1. Introduction
The ElectroSport ESG122 Stator is a high-quality replacement component designed for Honda XR80, XR100, and CRF100 models. It is engineered to provide reliable performance, including 100W of lighting output. This stator is manufactured with a modern core using high-grade lamination material to minimize magnetic losses and features high-grade copper wire wound on advanced machines for optimal results. It comes complete with high-quality lead wires, rubber seals, and connectors, ensuring a direct plug-in replacement for your OEM stator.
Figure 1: The ElectroSport ESG122 Stator. This image displays the complete stator assembly, including the central metallic core with copper windings, attached wiring harness with multiple colored wires, and various connectors and rubber seals. A yellow wire with a ring terminal is visible at the bottom left.
Key Features:
- Better than OEM replacement Stator
- Plug-in replacement stator complete with connectors and seals
- Optimized winding configuration for superior output across the RPM range
- Manufactured with modern high-grade components for optimal performance
- Comes with a Full One Year Warranty
2. What's in the Box
Upon opening the package, please ensure all components are present and undamaged. The package should contain:
- 1 x ElectroSport ESG122 Stator
Note: No additional accessories or tools are included unless specified by the retailer.
3. Setup and Installation
The ESG122 Stator is designed as a direct plug-in replacement for the OEM stator. While installation is generally straightforward for experienced individuals, it is recommended that installation be performed by a qualified mechanic or technician due to the electrical nature of the component and the specific requirements of motorcycle maintenance.
General Installation Guidelines:
- Safety First: Ensure the motorcycle's battery is disconnected before beginning any electrical work. Allow the engine to cool down completely.
- Access the Stator: Locate and remove the engine cover that houses the stator. This typically involves draining engine oil and removing several bolts. Refer to your motorcycle's service manual for exact procedures.
- Disconnect Old Stator: Carefully disconnect the wiring harness of the old stator from the motorcycle's electrical system. Note the routing of the wires and the location of any rubber seals.
- Remove Old Stator: Unbolt and remove the old stator from its mounting points.
- Install New Stator: Position the new ElectroSport ESG122 Stator in place, ensuring proper alignment with mounting holes. Secure it with the original or appropriate new bolts, tightening them to the manufacturer's torque specifications.
- Connect Wiring: Connect the new stator's wiring harness to the motorcycle's electrical system. The ESG122 comes with high-quality lead wires, rubber seals, and connectors for a direct fit. Ensure all connections are secure and properly sealed to prevent moisture ingress.
- Route Wires: Route the wires carefully to prevent pinching or abrasion. Use the provided rubber seals to ensure a watertight seal where wires pass through the engine casing.
- Reassemble: Reinstall the engine cover, ensuring the gasket is in good condition. Refill engine oil if it was drained.
- Test: Reconnect the battery and test the motorcycle's ignition and lighting systems to confirm proper operation.
For detailed, model-specific instructions, always consult your motorcycle's official service manual.
4. Operating Principles
The ElectroSport ESG122 Stator is a critical component of your motorcycle's electrical system, responsible for generating electrical power for both the ignition system and auxiliary lighting. It functions by converting mechanical energy from the rotating crankshaft into electrical energy through electromagnetic induction.
Key Functions:
- Ignition Power: The stator provides the necessary electrical current to power the ignition system, which includes the CDI unit and ignition coil, enabling spark plug firing for engine operation.
- Lighting Output: The ESG122 specifically provides 100W of lighting output, ensuring sufficient power for headlights, taillights, and other electrical accessories.
- Battery Charging: In conjunction with a rectifier/regulator (not included), the stator also contributes to charging the motorcycle's battery, maintaining its charge during operation.
The design of the ESG122 allows for the lighting output to be left unconnected if not needed, without affecting the operation of the ignition side of the stator.
5. Maintenance
The ElectroSport ESG122 Stator is designed for durability and requires minimal routine maintenance. However, periodic inspection can help ensure its longevity and optimal performance.
Recommended Maintenance Practices:
- Visual Inspection: During routine engine maintenance (e.g., oil changes), visually inspect the stator's wiring and connections for any signs of wear, fraying, or corrosion. Ensure rubber seals are intact and providing a good seal.
- Cleanliness: Keep the area around the stator clean and free from excessive oil, dirt, or debris, which can contribute to overheating or insulation breakdown.
- Connection Integrity: Periodically check that all electrical connections related to the stator are tight and secure. Loose connections can lead to intermittent power supply or damage.
- System Checks: If you experience issues with lighting or battery charging, it is advisable to have the entire charging system, including the stator, rectifier/regulator, and battery, tested by a professional.
Avoid using harsh chemicals or abrasive materials directly on the stator windings or electrical connections.
6. Troubleshooting
If you encounter issues with your motorcycle's electrical system after installing or while using the ESG122 Stator, consider the following common troubleshooting steps. Always consult a qualified mechanic if you are unsure about any diagnostic or repair procedures.
Common Issues and Solutions:
| Problem | Possible Cause | Solution |
|---|---|---|
| No Spark / Engine Not Starting | Faulty ignition side of stator, faulty CDI, faulty ignition coil, wiring issue. | Check all wiring connections. Test stator output with a multimeter (refer to service manual for specifications). Inspect CDI and ignition coil. |
| Lights Dim / No Lights / Battery Not Charging | Faulty lighting coil of stator, faulty rectifier/regulator, loose connections, discharged battery. | Check battery charge. Inspect all lighting circuit connections. Test stator's lighting coil output. Test rectifier/regulator. |
| Intermittent Electrical Issues | Loose or corroded connections, damaged wiring, intermittent stator fault. | Thoroughly inspect all wiring and connectors for damage or corrosion. Ensure all connections are tight. |
| Overheating Stator | Excessive electrical load, poor ventilation, internal short. | Ensure no excessive accessories are drawing power. Verify proper oil level and circulation. Professional diagnosis recommended. |
Always refer to your motorcycle's specific service manual for detailed electrical diagrams and testing procedures.
7. Specifications
| Attribute | Detail |
|---|---|
| Brand | ElectroSport |
| Model Number | ESG122 |
| Manufacturer Part Number | ESG122 |
| OEM Part Number (Reference) | 215080 |
| Compatibility | Honda XR80, XR100, CRF100 models |
| Lighting Output | 100W |
| Item Weight | 6.4 ounces (approx. 181 grams) |
| Product Dimensions | 7.87 x 5.31 x 2.36 inches (approx. 20 x 13.5 x 6 cm) |
| Exterior Finish | Painted |
| ASIN | B003172796 |
| Date First Available | December 18, 2009 |
8. Warranty Information
The ElectroSport ESG122 Stator comes with a Full One Year Warranty from the date of purchase. This warranty covers defects in materials and workmanship under normal use and service.
Please retain your proof of purchase for warranty claims. The warranty does not cover damage resulting from improper installation, misuse, neglect, accident, alteration, or unauthorized repair.
For specific warranty terms and conditions, please refer to the official ElectroSport warranty policy or contact their customer service.
9. Customer Support
For technical assistance, troubleshooting, or warranty inquiries regarding your ElectroSport ESG122 Stator, please contact ElectroSport customer service directly. You may also reach out to the retailer from whom you purchased the product.
When contacting support, please have the following information ready:
- Product Model: ESG122
- Date of Purchase
- Description of the issue
For the most up-to-date contact information, please visit the official ElectroSport website or refer to the packaging materials.