1966 CT200 stator rewind help

[Stevepasc]

Rebuilding the engine on a 1966 CT200 trail 90. While disassembling the stator area was full of oil contaminated with water (bike had sat outside for ~5 years before I got it) and the stator was all rusty and the insulation on the wires was cracking and falling off…

https://imgur.com/a/loh8KZ5

I looked on eBay and there were other stators in similar condition for $80-$140 but they all looked in pretty bad shape. They had a N.O.S. One for $200 plus shipping from Thailand.

I found this post on a ct90 & ct110 forum where somebody went over rewinding the coils on a ct90 stator:

https://www.tapatalk.com/groups/hondatrailcts/stator-rewind-t13985.html

I know the CT90 is slightly different then the CT200 so I used this as a starting off point, and I busted out the micrometer and measured the wires on the coils, it was roughly 21awg and 20awg (instead of the 18awg and 22 awg mentioned in the thread I found)



I soaked the stator in acetone and scraped all the old potting compound off the coils, then I sat down, started taking notes, drew up a diagram and started unwinding the coils, counting the number of winds, and the orientation of the windings and how they went from one core to the next. My stator had 150 windings on the 20awg wire coils and 200 on the 21awg coils, different from the 150/170 windings on the stator in the post. I saved the little rubber grommet and the wires that connect to the stator and lead out to the rest of the bike to reuse, stripped everything off the stator core, cleaned it up with a wire wheel to remove all rust and debris, and am ready to start applying potting compound to the iron cores, as mentioned in the post I found, but I have one major issue:

On the post I found the coils opposite from each other were wound opposite directions, one would be clockwise, and the one across from it would be counterclockwise so then the magnets on the rotor were spinning “the electricity would be traveling in the same direction” according to the post I found. In addition to that, the coils next to each other would also go from clockwise to counterclockwise to clockwise as you went around the stator… however when unwinding this stator all the coils were wound counterclockwise. Every single coil. So I have no idea what to do…. Does anybody have experience rewinding stator coils? Especially those on the CT200? Just want some clarification on this before I start winding it and possibly screw up the electrical system by running reversed polarity thru it or something….

Any expertise on this subject would be greatly appreciated, I can’t find much info online except for the forum post I already linked to above…

Thanks in advance

 

[Flyin900]

MMM $200 US plus shipping sounds attractive to me personally. Yet it depends on your situation and desire to learn a new skill set.

Regarding the windings, I have no input from any experience myself. If your windings were all in the same direction then that is clearly the correct direction for your system. The other stator is done that way for that particular unit. I personally would follow what you found when you unwound your unit and base the rewind on that information.
It will be interesting to see how it works out for you and credit to your perseverance and determination to try a new skill.

 

[stl360+450]

Can you describe the pattern by which the coils are linked between poles for the two stators (CT200 vs. CT90)?

I suspect that the patterns are different and by skipping poles that align with opposite rotor magnet polarity, the CT200 stator does not require alternating winding patterns. I can't say I am an expert on this, so consider this to be thinking out loud.

I'm very interested to follow this project. I've never wound a stator, but I think it would be very satisfying to make one work. Very cool if you can do it!