Cr500 Stator Requests

[KMS]

Thanks for the pics! I was very curious to see how 200 watts came to be on this particular stator...answer = external coil system. Allows for great coil "real estate" yet keep a flywheel diameter relatively small, thus having minor effect on crankshaft inertia.

 

[adamd1979]

Not really interested in running lights for my cr500, but I would like to have a way to feed power to my trailtech voyager computer that I got for my 4 stroke last season. Had a service honda stator that came with the bike, but hated how it was a pain to start. The guys at trailtech said that the batt on the comp would last a while, but I've not heard from anyone that runs one if it would last all day in the cold with the gps running. Has anyone ran these on there bikes all day without power from a separate battery?

 

[summitboy]

I was just talking with Adam Millar from Millar Racing. He said he may be able to offer a higher output stator for the 500 using Honda parts. Trying to get a wattage and a price. May be a reliable solution.

 

[M5-]

Ahhh. The elusive holy grail....

M5

 

[summitboy]

Millar tells me the output will be around the 110 watts. Factory Honda parts.

 

[wwillf01]

I can tell you this a larger and lower output ones are being tested for the cr500 as we speak from a stator manufacturer in the usa... hopefully we will see something to buy soon

 

[summitboy]

Hopefully they aren't using Electrosport parts as some do. Kinda junky. Eline

 

[wwillf01]

Nope

 

[M5-]

any more info on this, power is moving its way up my CR500 task list?

M5

 

[street500]

The KTM heater is 20 watts. Doesn't work. The Service Honda is a pile of junk. The stator burnt up on me within a couple weeks. The stator melted and the windings unraveled. The ignition seemed to work fine but the rabbit kick is a dumb idea and a pain in the ***. Especially when you are starting a 500 cold.

The Honda/Eline/Baja Designs is a true 200 watt external stator. Like i said Honda made this part oem in 2001 for the Australian CR500E. Then Eline copied it with a fancy machined cover. You bolt another smaller flywheel to the stocker. The left case cover is a little wider than a stock piece. The Eline consists of two separate 100watt windings. The windings are super thick, not like this new gen stuff with the thin wire in it. I notice no power loss with this stator. So you have the stock Honda stator for the ignition and the Eline for all your goodies. The Eline is the bomb.

The Eline was 439.00 US back in 2004. Now to find one less than 1000 is pretty tough. I know of 3 Elines for sale. 2 of them are brand new ! To make a stator like this now would cost upwards of 700 bucks, not cheap. I bought mine for 650.00 bucks last year !

I know this is an ancient thread but I had to revive it.

I recently acquired a CR500R with this attached to it:

Does anyone know how it is wired up? I am not sure if I get its true potential, as my headlights run really dim at idle (55 watt).

How to test or measure it, and should I rewire it?

 

[summitboy]

So these eline stators are two separate 100watt windings. 2 wires per coil. Not sure what kind of regulator u have there. The reg gives u DC power. I would need some close up pics of the wiring to see what u have. I believe i have a diagram for that unit somewhere. I get back home from Lacrosse Provincials on Monday and can help u out then. Is there a battery in the system ?

In my setup i use one coil with a battery. I run heted grips, helmet light, gps. No issues. I may run the second coil in mine to another regulator. 2 regs and a battery. Not sure its needed. Your setup is the best power setup for the CR500. Nothing is better.

 

[street500]

So these eline stators are two separate 100watt windings. 2 wires per coil. Not sure what kind of regulator u have there. The reg gives u DC power. I would need some close up pics of the wiring to see what u have. I believe i have a diagram for that unit somewhere. I get back home from Lacrosse Provincials on Monday and can help u out then. Is there a battery in the system ?

In my setup i use one coil with a battery. I run heated grips, helmet light, gps. No issues. I may run the second coil in mine to another regulator. 2 regs and a battery. Not sure its needed. Your setup is the best power setup for the CR500. Nothing is better.

The battery is all taped up and measures around 6 volt.
When I have the bike on idle and hit the throttle the battery voltage fluctuates between 6 and 14 volts.

I should probably buy a new battery, but which? Where do I stow it?
There is limited space with KN filter, and I want to remove the cloth bag that holds the battery now. (located on the back plastic)

Its good to hear there is hope for my system.
I will get you some better pics when I wake up, its 4 am here now and I am endlessly searching for CR mods, time to sleep.

Where should I aim the camera ?

 

[street500]

I have now dug into the black silicon and see three wires.

The blue is connected to one stator wire.
The brown is connected to one stator wire.
The yellow & green is connected to two stator wires.

One of the two wires that runs to the yellow & green has snapped of, dont know if that was because of me digging or if it was like that.

It is kind of hard to see the yellow & green wire, but I have zoomed in on it in the second picture.

What I am now asking is, how is this wired?
And if you cannot see it by the pictures, how can I measure it so it would be clear?

 

[summitboy]

Here is mine. Mine is a Honda. It has two yellows, a red, a black. each wire goes to a end of each of the two coils. From what i remember just test two wires for resistance and when you find each end you will see a completed circuit with roughly 0.4ohms. That will be one coil. Clear as mud ?

 

[street500]

Clear clear.

When I measure from blue to yellow & green it reads 0.4 ohm.
And from brown to the loose wire i also get 0.4 ohm.

blue has one stator wire
yellow & green has two
brown has one

so mine is then like this:

blue-stator wire-yellow&green-stator wire-brown

So it is the same stator as you have, but why is mine hooked up this way?
And what is the best way to harness all the powah?

Thanks for answering summitboy you are the absolute authority on this matter.

 

[street500]

 

[summitboy]

Its the same. Mine is a Honda and yours is ELINE. Yours is a 3 wire i believe out of the housing ? Mine is 4. I have the manual for your eline. Maybe i will try and post them when i get a chance. For my setup i would need two seperate voltage regulators. The manual states use one red and a yellow to volt reg. If you need the other coil u would require another reg as well. I only use one bank of 100w on my system. If i snowbike again next year i have another volt reg and will add the second coil into the system. I believe there were actually 3 companies. Honda made the original stator (Australian CR500E). Eline came along and copied it. Then Baja Designs also got a hold of it as well and sold them. Lots wish they still made them but there is 0 money in it as the stators came from Italy originally and the parts are to expensive hence the 1000 dollar price tags on them now. Nothing beats them for power. Nothing. They can be easily rebuilt.

 

[needpowder]

"If" you snowbike again next year?!?!?

 

[street500]

Yes I have 3 wires out of the housing, but it does not look "stock".
There is bad soldering and black silicon all over the place, and the brackets that the wires are connected to on your picture is destroyed and just bits and pieces are here and there.

How do you distinguish ELINE from Honda?
What does the Honda look like on the outside, and the magnet rotor?



I have found replacement stator and magnet rotor for 300$.
The magnet rotor has fins on it that needs to be turned to fit the case.

 

[street500]

I would very much like the wiring diagram.