How bad is this?

[jojob]

Pulled the flywheel off, and this is what I found. How bad is it? Is there a way to fix it, or am I stuck buying a new one? Any ideas are greatly appreciated. Do I need the coil for the bike to actually run? This is for a 1976 GT 500

[tz375]

That looks bad. I believe those are the two battery charging coils which you will need to run lights, horn etc. I think that the third coil at 5 o'clock is the ignition coil.

Look for one on ebay or see if you can get new coils and if all else fails they can be rewound. I have had coils rewound in Australia and by Kevin Mayer in Colorado. There are probably others. It can be done.

[dollydog]

looks like somebody screwed the rotor extractor bolts in too far d'oh!
cheers, dd.

[jojob]

I'm assuming that I can't just solder the wires together, huh?

[dollydog]

no mate, they won't work, file them in the bin or get them rewound?
cheers, dd.

[sportston]

I'm assuming that I can't just solder the wires together, huh?

Not likely to work unless you can ensure that that each wire is insulated from those around it.
+1 on the get it rewound or find a usable replacement

[dorT500]

Figuring out electrical problems is not my strong suit but I would think continuity and a certain resistance measured in ohms determines if a used one you might come across is bad or on it's way out. Maybe others will chime in on that. I don't know if the GT500 service manual shows how to test them. Good Luck on whatever you decide.....as you know by now, the price of those coils available from Suzuki is enough to ruin your day....maybe a few days.

This must be the company (Kevin Mayer) member tz375 was referring to about rewinding them.

http://www.mayers-mc.com/services/elect ... ecialists/" onclick="window.open(this.href);return false;" onclick="window.open(this.href);return false;"

[tz375]

Correct. Kevin wound a TZ250 stator coil for me a few years ago and did and excellent job.

[jabcb]

There is only one magneto stator listed on eBay & its got the same problem as yours.

Mine has some sort of silicon sealant repair on the CDI coils + one of the charging coils has a loose winding. Some duct tape was used on the wiring on the back side of the mounting plate.

Rats!

[sportston]

If you want hours of fiddly fun, you could rewind them yourself quite cheaply. Get the right gauge winding wire, count the number of old windings and make sure you wind new wire on neatly, tightly and carefully with the same amount of turns. Don't forget to scrape off the varnish from the ends when you solder them.
Sounds simple, but can be quite time-consuming and tricky.

[dorT500]

I am really getting curious now how much it would cost for each coil. Seems like it would only take a few minutes each, after set up, if the same size wire is used throughout each coil winding and with the machines I have been seeing.

Here is another company, in Australia.

https://www.smallcoilrewinds.com.au/ind ... ng-service" onclick="window.open(this.href);return false;" onclick="window.open(this.href);return false;


50 Edols Street, Geelong North, Victoria 3215, Australia.
Phone:- +61 3 5278 8454

Email:- enquiry@smallcoilrewinds.com.au

[sportston]

I am really getting curious now how much it would cost for each coil. Seems like it would only take a few minutes each, after set up, if the same size wire is used throughout each coil winding and with the machines I have been seeing.

The reels of winding cable I have last for years unless you do a lot of rewinds. But rewinding without the benefit of machinery is a pain in the bum. The problem is to get the windings tight enough by hand and then wrapping or glueing them in place so they don't spring back as soon as you let go.
I'm sure there are proper ways to do this, but I've never been shown how to do it without fingers slipping and several expletives uttered every few minutes or so. Please note, I do not claim to be an expert at this!
Last time I did it I made up a little tool to help from plywood that worked a little like a reel to reel tape player. the rotator shafts need to be a tight fit to keep the tension. You also need a couple of marks on the winding shaft so you can count how many turns you have done as it rotates.
I suggest you don't attempt to use a cordless drill to rotate it, as it is too fast. Use a hand crank instead.

[dorT500]

I was just curious how much the companies above would charge member jojob to rewind all those coils for him. It may be surprisingly less than expected. If I were him I would contact that company in Australia and the other one......compare prices, consider shipping costs.....it's bound to be a lot less than $300-$400US for four or five coils from Suzuki.

[joolstacho]

Ignition alternator coil is available from Rex's by the look of it, I'd enquire with them re lighting/charging coils too.

http://www.rexs-speedshop.com/epages/es ... Stators%22" onclick="window.open(this.href);return false;