How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG) - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
Reply
 
LinkBack Thread Tools
post #1 of 115 (permalink) Old 11-11-2008, 7:18 AM Thread Starter
Administrator
 
Join Date: Mar 2008
Posts: 8,367
 
How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Compliments of FOG:

See attachment!
Attached Files
File Type: doc Converting a 2nd generation Flywheel.doc (2.92 MB, 1553 views)
ratchet is offline  
Sponsored Links
Advertisement
 
post #2 of 115 (permalink) Old 11-12-2008, 10:57 AM
Senior Member
 
BCmcrider's Avatar
 
Join Date: Jun 2008
Posts: 119
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

FOG, won't this procedure throw the flywheel out of balance due to removing material from one side only? Even if not felt due to the rest of the vibrations in the engine, I wonder if this would have long term implications on the durability of the crankshaft.

Author:Victoria Motorcycle Club Website http://www.vmc.bc.ca/
BCmcrider is offline  
post #3 of 115 (permalink) Old 11-12-2008, 12:34 PM
fog
Senior Member
 
Join Date: Oct 2006
Location: Mt home, AR
Posts: 18,038
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

No, as the material is not only on 1 side but almost all the way round. The first gen wheel are configured this way. I never checked the balance on one but I could. all the ones I have done (5 or 6) seem to be fine with no more than normal vibes. I will check the balance on the next one I do.

The picture show how I usually balance cranks with the flywheel attached


FYI these are the bikes that use the same rotor :Kawasaki: ER5, GPZ500,GPZ1100, Z1000J
EN450, EN500,


FOG

[attachment deleted by admin]

I hate PMs if you want to contact me, find my email address.
fog is online now  
 
post #4 of 115 (permalink) Old 11-13-2008, 1:23 AM
Senior Member
 
Join Date: Jun 2008
Posts: 603
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Quote:
Originally Posted by FOG
No, as the material is not only on 1 side but almost all the way round. The first gen wheel are configured this way. I never checked the balance on one but I could. all the ones I have done (5 or 6) seem to be fine with no more than normal vibes. I will check the balance on the next one I do.

The picture show how I usually balance cranks with the flywheel attached

FOG
seriously? FOG I'm just going to say that you probably know more about this motor than the guys that engineered it.

YAY MOTORCYCLES!
racinfast002 is offline  
post #5 of 115 (permalink) Old 11-28-2008, 3:27 AM
Senior Member
 
Join Date: Oct 2006
Posts: 4,373
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Quote:
Originally Posted by racinfast002
seriously? FOG I'm just going to say that you probably know more about this motor than the guys that engineered it.
He knows WAY more than they do, and certainly would have designed a much better motor. and odds are it'd be called a CBR500RR and say HONDA.

Seriously though, FOG's knowledge is exceedingly vast on a great many things and I'm pretty confident that the man could draw up plans easily to make a motor worthy of Honda's CBR line.

for best results, mix with beer and motors. <br /><br />2 86 Ninja 1000R's
bobthebiker is offline  
post #6 of 115 (permalink) Old 8-26-2009, 6:17 PM
Member
 
Join Date: Aug 2009
Posts: 59
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Quote:
Originally Posted by FOG
FYI these are the bikes that use the same rotor :Kawasaki: ER5, GPZ500,GPZ1100, Z1000J
EN450, EN500,


FOG
you are the man fog... iv been calling salvage yards all over the country today looking for a 2nd gen flywheel and everyone that iv talked to iv had to argue that i can modify it to work, but they keep saying that the 2nd gens won't work lol cheapest I found was $150...are the flywheels from the bikes you listed the same as the 1st gen or 2nd? and are there certain years of the bikes?
ex500raptor is offline  
post #7 of 115 (permalink) Old 10-5-2009, 6:35 PM
Member
 
Join Date: May 2009
Posts: 55
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Does removing the flywheel require the use of a flywheel puller? I can't find that tiny piece of information in any discussion about the replacements, and I don't want to cause a bunch of damage by removing it improperly.
AncientTV is offline  
post #8 of 115 (permalink) Old 10-5-2009, 6:55 PM
fog
Senior Member
 
Join Date: Oct 2006
Location: Mt home, AR
Posts: 18,038
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Yes but it a simple 18 X 1 mm Bolt, That screws into a thread put there for the purpose.

FOG

I hate PMs if you want to contact me, find my email address.
fog is online now  
post #9 of 115 (permalink) Old 4-11-2011, 6:26 PM
Senior Member
 
Join Date: Mar 2011
Posts: 211
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Hello - can someone please post a link to the actual instructions and/or pictures? This thread is useless otherwise, especially as a sticky. Thanks!

