I'd be very curious to see your fix. Several companies have taken a shot at 1125 rewinds with mixed results. I agree that the super think coatings tend to hold in heat.
08 stators are rated at 432W and are solid. 09s are 520w and obviously generate more heat than can be managed. Rewinding an 09 stator to 08 specs has been discussed quite a few times. But there is more to it. In addition to the 08 stator generating less heat, it is also a more effective heat sink. The 08 spreads the heat across 18 poles, while the 09 has only 12 poles. The 08 has more surface area to dissapate heat. So, even if the 09 is rewound to near 432W, each pole will need to handle more heat than on a 08 stator.
Comparing the 2 side by side. The 08 is clearly of higher quality:
08 - Machine wound, 18 pole, made in Croatia, looks just like other Rotax stators.
09 - Hand wound, 12 pole, not stamped with a country of origin (which probably means made in USA), looks just like other HD stators.
I'm sure there is a story behind that, and it ends with trying to cut costs, which is a goal for most manufacturing processes.
There were many articles on BadWeb about 08 batteries going flat in short periods with a bike not riden. The higher output on 09 models was supposed to address that, and I am a believer that Buell attempted to address problems with every model they released. I'd heard that the 08 stator was the highest output that Rotax recommended so Buell looked elsewhere, but the Buell world is full of whispers.
The 09 stator is 5x the price of other Buell / H-D stators. Added to the cost of warranty replacements and the cost of paying dealers to install the bandaid harness upgrade it didn't meet any objective to cut costs. It is possible that the retail value of the stators that H-D end up putting on my bike under warranty may exceed what I paid for the bike new.
The rewind I'm talking about doesn't look at the 08 spec. From what you have said it seems like the 08 is in everyway higher quality. The rewind is to make the 09 stator more robust. By using thinner wire the output is reduced and so it the heat. The only place it is noticible is at idle where the charging drops to the high 12V. Once you are riding you are in the high 13V - 14V output range.