[1953onlytwo]

97 TW: Picked this up from a barn. I was told that the bike was used to teach a young rider on. Rider grew up and returned the bike with an oil leak from the side cover. The oil leak was repaired and once put back together it would not run (another pinched wire). I bought the bike and the picture shows what I found. The more tape I removed the more I found. I removed what little factory covering that was left. Even the wire from the lower case (not pictured) had several open bare wire spots. I’m new to all this so expect some real dumb questions
Picture item #1 is this the normal color or is the wiring damaged?
#2 Due to all the open spots in the wire cover and three solder joints is it best to
Make a new harness or tape and cover

 

[Fred]

I would test before deciding to replace. Service manual will show go, no-go impedence values for those circuits, I woud test all leads and the coils with a multimeter. Heat shrink tubing can be a superior alternative to tape over any suspect wire section. Wire bundle needs to be of a fairly compact, tight diameter to fit through port in case without replicating the fatal pinching your bike suffered.

 

[1953onlytwo]

thanks for reply. Electronics is a new thing for me. Can you suggest a locations for a download of test procedures?

 

[Mistervelocity]

What you have there appears to be a 1987. It is it's own animal so testing and wiring diagrams will be different from 88-up.

As for repair, I bought a used complete stator cover last year with some giant butt connectors and some minor insulation cracks beginning. I replaced them one by one with smaller soldered connectors, shrink wrap, then electrical tape. It was a snug fit but it fit the wiring channel much better. These are the only photos I took, but you get the idea.

 

[1953onlytwo]

Great suggestion....thank you sir

 

[reddave]

Here's a tip to make sure you pinch the wires when installing the side cover. Jiggle the wire pack around a little bit when slowly installing the side cover. Every couple of millimeters move the wires around a little bit to ensure they don't get pinched. If they do - you will feel it by tugging on the wires before the cover is fully seated. I wish I could remember who posted that tip - I'll just have to credit it to the forum in general...

 

[1953onlytwo]

Thanks you Ill try this when I put it together

 

[Fred]

A Service Manual can be very helpful. has saved my bacon more than once
Here is link for a searchable downloadable PDF file:
TW200 Service Manual - searchable pdf

 

[1953onlytwo]

has anyone rebuilt the stator on a 97? Does it have 1 or 2 wires?
Ive been looking for a old burned on one to try. Any suggestion would be great.

Thanks for the service manual info Fred, got it Thanks you sir

 

[Mistervelocity]

As stated earlier, you have an '87, not a '97. If your asking about the part labeled #2 in your first post, that is the Pulser Coil that has the 2 wires. 1987 has its own part number - 1 year only. 1988-2000 are the same. 2001-up are the same. All TW Pulser Coils have 2 wires. Your stator, again 1987 only, appears to have 5 wires.

 

[1953onlytwo]

sorry it is a 87 my head is up side down trying to to figure all this out thanks

 

[Mistervelocity]

Ahh, carry on then. Just didn't want you headed down the wrong path since '87s are different than the rest. Partzill shows both parts as "unavailable" and I don't see any on ebay right now. Not sure if there's an aftermarket replacement for either part. You can probably ohm test the stator but not sure if the pulser coil can be bench tested or not.

 

[1953onlytwo]

I have decided to rewind my 87 (got it right this time stator. Does anyone know the size of the wire? or number of turns?
Suggestions would be great,,,, Thanks

 

[PlacerLode]

What you have there appears to be a 1987. It is it's own animal so testing and wiring diagrams will be different from 88-up.

As for repair, I bought a used complete stator cover last year with some giant butt connectors and some minor insulation cracks beginning. I replaced them one by one with smaller soldered connectors, shrink wrap, then electrical tape. It was a snug fit but it fit the wiring channel much better. These are the only photos I took, but you get the idea. View attachment 234919 View attachment 234920

Nice clean repair

 

[1953onlytwo]

yap its a 1987,,,saw your pictures..super. Do you know the size wire thats on #1 in my picture? any date would help

 

[Fred]

1954onlytwo,
1) please confirm I sent you link for the 1987 service manual , model year should be listed on page 1. If not a better attempt using forum search function should locate it.
2) I will check to see if I have an '87 pulser coil & possibly stator in an outbuilding before sea of frozen mud melts in its daily freeze/thaw cycle and let you know, all part of a pay-it-forward pile from CJ7Pilot.

 

[Fred]

This may be 1987 pulser coil?

Was among other presumedly ‘87 electrical rat’s nest of donated parts.

No stator assembly though, believe this is a later model. Any help identifying?

Please let me know if any of these surplus parts can help get your '87 rolling again. Hate to see No Longer Avaialble parts ruin one's plans.

 

[Mistervelocity]

Fred, that stator is 2001-up. Not sure about the pulser coil.

 

[Fred]

That was what I was thinking too r.e. side case with stator & pulser, resembles my 2003 & 2006.
How to determine vintage of other loose pulser in picture? No part # I could discern, but was with other wiring TW wiring I do not recognize as being from more modern vintage. However I got everything from fellow with both '87 and a newer TW.
Also have a rebuilt untested XT250 engine, was thinking of trying to mate the depicted cover plus newer TW200 flywheel and CDI to make a 5-speed thumper if only had confidence it would fit in a TW frame.

 

[1953onlytwo]

Fred,,,,you did send the manual link and I have it on my computer.. I think we have narrowed it down to the coil or cdi.. I should have a coil in by Friday.
So we will see.. If it is the CDI I will really consider changing to a newer stator system. I have a friend that had a 87 I will try his CDI first and go from there.
As soon as I know something Ill post and let you know about any parts. Thank you sir very much