"Nothing is foolproof... to a sufficiently talented fool"
dalex is offline  
post #10 of 115 (permalink) Old 4-11-2011, 8:34 PM
fog
Senior Member
 
Join Date: Oct 2006
Location: Mt home, AR
Posts: 18,038
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

There was a link, For some reason the Admin deleted it

FOG

I hate PMs if you want to contact me, find my email address.
fog is online now  
post #11 of 115 (permalink) Old 4-11-2011, 9:23 PM
Pogo
Guest
 
Posts: n/a
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Whoa, weird. Someone fix this. FOG's instructions were pivotal for 1st gen owners.
post #12 of 115 (permalink) Old 4-11-2011, 9:40 PM
Administrator
 
knightslugger's Avatar
 
Join Date: Oct 2006
Posts: 25,447
           
Garage
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

it was from a space freeup.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
knightslugger is offline  
post #13 of 115 (permalink) Old 4-11-2011, 10:27 PM
fog
Senior Member
 
Join Date: Oct 2006
Location: Mt home, AR
Posts: 18,038
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Since this chintzy ass site can't afford the space. I will email anyone who whishes the instructions with the pictures.

FOG

I hate PMs if you want to contact me, find my email address.
fog is online now  
post #14 of 115 (permalink) Old 4-11-2011, 10:36 PM
Senior Member
 
Join Date: Mar 2011
Posts: 211
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

I remember looking here about two weeks ago and it was still complete.

In the meantime, the best alternative reference I found is this:

http://www.ex-500.com/index.php/topic,9980.0.html (and it links back to this thread in the last post )

"Nothing is foolproof... to a sufficiently talented fool"
dalex is offline  
post #15 of 115 (permalink) Old 4-11-2011, 10:51 PM
Administrator
 
knightslugger's Avatar
 
Join Date: Oct 2006
Posts: 25,447
           
Garage
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Quote:
Originally Posted by FOG
Since this chintzy ass site can't afford the space. I will email anyone who whishes the instructions with the pictures.

FOG
i dare you to do better.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
knightslugger is offline  
post #16 of 115 (permalink) Old 4-11-2011, 11:20 PM
fog
Senior Member
 
Join Date: Oct 2006
Location: Mt home, AR
Posts: 18,038
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

OK Splain how the "alternative" is OK but the correct method dosen't fit?

FOG

I hate PMs if you want to contact me, find my email address.
fog is online now  
post #17 of 115 (permalink) Old 4-11-2011, 11:21 PM
Administrator
 
knightslugger's Avatar
 
Join Date: Oct 2006
Posts: 25,447
           
Garage
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

doesn't fit? come again?


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
knightslugger is offline  
post #18 of 115 (permalink) Old 4-11-2011, 11:47 PM
fog
Senior Member
 
Join Date: Oct 2006
Location: Mt home, AR
Posts: 18,038
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Quote:
Originally Posted by Knightslugger
doesn't fit? come again?
it was from a space freeup.

??

FOG

I hate PMs if you want to contact me, find my email address.
fog is online now  
post #19 of 115 (permalink) Old 4-12-2011, 12:13 AM
Administrator
 
knightslugger's Avatar
 
Join Date: Oct 2006
Posts: 25,447
           
Garage
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

We had to clean up some old files that weren't being use because our space for attachments had been used up. all 2 GB of it. your attached file was included, not by desire. you are free to reupload it. better still, add it to the wiki so we don't have this issue again.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
knightslugger is offline  
post #20 of 115 (permalink) Old 4-12-2011, 7:21 AM Thread Starter
Administrator
 
Join Date: Mar 2008
Posts: 8,367
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

does anyone have a saved copy of the PDF?
ratchet is offline  
post #21 of 115 (permalink) Old 4-12-2011, 7:59 AM
fog
Senior Member
 
Join Date: Oct 2006
Location: Mt home, AR
Posts: 18,038
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

I have it
FOG

I hate PMs if you want to contact me, find my email address.
fog is online now  
post #22 of 115 (permalink) Old 4-12-2011, 12:10 PM
Senior Member
 
Join Date: Mar 2011
Posts: 105
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Is there anyway I can see the actual tutorial?
Seek is offline  
post #23 of 115 (permalink) Old 4-12-2011, 12:13 PM Thread Starter
Administrator
 
Join Date: Mar 2008
Posts: 8,367
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

FOG,
can you e-mail the pdf to me again?

I'll find another spot to host it.
ratchet is offline  
post #24 of 115 (permalink) Old 4-12-2011, 1:06 PM
fog
Senior Member
 
Join Date: Oct 2006
Location: Mt home, AR
Posts: 18,038
 
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

I just sent it to Slugger

FOG

I hate PMs if you want to contact me, find my email address.
fog is online now  
post #25 of 115 (permalink) Old 4-12-2011, 1:36 PM
Administrator
 
knightslugger's Avatar
 
Join Date: Oct 2006
Posts: 25,447
           
Garage
Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

thank you FOG.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
knightslugger is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome