Boxerworks.com

How do I separate an Airhead rotor to re-wind it and what diameter or gage of copper wire is best to use.
For heat resistant epoxy pasted on each layer as the winding progresses I am thinking JB-Weld.

The copper wire is coated with an insulating varnish, so it cannot short to anything it touches when it is wound. You probably would be better off in having a generator repair shop rewind it as they would have the proper materials. I am not sure if a electronic supply house would have heavy enough wire.

gg

http://www.euromotoelectrics.com/produc ... tor642.htm
or for a bit more you get all the parts that could fail.
http://www.euromotoelectrics.com/produc ... t-bmw+.htm

Are you sure that you wish/need to rewind it? Is it open? It presses apart and you will find that the wire is broken on the end, or that is usually the fault. It can be solder up again and pressed back together.

That is all that the rebuilders do.

Yes, I've checked the wires for continuity and there is no problem between the contact rings and the wires at the windings so the break must be in the windings. The epoxy would be to hold the wires against movement not as a substitute for the laquer on the wires. I'll press this apart and see what I can find and maybe not have to rewind. This is a spare I'm playing with so I'm not holding up on fixing a bike at the moment but it is one of those things which would be nice to carry as a spare. Thanks for the responses - maybe I'll post a pic of the pressing operation when I figre how to do it.

Well my 12 ton press is having no effect on this thing. Does anybody know what it takes to separate one of these rotors or if there is a better procedure than others.

A couple of hot and cold cycles and maybe a couple of judicious taps with a hammer while under preasure.

I never done it before so don't count on my advice.

Apparently the "fingered" parts press off each end - according to:
http://www.sidecar.com/mbbs22/forums/th ... p?tid=5029