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80s Suzuki DS80 rebuild has begun!

  1. #76
    TWINS! xrocket21's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!


    Quote Originally Posted by Kurlon View Post
    I did some digging around and couldn't find an aftermarket option. Give Rick's Motorsports Electronics a call and see if they'll do a repair/rewind if you don't want to try tackling the job yourself?
    Quote Originally Posted by breakdirt916 View Post
    Custom Rewind in Alabama (guy had a stroke, so call and get his number than text him) or Baja designs but their customer service kinda sucks
    Ok, thanks guys

    We'll get this damn thing running!!!

    - - - Updated - - -

    Quote Originally Posted by Kurlon View Post
    I did some digging around and couldn't find an aftermarket option. Give Rick's Motorsports Electronics a call and see if they'll do a repair/rewind if you don't want to try tackling the job yourself?
    cliffs on doing in myself? How do I know how many tuns it is, just count em? what about gauge?

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  2. #77
    Lifer Kurlon's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    Quote Originally Posted by xrocket21 View Post
    cliffs on doing in myself? How do I know how many tuns it is, just count em? what about gauge?
    Step one is an autopsy, slowly unwind it noting direction, turns, and size of wire. Get new wire, reverse the steps and wind it back on.

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  3. #78
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    Re: 80s Suzuki DS80 rebuild has begun!

    Ok, so I finally went and picked the bike back up today.

    With my calipers I measure the diameter of the wire to be about 0.6mm, 0.021"

    used this: https://www.convertunits.com/from/mils/to/mm

    to convert the 0.6mm to 23.622 mils

    This site:

    https://www.flight-mechanic.com/wire...rical-systems/

    shows 23 ga to be 22.6 mils and 22 ga to be 25.3 mils.

    I figure including my wire is mot likely 23 ga.

    BUT, I found this:

    https://www.amazon.com/Remington-Ind...63&sr=8-5&th=1

    with a 0.0221 diameter. but 24 ga.

    This stuff is 23 ga, but double coated so its thicker

    https://www.ebay.com/itm/Magnet-Wire...sAAOSw~CFY8BnP

    Maybe I want double coated for a dirtbike application?

    Thoughts?

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  4. #79
    Lifer Kurlon's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    I'd say go 24 ga, double coated. Not so much 'cause it's a dirty bike, instead thicker insulation just means less opportunities for nicks/handling during winding to cause issues with the final coil.

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  5. #80
    TWINS! xrocket21's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    Quote Originally Posted by Kurlon View Post
    I'd say go 24 ga, double coated. Not so much 'cause it's a dirty bike, instead thicker insulation just means less opportunities for nicks/handling during winding to cause issues with the final coil.
    Why do you say smaller 24 gauge wire?

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  6. #81
    Lifer Kurlon's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    It gets the OD closer to what you have now, winding count is more important than copper diameter for this application I believe.

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  7. #82
    TWINS! xrocket21's Avatar
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    Re: 80s Suzuki DS80 rebuild has begun!

    Quote Originally Posted by Kurlon View Post
    It gets the OD closer to what you have now, winding count is more important than copper diameter for this application I believe.
    Awesome, thanks man

    Your order's in!
    When your order is done processing, we'll email info
    You should get it by Sat, Sep 19.

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