How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG) - Page 2 - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #26 of 146 (permalink) Old 4-12-2011, 2:48 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Tutorial re-uploaded


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post #27 of 146 (permalink) Old 4-12-2011, 2:50 PM Thread Starter
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

if anyone has the old PDF, can you PM me?
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post #28 of 146 (permalink) Old 6-16-2011, 4:26 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Am I the only one wondering why these great tutorials, how to's, and explanations FOG has so graciously supplied us with stay hidden amongst the threads? We have a Wiki site right? Unless there's something I'm missing, why hasn't anyone added pages for these expert instructions?
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post #29 of 146 (permalink) Old 6-16-2011, 6:16 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

They are not hidden they are where they belong in the HOW too Section.

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post #30 of 146 (permalink) Old 6-16-2011, 8:10 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Because nobody actually wants to go through and figure out what the hell FOG is trying to say in some of the sentences he writes!
post #31 of 146 (permalink) Old 6-16-2011, 8:18 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

So they would rather be miss directed?

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post #32 of 146 (permalink) Old 6-27-2011, 5:01 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Quote:
Originally Posted by Rinzler
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.
Challenge accepted. hs.ucf.edu.

Site i managed for about 6 years.
post #33 of 146 (permalink) Old 7-7-2011, 11:03 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Sorry to bring this up, I am new to the forum, and therefore a rookie when it comes to this stuff. After much research I found that 2nd gens are considered to be 1994+. I found out the hard way that this is not true when it comes to Flywheels. After purchasing a used 2002 flywheel, I noticed when it got sent to me that those trigger points do not exist. Can anyone confirm what years will work for this modification so I do not make the same mistake. Thanks
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post #34 of 146 (permalink) Old 7-7-2011, 11:08 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Quote:
Originally Posted by RLNTHDR
Sorry to bring this up, I am new to the forum, and therefore a rookie when it comes to this stuff. After much research I found that 2nd gens are considered to be 1994+. I found out the hard way that this is not true when it comes to Flywheels. After purchasing a used 2002 flywheel, I noticed when it got sent to me that those trigger points do not exist. Can anyone confirm what years will work for this modification so I do not make the same mistake. Thanks
I would put my money on the flywheel being incorrectly listed, because so far the 1st/2nd gen split has held true with no exceptions.
post #35 of 146 (permalink) Old 7-8-2011, 1:51 AM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Quote:
Originally Posted by RLNTHDR
Sorry to bring this up, I am new to the forum, and therefore a rookie when it comes to this stuff. After much research I found that 2nd gens are considered to be 1994+. I found out the hard way that this is not true when it comes to Flywheels. After purchasing a used 2002 flywheel, I noticed when it got sent to me that those trigger points do not exist. Can anyone confirm what years will work for this modification so I do not make the same mistake. Thanks
Yea, im goin with you have somehow messed up VS the parts fiche from ron ayers + kawi service manuals + personal experience + forum experience have somehow messed up. Where did you buy it from and show us some pictures so we can identify it for you.
post #36 of 146 (permalink) Old 7-8-2011, 7:41 AM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

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

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post #37 of 146 (permalink) Old 8-5-2011, 2:32 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Hi. i saw that you guys know some things about transforming a 2nd generation flywheel to the 1st gen.
my english is not to good...i'm from hungary...
Now...could you help me with some pictures about the 1st gen and 2nd gen.flywheel?i could use them to understand the thing.My flywheel is on the moto..if you got pics pls send them to me on my e-mail: [email protected].

Thanks!
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post #38 of 146 (permalink) Old 8-5-2011, 2:52 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

https://www.ex-500.com/index.php?acti...0;attach=28069

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post #39 of 146 (permalink) Old 8-6-2011, 1:01 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Thank you! i could also use a picture with te first gen.flywheel in good shape...a working one.Help pls!
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post #40 of 146 (permalink) Old 8-6-2011, 4:00 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

What do you want? first picture right side is a un doctored 1st gen flywheel.

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post #41 of 146 (permalink) Old 8-7-2011, 6:36 AM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

I want a picture with the 6 magnet first gen.flywhell brand new.without missing or broken parts.Thx.
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post #42 of 146 (permalink) Old 8-7-2011, 11:55 AM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Why?

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post #43 of 146 (permalink) Old 8-7-2011, 8:36 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

i need it so i can see how big is the damage at mine,when i will take it off.Thx.
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post #44 of 146 (permalink) Old 8-7-2011, 9:49 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

You won't have any trouble recognizing the damage.

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post #45 of 146 (permalink) Old 8-8-2011, 7:45 AM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

ok.ty.i hope it will be ok
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post #46 of 146 (permalink) Old 8-22-2011, 12:18 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

ok,so i remove that extra material(like in that pdf.file)...and in the outside it will look exactly like a flywheel from 1987?
The difference will be only in the inside?it will work?
10x
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post #47 of 146 (permalink) Old 8-22-2011, 12:31 PM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Quote:
Originally Posted by mandolin
ok,so i remove that extra material(like in that pdf.file)...and in the outside it will look exactly like a flywheel from 1987?
The difference will be only in the inside?it will work?
10x
yup. If you have done the outside properly it will work great.
post #48 of 146 (permalink) Old 8-26-2011, 2:39 AM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

i made everything as is says in the pdf.file...and it dosent work.something is not sincronized,it works but not properly...it gives spark to fast,way before it should....i have no idea what went wrong...
Ideas?
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post #49 of 146 (permalink) Old 8-26-2011, 8:44 AM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

i found the problem....nobody sad nothing about the 2nd gen.flywheel having that 'trigger' on the other side to....so i modified as it sad in the pdf.file...but on the other side it has trigger to.....

this is how it looks.

So i have to remove that to?
Attached Images
File Type: jpg flywheel 2nd gen..jpg (433.6 KB, 85 views)
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post #50 of 146 (permalink) Old 8-26-2011, 9:52 AM
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Re: How to modify a 2nd Gen flywheel for a 1st gen bike (by FOG)

Boy I don't know how I could have made it any clearer. The new flywheel has to match the old one exactly all the way around. And mind that the orientation to the cranshaft key is exactly the same as well.

If you do it wrong you have ruined your flywheel. I have repaired a ruined one, By removing all the triggers and welding on a correct one in the right place. but the welding must be TIG and only small tacks. Too much heat will destroy the glue holding the magnets.

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