How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG) - Page 5 - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #101 of 115 (permalink) Old 9-13-2014, 11:15 AM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Quote:
Originally Posted by ArkiTech
Fog in one of posts you writted that we have to downgrade gen2 flywheel to use it in our motorcycle, can we insted o this upgrade ignition or something else in gen1 to use better flywheel ?

Will all models of: ER5, GPZ500,GPZ1100, Z1000J, EN450, EN500 flywheel work after modify in gen1 GPZ 500 ? Some of ER5 flywheel looks like a little bigger.


Yes ,but it's much more difficult and expensive, you then must change the whole wire harness and igniter, just to make the engine run . Then several other things to be compatable with the wire harness, like the Ignition Switch.

Just alter the fly wheel, there is no benefit to doing it the hard way.

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post #102 of 115 (permalink) Old 4-4-2015, 1:01 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

I've added FOG's writeup to the wiki. http://www.ex-500.com/wiki/index.php...el_replacement

It's the exact same instructions and pictures as his Word document, just wikified to avoid forum cleanup issues and needing a separate program to view it.


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post #103 of 115 (permalink) Old 5-2-2015, 2:39 AM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Big thank you to FOG
After the mod I had another problem to which Fog helped with very good advice which got me back on the road.
The guy is a legend as I'm no mechanic
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post #104 of 115 (permalink) Old 3-6-2016, 6:28 AM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

hello fellow member , i have 1991 gpz 500 , flywheel dead , saved all magnetic bits so nothing in engine , good , now bought second gen one and the pick ups are two instead of one previously , now i have four cables coming out but need only two for the wiring , so , is there anywhere a read up of how to reconnect the right wires so the sparks can fly ? i would really appreciate your helps or hints , thank you very much christian
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post #105 of 115 (permalink) Old 3-6-2016, 6:53 AM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Quote:
Originally Posted by vonmerowing
hello fellow member , i have 1991 gpz 500 , flywheel dead , saved all magnetic bits so nothing in engine , good , now bought second gen one and the pick ups are two instead of one previously , now i have four cables coming out but need only two for the wiring , so , is there anywhere a read up of how to reconnect the right wires so the sparks can fly ? i would really appreciate your helps or hints , thank you very much christian
if you read the whole of this topic you would not need any further information, gen 1's and gen 2's are wired differently, unless you want to change the whole wiring loom igniter ect, just do as Fog instructed and modify the flywheel leaving the wiring alone.
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post #106 of 115 (permalink) Old 2-28-2017, 8:56 PM
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Hi. I have bought a new stator and flywheel from eBay for my '92 ex500. Both were busted in the bike. The stator I got has one pick up. The one in the bike has two (see picture). The flywheel I got has two contacts and i understand that I have to grind them down to match the gen 1 flywheel. Now I am confused as to what I have. The parts catalog images are the same for both generations and are no help. How many contacts does the flywheel have in both gens and how many pickups on the stator? Please advise.
Thanks.
Ben
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post #107 of 115 (permalink) Old 3-1-2017, 12:33 PM
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The Gen 2 flywheel has two triggers.
Staggered, with a single pick up in the cover.

The Gen 1 has a single trigger but with two pick ups in the cover.

You have a Gen 1 cover, two pick ups.
But you bought a Gen 2 pick up assembly.

The Gen 2 flywheel must have the one trigger ground off to work with the Gen 1 pick ups.

O_E_M

ETA:
Is there a reason you can't use the Gen 1 pick ups?
Were they damaged?

Otherwise, you'll have to do some swapping around to make stuff work.
If you are trying to use the new single pick up, then the flywheel will not have to be modded.
But you will have to mod the wiring (and possibly change the cover) to work with the Gen 2 pick up.
I can't remember if the cover will have to be changed or not, @Saabnut could 100% answer that.

Unless there is some specfic reason you can't use the existing Gen 1 two pick up system, leave it be and mod the flywheel.

Last edited by one_evil_monkey; 3-1-2017 at 12:40 PM.
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post #108 of 115 (permalink) Old 3-1-2017, 2:19 PM
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Stator covers are identical between both generations.

Runners:
1990 EX500 - 115,000 miles as of March 12th, 2017
1988 Honda XR600 - Street legal play toy
*I have a large inventory of used factory EX parts, both gen1 and gen2, feel free to PM me if you are looking for something*
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post #109 of 115 (permalink) Old 3-3-2017, 6:42 PM
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Thanks to you both. To answer your question OEM... The insulation resin on the stator that came with the Gen1 bike is chipped. I am assuming this happened because the flywheel magnets were falling apart. If the insulation chipping on the stator is not an issue I would prefer to leave it in there and mod the gen2 flywheel. If it is an issue then I am guessing that I need to install the gen2 flywheel (unmodified) and the gen2 stator and figure out something with the wiring differences. ??
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post #110 of 115 (permalink) Old 3-3-2017, 7:14 PM
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You should be fine using the original stator. Mine has damage from two flywheels chucking magnets and it functions just fine.
However, if you really would feel more comfortable using an unaffected gen1 stator, I'm sure I've got one somewhere.

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1988 Honda XR600 - Street legal play toy
*I have a large inventory of used factory EX parts, both gen1 and gen2, feel free to PM me if you are looking for something*
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post #111 of 115 (permalink) Old 3-3-2017, 7:41 PM
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Quote:
Originally Posted by Saabnut View Post
You should be fine using the original stator. Mine has damage from two flywheels chucking magnets and it functions just fine.
However, if you really would feel more comfortable using an unaffected gen1 stator, I'm sure I've got one somewhere.
That's good news and I appreciate the offer. But, I'm willing to save some shipping costs if the one that's in there will do. I will hit you up if disaster strikes.

Anyone need a GEN 2 Stator?? haha
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post #112 of 115 (permalink) Old 3-14-2017, 12:46 PM
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Note the 3 3/8 dimension should be 2 3/8 as shown on the picture of the caliper.

How do you change the WIKI? or for that matter the attachment in the How too page?

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post #113 of 115 (permalink) Old 3-14-2017, 11:41 PM
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I think you have to be a "group user" to edit the wiki FOG. I am having trouble logging in to the wiki (there are things like tire specs you can't see without logging in). It keeps shooting me back to the forum page. ?? If you figure it out let me know.

I have your flywheel how-to printed out and ready to go. Thanks for all the info. What do you think about stacking the flywheels on top of each other with the T marks aligned and double checking measurements with a square?

'92 EX500- "Project Lazarus"
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post #114 of 115 (permalink) Old 3-15-2017, 12:06 AM
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It's been a few months since I've edited some stuff in the Wiki...
But as of late, I haven't been able to access it at all to edit and correct some of the misinformation.
None of the normal technical stuff was showing up, it was just some random suggestions for what looked like tech help...
The whole thing didn't look right.

O_E_M
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post #115 of 115 (permalink) Old 3-15-2017, 8:58 AM
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Wink

Well I checked my document file and the typo was there too. I had it posted in the how too section where I could have edited but it was deleted by ads as a space saver. Now it is posted as an attachment to the how too post and I cannot access it.
The typo is obvious and the adjoining photo clearly shows the correct reading on the caliper. you have to be a bit dense or just a anal editor to not get it right.

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