chilli
New member
long story short.... had to get new crank and case for my 99 srx, got sent crank and case for 2000+ by mistake. Ive already completely assembled the top end and really dont want to tear it down.
So i swapped my original stator and flywheel for the correct ones for my crank case.
PROBLEM!! - the wiring harness that comes from stator is completely different than the one that comes off 98/99 stator
How screwed am I to make this work, without having to replace entire wiring harness???
If I have to replace harness, will not having DCS and all the other differences (dual hand thumb, dual headlight) screw things up? do i need new cdi then too?
Please tell me theres a quick fix here
So i swapped my original stator and flywheel for the correct ones for my crank case.
PROBLEM!! - the wiring harness that comes from stator is completely different than the one that comes off 98/99 stator
How screwed am I to make this work, without having to replace entire wiring harness???
If I have to replace harness, will not having DCS and all the other differences (dual hand thumb, dual headlight) screw things up? do i need new cdi then too?
Please tell me theres a quick fix here
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if you used your original stator and flywheel then the harness would plug right in, so you must have only swapped the flywheel, but........ thats not really gonna be the issue, because you cant put the early flywheel on the 2000 case without grinding the boss for it to clear, as the pick up coil is located in a differnt spot.
youd need to use your original flywheel AND the inner stator, then grind the boss to clear the larger flywheel. Youll hten need to drill and tap 2 holes to relocate the pick coil around .020-.030" air gap between the magnets on flywheel to the pick up coil.
youd need to use your original flywheel AND the inner stator, then grind the boss to clear the larger flywheel. Youll hten need to drill and tap 2 holes to relocate the pick coil around .020-.030" air gap between the magnets on flywheel to the pick up coil.
chilli
New member
Ya that was my original plan, but then traded original 99 stator and dlywheel for newer. So they fit this crankcase perfect but now i have the wiring dilema
So based on this situation with 2001+ stator and flywheel, how can i fix it with the parts i have?
If i use compatible harness do i need the cdi as well? Or can i just swap harness and go?
So based on this situation with 2001+ stator and flywheel, how can i fix it with the parts i have?
If i use compatible harness do i need the cdi as well? Or can i just swap harness and go?
U will need cdi for sure plus you could also change dash panel because 01 srx has dual thumb and handlebar control. Plus u could run dual headlight because u have the high output now. And will also need a carb rack with a tps sensor like the 00 and up. U will like the upgrades.
I'm doing this to my 98 now and what I needed for parts are:
stator & flywheel
wiring harness
cdi
new style regulator
tach from 00 and up
carb rack with tps
wiring connector for coils
dual headlight & pod
headlight wiring harness for the hood section
This isn't a terribly difficult swap to do as long as you know what parts you'll need, I've had help along the way because I didn't realize the tach had to be swapped and then I found out the coils will need a connector because they fire differently than the 98/99.Plus I'm using my cases and figured I'd have to have a piece welded into them for the pickup coil but thanks to Betheviper he told me if I use a flywheel from an SX R 700 with the dual headlight,01 and up, it will fit right on and work great.Actually it give a few extra ft/lbs of torque according to him.As soon as I get this done I'm going to make a final list of what I changed /swapped and see if Tom will put it in the tech section for the next guy to follow.
stator & flywheel
wiring harness
cdi
new style regulator
tach from 00 and up
carb rack with tps
wiring connector for coils
dual headlight & pod
headlight wiring harness for the hood section
This isn't a terribly difficult swap to do as long as you know what parts you'll need, I've had help along the way because I didn't realize the tach had to be swapped and then I found out the coils will need a connector because they fire differently than the 98/99.Plus I'm using my cases and figured I'd have to have a piece welded into them for the pickup coil but thanks to Betheviper he told me if I use a flywheel from an SX R 700 with the dual headlight,01 and up, it will fit right on and work great.Actually it give a few extra ft/lbs of torque according to him.As soon as I get this done I'm going to make a final list of what I changed /swapped and see if Tom will put it in the tech section for the next guy to follow.
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To my knowledge there's no way to make the new style stator work with the old wiring harness because of the wattage/ power differences.
chilli said:
youll need basicly everything these guys listed here, so hopefully you can find a donor sled or this swap just got pretty expensive.
Would be a far cry cheaper to just do the mods to reinstall your correct 98-99 stator and flywheel.... otherwise your looking at a entire electrical change, cdi,entire front wireharness,regualtors,relays,carb rack,warmer rheostats,handwarmer grips, headlight, tach. I dont know doesnt seem like i would go thru all the expense and trouble to fix a problem like that, but thats just me.
chilli
New member
I am nervous about having to "grind down" the 2001 case to make the 99 stator and flywheel fit. Seems likie its really easy to mess that up, and end up with a useless crank case.
This mixup began with me being sent the wrong case / crank by mistake.... then the stator/flywheel swap I did seems to have compounded the issues, versus fix the issue.
If i have to tear it all down again, and use proper crank/case, although frustrating, makes it a much easier to fix the issue.
If it were summer, I would be ok with sourcing out all these parts but its december tomorrow and theres snow on the ground.... would kill me to miss another season... specially sinc I just spent 2 weeks on wifes "new to her" sled, giving it a complete overhaul.
If i can trade my crank/case/stator/flywheel back for compatible ones for 98/99, thats what Ill do... sucks to lose out on shipping $$$, but aside from chanigng my 99 to a 2001.....not alot of choices here
This mixup began with me being sent the wrong case / crank by mistake.... then the stator/flywheel swap I did seems to have compounded the issues, versus fix the issue.
If i have to tear it all down again, and use proper crank/case, although frustrating, makes it a much easier to fix the issue.
If it were summer, I would be ok with sourcing out all these parts but its december tomorrow and theres snow on the ground.... would kill me to miss another season... specially sinc I just spent 2 weeks on wifes "new to her" sled, giving it a complete overhaul.
If i can trade my crank/case/stator/flywheel back for compatible ones for 98/99, thats what Ill do... sucks to lose out on shipping $$$, but aside from chanigng my 99 to a 2001.....not alot of choices here
jabber800
New member
I think I have everything you will need to update to a 2001 ignition system. Give me a call.
Dan
Dan