cracked stator and flywheel magnet - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
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post #1 of 22 (permalink) Old 2-17-2017, 1:14 AM Thread Starter
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cracked stator and flywheel magnet

Hi All,

I just picked up a '92. It turns over but drains the battery quickly (a good battery from a mother bike) then the solenoid just clicks rapidly. When it does crank it maybe gets 2 or 3 revolutions then the solenoid starts clicking. I decided to pull the engine cover to get at the starter as the manual suggested and found that one of the flywheel magnets has a hairline crack in it and the "glazing" or resin coating on it and parts of the stator have cracked off. So, I have two questions. Do I have to replace these things in order to see if the bike starts? And, what years parts can I use? Flywheels seem to be hard to find for a '92. can I use a '98 or '00?
Any help is appreciated.

Thanks.
Ben
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post #2 of 22 (permalink) Old 2-17-2017, 1:37 AM
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You need to find a flywheel from a 1994-up model.
Modify it (the exterior pick ups) to work with the Gen 1 pick up coils.
Search the Wiki for info and the "For Sale" section for a Gen 2.

The battery needs a full charge, slow overnight with low amperage, and if can't start the bike twice in a row then....

ETA: Pull your battery and set it off on auto charger before you kill it totally.
Needs a bare minimium of 12.5V standing and 10.5V under load (starting) if it doesn't pass, then time to replace, period.

O_E_M

Last edited by one_evil_monkey; 2-17-2017 at 1:51 AM.
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post #3 of 22 (permalink) Old 2-17-2017, 11:31 AM Thread Starter
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Thanks O_E_M! I will give it a shot. I am worried that there is a short somewhere that is killing the battery. Are there common places to check for shorts?

Ben
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post #4 of 22 (permalink) Old 2-17-2017, 11:57 AM
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If there was a short to ground, it would blow a fuse. If there was a slow drain, you wouldn't notice anything unless you let the bike sit overnight.
All my bets are your battery either needs to be charged or is no good. Charge it, get it load tested.

As for the flywheel, it's a good thing you noticed it failing before it actually chucked a magnet. Do not run that motor until you replace it with a gen2 flywheel (as O.E.M. mentioned, 1994-later) that had been appropriately modified for a gen1.
As you noticed, they area bit hard to come by. I am fresh out, so look on ebay. You have to get a little creative sometimes to find one for a reasonable price. I've had good luck in the past searching for a crankshaft. Sellers sometimes don't bother removing the flywheel, and crankshafts aren't big money sellers. One I had been watching on ebay, with the flywheel still on it, just sold for 60 bucks.

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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 #5 of 22 (permalink) Old 2-17-2017, 10:31 PM Thread Starter
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Thanks Saabnut. I am looking as we speak. The crankcase search is a good idea. Hopefully this thing will be running soon.
Ben
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post #6 of 22 (permalink) Old 2-18-2017, 12:16 PM
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Check this:

eBay item number: 162219705827

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post #7 of 22 (permalink) Old 2-20-2017, 1:18 AM Thread Starter
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Quote:
Originally Posted by jorge moros View Post
Check this:

eBay item number: 162219705827
I saw that one. But the 90 bucks for shipping killed my buzz.. SO far $60 is the best deal I've found.
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post #8 of 22 (permalink) Old 2-20-2017, 7:54 AM
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Quote:
Originally Posted by blackiredi View Post
I saw that one. But the 90 bucks for shipping killed my buzz.. SO far $60 is the best deal I've found.
Whoa! Didn't see that... Good luck

Only two things are infinite, the universe and human stupidity, and I'm not sure about the former. -Albert Einstein.
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post #9 of 22 (permalink) Old 2-21-2017, 4:33 PM
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Quote:
Originally Posted by blackiredi View Post
I saw that one. But the 90 bucks for shipping killed my buzz.. SO far $60 is the best deal I've found.
Jump on that. It's the best deal you will find.

Runners:
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*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 #10 of 22 (permalink) Old 2-21-2017, 7:00 PM Thread Starter
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Originally Posted by Saabnut View Post
Jump on that. It's the best deal you will find.
Done. I am thinking that I should just get an aftermarket stator too since the insulator material is a chipped on mine. Can I get a gen2 stator and mate it directly with the gen 2 flywheel or do I have to retrofit the gen2 fw to a gen1 stator? Thanks in advance.

