[Camelrider]

On my 1996 TW I have lately some trouble, accelerating slow and not getting more top speed then 50 MPH. My first thought was something wrong with the carb, so I took that apart, cleaned and changed some parts, a shim under the needle and bigger main jet, but no more speed. The fuel consumption got bigger, 20 km on a liter in stead of 27km/l.

One funny thing that I noticed is that top speed is dependent on outside temperature, in the early morning its about 72-76 km/h, at noon it can get to 86-90.

So next is the ignition, first thought was of the CDI that’s the part responsible for the ignition timing. Today I measured the resistance of the ignition coil, was not so good, the pick up coil was a little higher then the specification and the source coil on the generator was no good also. For the CDI there is no way to check it out.

After some digging around on ebay, I decided to do an upgrade to the 2001-2011 generator and ignition.

For the moment I have ordered a 2009 stator, 2008 rotor and 2009 CDI on ebay. Also ordered a new ignition coil, where possible I prefer not to buy electric parts second hand.

I hope that the new generator fits inside the left side crankcase cover.

Does anyone know if this fits? Or any problem that could arise here?

 

[lizrdbrth]

There is quite a bit more to it, unfortunately. Converting from the '90's system to the 3-phase late model system is far more involved than the '87 to 90's swap.



I wrote it up in here somewhere. Can't seem to locate it presently.



All the left side engine cases are slightly different to accomodate each of the 3 systems.

 

[Camelrider]

Yes, I did expect that it would not be that easy.

 

[lizrdbrth]

Here are just a few of the issues. None of them are insurmountable, but you could have as much as 40 hours in the wiring harness alone if you're as slow at it as I am:



None of the connectors are the same. In additon to that a lot of them are reversed, male and female and/or have a different pin count. Component bracckets are in slightly different locations on older frames, such as the voltage regulator. The late model CDI uses a pin plug which directly fits to it, rather than separate wires protruding from it. The clutch and brake safety switches are wired slightly differently and the switches themselves have different connectors and are larger, so even the perches are a bit different on the late bikes. In short, almost everything is the same, but different enough that you'll spend a long time with a wiring diagram and soldering iron.



Contrast this with having a complete parts bike. I can change everything over in literally a couple of hours. Take everything under the left engine cover and swap it onto your old motor along with the cover. Take the tank, seat and fenders off, remove the old harness, route the new, reconnect all the wires, change the clutch and brake perches and switches, lengthen the regulator wiring, ride.



I don't want to mislead you into throwing more money down a rathole. Depending on your skill with such things with patience and a complete, headlight-to-tail light late harness and a side cover, perhaps you could make lemonade out of your situation.

 

[Camelrider]

Thanks, lizrdbrth, for the info. Most of the time I first check everything out in detail and then I decide to do it or not.

Now I got some 2008-2009 parts off ebay for a good price and did not want to mis out on it, so I first scooped them up and after that I started figuring out on how it would fit together. We will find a way, I am a licensed electrician and my son is an electronics engineer, that could help.

The 2009 CDI should be a direct fit. I understand that I have to look for a new side cover. That could be a problem, they are hard to find.

Oh and I have a lemon tree in my yard, so we can make lemonade if everything else goes bad. With a little patience it should be possible to make this conversion. I will wait till the parts arrive here, that will take a few weeks.

 

[lizrdbrth]

OK. I wasn't aware of your background. You can easily read and isolate only those circuits which need changing, pull/ add pins, etc. Most who ask about the conversion aren't so well equipped, but equally in need so I send them to the method with the best chance for success and least potential for permanently crossed eyes and hair loss.



Sorry if I sounded condescending.

 

[Bagger]

LB, you Sir are far too much of a Gentleman to ever be condesending. Worry Not.

Yo, please keep us updated with progress/pics. We are information junkies here!!!

BTW, I fell in love with your coundtry many years ago and hope to return there someday. Please take care and live well!



Bag

 

[Camelrider]

Thanks,lizrdbrth, I asked for info and you supplied it all and very fast, just keep on doing this.

It is much appreciated

condescending, I had to look that up in a dictionary; no way, you are doing fine.

Original I am from the Netherlands, so English is not my mother tongue.

Thanks and I will post how this works out.

 

[qwerty]

johanjos, you'll need both model wiring diagrams, available free in the online repair manuals and supplements. I updated a '91 with salvage parts from a wrecked '03, as lizrdbrth recommends. Not a difficult job at all. Adapting to the original harness would definately take more time. It's one of those big jobs made up of many little steps. It can be done one step at a time. You'll have no problems with your background, and save a ton of money.



You'll also benefit by upgrading to the late model headlight. I've found the added expense of a Sylvania Silverstar Ultra bulb makes as much difference as upgrading from the 35 watt early bulb to the late model 55 watt H4. The Sylvania bulb really is that much better.

 

[Camelrider]

Good point, since I will have more electrical output a stronger light bulb was considered, I will look out for the Sylvania bulb, thanks. The wiring diagrams and repair manuals I have already. I also found the stator cover on ebay, from a 2007 TW. So it looks like it that I have all the parts for the new ignition.

All together the used alternator, stator and rotor, CDI and stator cover was $210 on ebay. Not a bad deal I think, considering that a new stator and CDI would cost a lot more and would still leave me with the lower electrical output. There will be added some shipping costs and import taxes.

Maybe I should look out for the new wiring harness.

 

[Camelrider]

All the parts arrived and this weekend I put it all together, the 2009 wiring harness took some time to adept for the 1996 TW. Several wires had to be lengthened and some connectors had to be taken from the old cable beam, but everything works, except that the engine does not start. I will look into that next weekend.

Yes lizrdbrth, you are right, the upgrade of the wiring harness and wiring diagram to the 2009 version is not easy, it took me about 10-12 hours to rebuild the wiring harness. Now I am checking out what went wrong, because the engine does not start. So far it all checks out the same as the 2009 wiring diagram.

 

[Camelrider]

Today the engine started, the problem was with the main switch.

The main switch should also be changed to a new model switch,it functions different then the before 2001 model.

The start/stop switch on the right side of the handlebar should also be changed to the new model, it functions different.

The only thing left is now to wrap it all up and to ride.

 

[qwerty]

 

[demarko69]

Congrats