F800GS stator coil rebuild

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Photos taken while rebuilding an F800GS stator coil

Steps:

  1. Remove stator from motor
  2. Strip damaged wire
  3. Marinate in paint remover to get rid of insulation varnish (spray can cap in the center helps using less paint remover)
  4. Make insulation out of 0.25mm Nomex paper
  5. Cover stator with Nomex paper
  6. Painfully wind all 18 coils by hand.
  7. Treat blisters on fingers 
  8. Marinate in transformer varnish under vacuum to help penetrate inner coils
  9. Let dry...
Photos: 
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