Additional stator just for lighting

[81cr450]

I've been reading about kx lighting stator rewinds today & found mention of stacking an additional stator just to run the lights. Anyone seen any good old school write ups on this type of setup. I realize the mbz is the cats meow, but I like to tinker. Here's a kz650 cover to help illustrate the direction I'm thinking



I'm planing to use the 01 kx ignition system so it should be pretty light , flipping a second magneto would be near equivalent of a flywheel weight. Also, any thoughts on what street bikes have the highest output stators, or how you'd find that out

[Sandblaster]

I know one of the Team green bikes stacked 3 stators to run desert lights years ago and somewhere I've got pics of it externally but nothing internal.
I know putting different stators on the kx500 has been discussed and I even got a bunch of measurements for people years ago but we couldn't find a good fit. but I never compared any street bike stators.
Perhaps it's time to revisit this and document what we come up with...
Yeah, I currently run a MZB but if we found a less expensive option, more of our brethren could afford it...

[81cr450]

There's the outside cover pic you're referring to I believe.

If you pick the right stator one should be plenty, I found a stock hayabusa stator puts out 400 watts & a stock rzr stator is 500 watt. By the time I buy the newer 250 ignition $150 ,0$ if you're using what you already have though , & $150 for the other stator bits it really would be smarter just to cough the $500 for the mbz , .

I is probably not that smart though. Hence my next question, the magnetic polarity of the 2 stators side by side, would they need to be repellent or attractive, or would being on 2 different planes / diameter make that moot?

[Sandblaster]

Yep, that's the one I was talking about....
I'm not certain that the polarity would be a issue but I might know who to ask on that....
The problem with the bigger bikes stators is the size.
I think they may be too large.... But we'll see...
I have a buddy with a street bike salvage company and I may be able to do some looking around...

[81cr450]

Here's a pic of the direction I'm thinking. That's a rzr / sportsman 800 efi 500 watt stator flipped backwards on a 2001 kx "small" factory ignition.

[81cr450]

It does fit inside the stock housing, but the shaft would never work.

[81cr450]

Which doesn't matter to me other than it will be easier to put the factory ignition cover over the final mess. If you put the windings on the "outside" should be pretty straight forward & simple.

All the gears & hub center could be removed which will eliminate some weight, just shave it down on the lathe till all you have is the basic cup with magnets in it. You could also use the smaller hub flange from the stock magneto to center off of. Riveting them together might be a challenge???

[Sandblaster]

All I can say is H.U.G.E!!!
I like where this is headed...
Remove the gears and put that flywheel on a diet and I think you have something.
You could run lights, stereo, heated hand grips, and a cooler for the beer
Do I have anything you might need in my store?
If so, please let me know.

[81cr450]

All weights are grams that's 1383 grams the last digit is 1/2 gram measure. So total weight minus attaching rivets is 48.783.... ounces

Sorry for the upside down effing iPad pics,

[Sandblaster]

Nice job on the weight reduction.
I really like this approach.
If this works out I may do this for my trail bike I've been building forever...