R&D
hizzo, I am a machinist / welder. if you have questions drop me a note.

Stan
 

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and the Adventure Cycle
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If you're still thinking of a water (or was it oil) cooled stator cover, have ya considered a casting instead of all machined?
Just a thought.
 

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Hizzo, you are infatuated with your stator to much. Just mount a oil cooler in front of the radiator, fill with a good full syn and ride not wrench. Seriously, have you researched a oiler cooler set up with a different fan that would draw less amps than the factory one?(first sentence is in jest)
 

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Discussion Starter #6
i have looked into the oil cooled set up.... and i do like it, and if my frankenstator still doesnt hold up i may consider going through and installing it... i will also be taking oil temp readlings to see if i should install that.....


but i am onto something much bigger and better..... i got to thinking, how could the system be almost cured, and boosted at the same time.... I keep leaning back to a cars alternator set up.... now granted, we cant take a car alternator and just bolt it up very easy, but what if we could redesign the flywheel to where instead of permanet magnets, it had electromagnets....then the system would be truely regulated, over just being trimmed. but i kept thinking on how the brushes would have trouble in the oil...... but i think i have come up with a solution to this.... anyone familiar with single wire, or one wire alternators? we could use this principal to replace the flywheel. if we cant bring the alternator to the bike, then we will make our own ;).

my primary purpose of doing this is to help modernize the bike, and make it much more reliable.... right now, the only issue that i can see in reliablity that is a ticking time bomb, is the stator. plus, wouldnt you love 40-80 AMPS of juice (480-960 watts.....)... and if you could pay 500- 700 bucks to replace the whole charging system, and knowing it will last as long if not longer then a car alternator, wouldnt you jump at it? (we are talking about 100k+ possiable on one system, which is cheaper then 5 stators anyway)
 

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and the Adventure Cycle
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Sounds like a great idea.

I don't know much about alternators, so what does the one wire type do that would make it a better candidate for a mod like this?

If it were to be done, does any oil need to introduced into the area previously occupied by the stator then?

Glad someone here knows enough about electronics to be thinkin' of stuff like this!! Keep it up Hizzo !!
 

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Discussion Starter #8
Sounds like a great idea.

I don't know much about alternators, so what does the one wire type do that would make it a better candidate for a mod like this?

If it were to be done, does any oil need to introduced into the area previously occupied by the stator then?

Glad someone here knows enough about electronics to be thinkin' of stuff like this!! Keep it up Hizzo !!

instead of having the alternator having a communicator with sections (making it alternate) there is iron peices that bend the magnetic field. that means that the brushes last longer.... oil will still be needed to lub the cam chain and so on.... it will also help keep the system cool as it wont run anywhere near as hot.... i will try and scan in a drawling tonight....
 

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Discussion Starter #9 (Edited)

This is an overview of the entire system



this is one method, this would replace the magnets inside the rotor.



this is another method of doing the rotor... this would replace the magnets in there now,

hope this helps visulize the system. the voltage comming from the commuinicator dictates the rotors magnetic strength.... as less juice is needed, less voltage is used. same principal as a cars alternator.... this system will only produce what is needed, a very small regulator is needed to control the rotor's voltage, very little is burned off. Minimal heat, but still high great materials will be used to maximize the unit....
 
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