I am trying to swap an 09 bottom end onto my 07 bike.

Coming out of the generator wire cluster on the 07 are just these two plugs:



And coming out of the 09 generator wire cluster are these four plugs:


One of them I know goes to the neutral indicator (the small single round hole) On the 09 it's like a small headphone jack looking thing sticking out- but that's a different animal entirely on my 07:


I am looking at the manual and I can't make heads or tails of the wiring diagrams

I swapped the 07 generator onto the 09 bottom end. Partly because I know I don't have the right connectors with the 09 one on my bike, and partly because the 09 one's wires were all chewed up and a couple were torn.

Both of the left side plugs in the pictures look like they might be the male/female version of each, is that for the charging maybe?

Does anyone know if this is going to work or if I'm wasting my time?!

I'm about to light everything on fire.

I feel like my head is going to explode! hahaa

Thanks for any help.

 

Larry I'm feeling bad for you. I'm no help with the electrical stuff. I will tell you a little story though. My dad had a rototiller that was a bear to start, and never stayed running. One day he got fed up with it when it quit in the middle of his garden. He poured gas on it and lit it. No joke He said it made him feel better, but when he had to go buy a new one, he kind of regretted the little bonfire incident.
Good luck .
Dan

 

Sorry no help here.

 

I know you don't want to hear this, but you probably could have gotten your old one fixed by a reputable shop and riding by now for cheaper than you paid for the other bottom end.

Hey, just doing my part to cheer you up. Plus, I feel it's my duty to point out 20/20 hindsight.

Seriously, though ... sorry for your troubles man, I know that has to suck.

 

Cousinlarry, can you come up with some wire colours? Just took a look at my '09, but with the engine in place it's hard to even follow the harness. I'll have to take the bike off the lift and turn it around so I have more room to get in there (it's "parked" with the left side crammed by some shelving). DON'T give up. If you start getting too POed, walk away for a while. Give me a bit of time, I have the '09 wiring diagram printed, the two pages taped together to make one, and coloured.

 

Looking at the 09 wiring diagram, I think the 6pos. connector goes straight to the regulator/rectifier. It carries the three stator wires, plus three others that goes to the 3pos. connector (presumably the one on the left in your picture) to distribute regulated voltage to the bike.

This is wired quite differently on the 06-07: the three wires from the stator go to a 3pos connector, and from there go to the regulator. The latter has a separate 3pos. connector for the output.

Add to that that the crankshaft sensor connector is different, plus the neutral switch that is wired together with it, and you have quite some wiring work to do if you want to use the generator from the 09. And may be quite some work in sorting out what to connect where.

I don't see why using the 07 stator and harness would not work, if it fits mechanically on the 09 bottom end. This is the way I would do it if it was me.

Good luck,

 

Yes, the 07 generator fit right on the 09 bottom end, I have it all bolted up already. I just wonder what the wires it is lacking are?

ol'klx'er - thank you for the wiring help. I will get the colors tomorrow. I'll report back to base.

 

From all the stators I have seen there should be 3 yellow wires that put out AC.
These get changed to DC. There are 2 wires that to to excite the field coming from the regulator. I do not know the color, but can be followed to the rotor or fixed coil inside the rotor. Wires coming out of the rectifier should be black and red with 14 volts engine running and everything working.

Not MUCH help...

I would just go with the 07 stuff and be done with it.

David

 

sorry cant concentrate on the plugs, all i saw was latex gloves.... I just find that funny, i understand it, but its still funny. The only reason i wear gloves is to keep my hands warm. No gloves working on my truck or bike. I dont even wear gloves using a chainsaw and splitting wood with a 27 ton splitter.... never have.

 

One gross difference I noticed is that the neutral switch on the 07's use a 3 wire connector plug and the switch feeds into the Ignition as well as the interlock diodes. On the 09's it is a single pole switch which feeds into the crankshaft sensor's plug which then eventually goes to the interlock diodes. That will be one of your issues.

One of the other plugs you may be having troubles with could be the crankshaft position sensor...they look different from the 07 to the 09s too.