xs alternator windings

[planedick]

Yeah

Problem is adding wire to the field, not necessary to go bigger, will add a few amps, but to go beyond that is impossible as there is not any room to increase the number of turns or larger wire on the stator. Like Phil told me, "Maybe go from 22 to 25 amps max". Not enough to even bother...... The there's the problem with overcharging as we will lose control of the regulator and it would always overcharge.

[madmax-im]

It would seem to me to be easier just to upgrade to a higher amperage alternator.I have never considered this for my Yamahas' but my other bike has a 28amp alt. and there is an upgrade to a 40 amp alt. that is air cooled...the orig.alt. is oil cooled and can have problems in the summer cuz it has to run a fan to cool the engine...in traffic anyways...and plus I cant run anything like heated grips or extra lighting or heated clothing....

[Dennyz]

There was mention of the XJ alternator. What does it put out?

[TopCatGr58]

The XJ alt is rated at 26 Amp @ 5K rpm, per the Manual Appendices! ~25 Amps at 3500rpm, only 10Amps at 1K rpm!
T.C.

Yeah, I like the idea of putting on a new small auto type self contained reg/rect unit instead, either removing the Rotor and finding a way of putting in on the end of the shaft, or mounting a pulley system!?

[HobbyMan]

I would also like to put another alternator on my bike but I also like the looks of the stock engine case.

[GNEPIG]

You get 12v constant to the field coil(exciter), the regulator controls the ground to the field coil.
The green wire is a ground for the exciter(field coil) that is controled by the regulator. The regulator opens and closes this ground depending on the state of charge that your battery is in or the load applied on your electrical system.

If someone with access to a CnC machine, made a larger stator housing and adapter plate, then someone else could fill it with more windings.

Keep thinkin about it Hobbyman, this is good stuff.

[Dennyz]

It might sound a bit goofy, but what about driving an alternator off the middle drive (some how). You would only be charging while moving, but that is not much different than what the stock system does.

Making a bigger side case housing would be spendy (billet).

Sticking a small alternator under the carbs and running a belt might also work. It definitely change the looks of the motor on the right side.

Just think'n out loud.

[AlanB]

Hi Guys,

I think that MathH's Turbo bike runs a piggy-back alternator with a belt drive........ Anyone got pics?

AlanB

[HobbyMan]

What about using flat wire to rewind the stator? If you draw the space that the coils go through, flat wire should allow a heavier gauge and more turns. The only problem is actually getting flat enamel wire. I don't know where to look.

[TopCatGr58]

A slight Monkey Wrench?

I was pondering this mod, and then realized that "we" would have to get a different type of Tachometer IF we put on a different/aftermarket auto alt, since the tach feeds off of the XS's Alt for signal pulses/counts!

SO..... what Hobbyman is trying to do would be better in that we wouldn't have to put on a different tach. But like has been stated, limits to space for windings could lead to more $$ spent on the extra sized housing along with the cost of doing the windings?? Might be much more $$ than the cost of a tach?
T.C.

[planedick]

Flat wire...

Flat wire is available in the transformer industry. I have a couple of customers that I have made winding equipment for that uses it in larger transformers, but I don't know in what guages it is available in. In order to get more windings on the stator one would have to recut the laminates to allow a higher density of wire which is way to expensive for the few we are looking at. If we were to have a need for thousands of them it might be worth it. The laminates are the core of the stator that the wire is wound around. I have been to all the experts in the field and that is what I've learned. The project is not impossible, just very expensive.....

[Pat Kelly]

What do other bikes (besides the XJ) use? Anything that can be adapted to the XS/XJ engine?

[TopCatGr58]

Hey Pat,

I think you're asking about the other bikes ALTs, vs. tachs!
I looked at the Microfiche, and the FJ's use what appears to be a self contained generator that fits onto the end of the crankshaft, but not sure of it's mounting? The Viragos and the V-4 engines used similar type windings and rotor design, but looks like brushes like the XJ. I couldn't find any service/spec pages to see how many AMPs they provide?

I know WildKat has an FJ, she might know how many AMPs, or have a manual that provides that info, along with how it's mounted to the engine, on the crank shaft, or separately?
T.C.

[HobbyMan]

I know anything is possible. NASA proved that long ago by going to the moon. My goal is to prove that a 19yr old on a limited budget can do it.
On another not, I will not be able to perform the alternator tests that I wanted to do over spring break. I was recruited to sail at the Farr 40 acura cup(prerequisite to Farr 40 worlds) over spring break. It is in Miami and they are footing the bill. Some guy donated almost 1/4 mill dollars to bring our team down

[GNEPIG]

The only right side pics that I have saved of Mathh's bike. Not sure what kind of alt he is using but it has to be small.






The FJ's alt sits on top of the transmission right behind the cylinders and faces to the left. It is driven from the middle of the trans/ engine somewhere. There is a casting where it plugs into the top of the cases.