cracked stator and flywheel magnet - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
LinkBack Thread Tools
post #1 of 8 (permalink) Old 2-17-2017, 2:14 AM Thread Starter
Junior Member
 
Join Date: Jan 2017
Posts: 7
 
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
blackiredi is offline  
Sponsored Links
Advertisement
 
post #2 of 8 (permalink) Old 2-17-2017, 2:37 AM
Senior Member
 
one_evil_monkey's Avatar
 
Join Date: Oct 2012
Location: North Carolina, US
Posts: 10,519
  
Garage
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 2:51 AM.
one_evil_monkey is offline  
post #3 of 8 (permalink) Old 2-17-2017, 12:31 PM Thread Starter
Junior Member
 
Join Date: Jan 2017
Posts: 7
 
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
blackiredi is offline  
 
post #4 of 8 (permalink) Old 2-17-2017, 12:57 PM
Senior Member
 
Saabnut's Avatar
 
Join Date: Feb 2012
Location: Santa Rosa, CA
Posts: 1,567
 
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.

Runners:
1990 EX500 - 114,000 miles as of February 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*
Saabnut is offline  
post #5 of 8 (permalink) Old 2-17-2017, 11:31 PM Thread Starter
Junior Member
 
Join Date: Jan 2017
Posts: 7
 
Thanks Saabnut. I am looking as we speak. The crankcase search is a good idea. Hopefully this thing will be running soon.
Ben
blackiredi is offline  
post #6 of 8 (permalink) Old 2-18-2017, 1:16 PM
Senior Member
 
jorge moros's Avatar
 
Join Date: Nov 2014
Posts: 349
 
Check this:

eBay item number: 162219705827

Only two things are infinite, the universe and human stupidity, and I'm not sure about the former. -Albert Einstein.
2007 Ninja 500R
jorge moros is offline  
post #7 of 8 (permalink) Old Yesterday, 2:18 AM Thread Starter
Junior Member
 
Join Date: Jan 2017
Posts: 7
 
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.
blackiredi is offline  
post #8 of 8 (permalink) Old Yesterday, 8:54 AM
Senior Member
 
jorge moros's Avatar
 
Join Date: Nov 2014
Posts: 349
 
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.
2007 Ninja 500R
jorge moros 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