Still a cheap bike..... I keep telling myself.
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post #11 of 22 (permalink) Old 2-21-2017, 7:04 PM
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Electrically the rotor(flywheel) and the stator are the same from all years . The only difference in the triggers for the ignition on the outside of the rotor.

Fog

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post #12 of 22 (permalink) Old 2-21-2017, 7:06 PM Thread Starter
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Electrically the rotor(flywheel) and the stator are the same from all years . The only difference in the triggers for the ignition on the outside of the rotor.

Fog
Awesome. Thanks FOG.
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post #13 of 22 (permalink) Old 2-21-2017, 7:09 PM
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Get the factory gen2 and modify it. The build quality will be much better than the aftermarket gen1 replicas, plus that aftermarket garbage will actually cost notably more than 60 bucks.

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 #14 of 22 (permalink) Old 3-6-2017, 12:23 PM Thread Starter
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Got the flywheel off thanks to a 18x1.5x50mm bolt (instead of a $12 "flywheel puller"). I had read one of FOG's posts on another thread, so a big thanks for that!

'92 EX500- "Project Lazarus"
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post #15 of 22 (permalink) Old 3-20-2017, 8:36 PM Thread Starter
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Gremlins. Two busted wires. One ignition one charging. Maybe that's why it won't spark. I think the lesson is careful how deep you dig.
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post #16 of 22 (permalink) Old 3-20-2017, 8:43 PM
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Nah.... you don't need those silly little wires for anything.
Just cut 'em off.

Joking of course... calm down, people. LOL

O_E_M
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post #17 of 22 (permalink) Old 3-21-2017, 8:29 PM
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Soooo, do you want some fresh wiring? I've got plenty.

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 #18 of 22 (permalink) Old 3-21-2017, 11:01 PM Thread Starter
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Originally Posted by Saabnut View Post
Soooo, do you want some fresh wiring? I've got plenty.
Ahhh crap. I wish I would have checked in earlier. I just got it all back together with a new gasket and everything. Thanks though. If it doesn't work I will take you up on it. I ended up soldering the broken ones and added some new shrink tube. I don't trust those little butt joint pinch connectors. Then put some new wrap on the whole bundle. I'm going to go through all the connections (side stand, etc.) while I clean the carb just to make sure it's not some other little thing I didn't notice.
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'92 EX500- "Project Lazarus"
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post #19 of 22 (permalink) Old Yesterday, 1:12 PM
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Soldering is the way to go and that should work just fine. However, I don't think you'll be happy with how that harness will route. It's normally supposed to tuck underneath the front edge of the sprocket cover along with the wiring for the neutral sensor, kick stand and oil pressure sensor, but it won't fit as you have it wrapped now. I'm actually not even sure you'll be able to get the sprocket cover on at all. I highly recommend going with a good, factory stator harness.
I can fit it into a small flat rate, so shipping would be something like 6 bucks. All I'd want extra on top of that is 2 or 3 bucks so I can buy a beer to drink while I look for it in my stock .

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 #20 of 22 (permalink) Old Yesterday, 1:59 PM
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Not sure of why...but extreme heat effects in Ducati and VFR land...either crusty, burnt or severely undersized stator output wires benefit greatly and justifies proactive replacement and upgrade in size.

"I don't trust those little butt joint pinch connectors." quote blakiredi

I'd tend to agree. I've had very good luck with solder type butt connectors, always keep a few in stock, various sizes from 22ga to 12ga. Quite reliable. Plastic crimp type...no way..would never use anywhere within a charging system.
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File Type: jpg stator2.JPG (186.5 KB, 4 views)

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post #21 of 22 (permalink) Old Today, 12:10 AM
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Soldering is the only way to go.
Other methods (crimp butt splices) are inferior and shows a lack of giving a crap.

A little sloppy with the gasket stuff there, eh? Haha

And yeah, that loom wrap you've got isn't going to work.
Too bulky.

O_E_M
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post #22 of 22 (permalink) Old Today, 2:48 AM Thread Starter
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Yeah, I didn't like the look of the rubber wire grommet in the cover so I Yamalubed the crap out of it. Can the factory harness be fitted without removing the plugs Ducatiman? I was thinking of running without the sprocket cover or casting a custom open aluminum one.

'92 EX500- "Project Lazarus"
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