This leads to questions, please bear with me, background may help get best answers …
I’ve been all-weather touring/camping for 40+ years and plan on continuing for a long time. Perhaps a bit above average mechanical competency, I’ve always maintained and modified my own machines. I'm comfortable repairing/modifying all systems of non-injected motorcycles.
I’m considering purchase of a very low-miles box-stock original ’96 Trophy 900 (gen 2, twin headlight) garage queen as a slight downsizing replacement for a long faithful but extremely top-heavy heavy ZG1000 Concours (it has 150+ lbs on the Trophy; my body is not quite keeping up with my attitude
). The 900 Trophy is attractive to me for many reasons understood by y’all already.
This specific very clean example obviously needs a complete refresh of everything rubber in it, that’s not a problem; nor is total fluid flushing and non-engine bearings refresh. I think I have a good handle on the ‘top ten issues’ with the Trophy, and mitigating most of those is not a problem (coils, alternator bolts, for example).
Lots of searching in this great forum leaves me with two issues needing confirmation / clarification / opinion:
1. I believe that the Trophy has a 400W (nom) alternator (perhaps the identical Denso unit as the single-headlight ZG1000). In winter I run up to 130W of heated gear, which can require close monitoring of charging voltage on the single-headlight Connie, particularly if stuck in low-speed traffic (so shut-down the heat for a bit and press-on ;-). Not a problem with the revs above 3k. Can I expect about the same with the two-headlight Trophy? Any problem installing a cut-out relay on one headlight and running ‘cyclops’ to gain 55W if needed?
2. Regarding the starter sprag clutch issue …. if a one-time most reliable fix
, the consensus seems to be install the latest version OEM sprag assembly, clearancing the case as needed. I understand this may also require swapping of only one gear (no shafts) in the tranny to match the larger 53-tooth sprag, correct? The VIN on the '96 Trophy 900 of interest is 034XXX. It is a ‘grey engine’ and does not appear to have the ‘convenient access plate’.
I can do the sprag fix in my workshop no problem. Even with ‘impending failure warning’ I don’t think it is a situation I’d want to have come up on a multi-thousand mile, multi-week trip. Finding myself facing ongoing push-starts or risk of loose and destructive bits in the tranny while on the road is not acceptable, I’d need to preempt the matter with a high-confidence fix for the machine to meet my needs.
Clarifications / comments most appreciated. TIA.