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Electric upgrade question

2524 Views 13 Replies 5 Participants Last post by  demarko69
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?
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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.
1 - 2 of 14 Posts
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