Installing more than one lighting coil.

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Installing more than one lighting coil.

Postby Brian » 05:57 am Jun 21 2012

I realize the stock stator plate will only mount one lighting coil but I was wondering how big a deal it would be for someone with machine skills to make a stator plate that would accomodate two lighting coils along with the ignition coil.

Would that be do able? It might be a way to get more lighting power instead of squeezing in a few more windings on the stock lighting coil.

Just thinkin' out loud.
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Postby canyncarvr » 11:24 am Jun 21 2012

Doable?


Why not? Happens all the time.

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Didn't find an output rating of the above (cursory search)..but similar units are advertised at 250W.

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Postby SS109 » 02:27 pm Jun 21 2012

The hard part would probably getting it timed correctly. I tried looking for an SR stator setup but haven't been able to locate one yet.
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Postby pumpguy » 06:42 pm Jun 21 2012

A while back I contacted a dealer in Australia asking about this same thing. He replied with a quote for a multi coil stator like the one shown. As I recall, the price was in the $500 region.

Back in the day, using 2 lighting coils in parallel was common in Villiers, BSA Bantam, Harley Hummer, etc. two strokes. Cushman also used 2 lighting coils in parallel for their scooter engines. I'm sure some internet research would provide lots of detail.

I haven't taken the flywheel off my 97 KDX 200 yet, but from pictures I've seen, I would think there's room for an additional lighting coil. Obviously, a special stator plate would have to be made up.

Regarding ignition timing, in the days of breaker points it was a simple matter to use a dial indicator to measure piston travel and some cigarette paper or a continuity tester to tell when the points opened and that was when the spark occurred.

Today, I would think a battery powered timing light and a degree wheel mounted on the flywheel would be a good way to check ignition timing. I have thought about graduating the rim of the flywheel with degree marks. Of course the engine would have to be spinning for this to work.
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Postby diymirage » 03:45 pm Jun 22 2012

would it be worth all the extra effort over rewinding the stock stator?
if i remember correctly, the rewound stock unit will put out a good 100 watt
the multi coil shown about is listed at 250 but how much do you really need ?
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Postby rbates9 » 04:06 pm Jun 22 2012

diymirage wrote:would it be worth all the extra effort over rewinding the stock stator?
if i remember correctly, the rewound stock unit will put out a good 100 watt
the multi coil shown about is listed at 250 but how much do you really need ?



As much as you can get! :wink:
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Postby SS109 » 05:13 pm Jun 22 2012

diymirage wrote:...but how much do you really need ?

If you like night riding then you need every watt you can get! Night riding at night requires some pretty big lights to not get yourself killed. Of course, there are some really nice low power consumption LED lights out now but they are not cheap. Probably a wash when all considered.
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Postby diymirage » 05:39 pm Jun 22 2012

SS109 wrote:
diymirage wrote:...but how much do you really need ?

If you like night riding then you need every watt you can get! Night riding at night requires some pretty big lights to not get yourself killed. Of course, there are some really nice low power consumption LED lights out now but they are not cheap. Probably a wash when all considered.


as opposed to night riding on my lunch break ? :wink:

maybe its because most of my night riding is limited to city streets where there is decent lighting anyway but shouldnt a 75 waat headlight cover it ?
on 100 watt stator that would leave 25 for a tail/brake light and turn signals (if you choose to run those)

seems plenty to me

and yes, the LEDs do look cool but i dont think id care to pay for it
(i have tried running LED foglight bulbs in the KDX as a headlight and they did allright but no reall improvement over stock)
not too mention they dont stand up to off road riding
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Postby SS109 » 06:38 pm Jun 22 2012

I am talking about night riding off road. Think about how hard it is to ride on single track when it gets dark. You need awesome lighting for that! As for the LED lights I'm talking about, they aren't the cheapies. I'm talking about ones like these: https://www.rigidindustries.com/category-s/129.htm

Image

I think two these mounted up front would be perfect for night riding and only draw 25.5 watts each. The only problem is the $300 price tag! :shock:
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Postby Brian » 07:12 pm Jun 22 2012

I'm not sure if the stock stator can be wound to put out 100 watts but I think it can get close. If your running thin enough wire to get enough windings for the increased wattage I think you are putting the stator at it's limit which may make it more prone to failure if you actually use it's maximum output on a regular basis.

If you can install two lighting coils you might be able to get enough extra lighting power to run a high output headlight, or several lights, or even a headlight and electric gloves/vest.

Just say'n stuff (brainstorming) :mrgreen:

Extra wattage gives you more options.
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Postby SS109 » 09:30 pm Jun 22 2012

Brian wrote:I'm not sure if the stock stator can be wound to put out 100 watts...

Yes, it can! Member Slick Nick has proven that you can get 100 watts by rewinding the stator. Check the "Best of the Best Mods" stickied thread for the details.
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Postby Brian » 01:05 am Jun 23 2012

I read that post (and watched the You Tube video) and it seems to me that there was some question about that being the true output. With so much "back and fourth" between posts I could never really figure out if that was the correct output or not. Either way, it would be cool to mount two of them under the cover. Two hundred watts could power quite a bit of light.

Since you mentioned Slick Nick...I wonder how those bearings are holding up? :lol:
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Postby Slick_Nick » 07:11 am Jun 23 2012

Read the final "results" post I made in that thread. Iirc, I tested ot to 103W at a "normal cruising RPM"
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Postby the machinist » 03:59 pm Jun 24 2012

Brian wrote:I realize the stock stator plate will only mount one lighting coil but I was wondering how big a deal it would be for someone with machine skills to make a stator plate that would accomodate two lighting coils along with the ignition coil.

Would that be do able? It might be a way to get more lighting power instead of squeezing in a few more windings on the stock lighting coil.

Just thinkin' out loud.

I would be willing to take on this project if you could provide the needed pieces. I will do this at our shop free of charge and document the results on this site. I'm also just up the road from Trail Tech, I think the would be down to help.
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Postby SS109 » 04:35 pm Jun 24 2012

Two stock coils would only give you 70-80 watts max and quite a bit less at idle. So, you would still need to rewind them for higher output so why bother when one rewound stator can put out more than two stock ones. So, the only other option would be to adapt a radial stator to the KDX like the one canyncarvr posted earlier. Now that could be interesting.
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Postby Brian » 11:44 pm Jun 24 2012

by SS109 » 01:35 pm Jun 24 2012

Two stock coils would only give you 70-80 watts max and quite a bit less at idle. So, you would still need to rewind them for higher output so why bother when one rewound stator can put out more than two stock ones.


The whole point is more lighting options. Two stock lighting coils might be more reliable that an equivilant rewound coil. Or maybe two rewound coils for the 200 watts of lighting power. Just say'n.
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Postby SS109 » 12:52 am Jun 25 2012

Brian wrote:
by SS109 » 01:35 pm Jun 24 2012

Two stock coils would only give you 70-80 watts max and quite a bit less at idle. So, you would still need to rewind them for higher output so why bother when one rewound stator can put out more than two stock ones.


The whole point is more lighting options. Two stock lighting coils might be more reliable that an equivilant rewound coil. Or maybe two rewound coils for the 200 watts of lighting power. Just say'n.

My whole point is that having a custom stator plate made to hold two stock coils just isn't worth it (cost and/or time wise) when rewound stators have proven just as reliable as the stock coils. However, if you have the time, the tools, and the know how, why not? Go for it! I always like seeing someone push ahead with new and different mods.
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Postby gregp » 02:57 pm Jun 27 2012

I just rewound my stock lighting coil this past weekend. I used 18 gauge magnet wire, and it worked great! It was very easy to do, and took about an hour. I am not running a 35/35w headlight, a standard 1157 tail/brake light bulb, 2 LED directionals up front, and 2 - 7 watt rear directionals, plus a 12v horn - all with no battery.
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Re: Installing more than one lighting coil.

Postby pumpguy » 03:25 pm Jun 27 2012

Can you tell us the length of wire and the number of turns you used?
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Postby diymirage » 04:12 pm Jun 27 2012

gregp wrote:I just rewound my stock lighting coil this past weekend. I used 18 gauge magnet wire, and it worked great! It was very easy to do, and took about an hour. I am not running a 35/35w headlight, a standard 1157 tail/brake light bulb, 2 LED directionals up front, and 2 - 7 watt rear directionals, plus a 12v horn - all with no battery.


yes, but can you tell us what you ARE running ?
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