Flywheel swap - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
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post #1 of 14 (permalink) Old 8-10-2018, 10:27 AM Thread Starter
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Flywheel swap

I did the search and found the thread for it but I cannot download the attachment for going gen 1 to gen 2 flywheel. Is anyone able to email it or post a link? Just picked up an 87 and the magnets are gonzo! What years are gen 2, 94+?

Thanks, site looks full of good info!
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post #2 of 14 (permalink) Old 8-10-2018, 10:37 AM
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I try to drop it here or send me your email to: [email protected]

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post #3 of 14 (permalink) Old 8-10-2018, 12:13 PM
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Did that document come thru? My email is acting up

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post #4 of 14 (permalink) Old 8-12-2018, 2:10 PM
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I added that to the wiki a few years ago, so we didn't have to mess with a Word doc. https://www.ex-500.com/wiki/index.ph...el_replacement


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post #5 of 14 (permalink) Old 4-10-2019, 11:10 PM
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So I have searched on the how to and wiki pages for this tutorial and it just goes to an error page. My Magnets just exploded and I need to do this conversion. Please email me at josephdavidfoto AT gmail.com
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post #6 of 14 (permalink) Old 4-11-2019, 3:34 AM
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Wieltronic in Belgium makes brand new flywheels for gen1 bikes. On eBay, they are normally $149 plus $32 shipping - still less than half the price of OEM, and no mods or balance issues. Better yet, here is someone in the US selling them for $135 w/free shipping. I got one and they are a good replacement.

https://www.ebay.com/itm/85-96-Kawas...IAAOSwm6lbPjOf

I finally figured out why I like Ducatis: With their exhaust note and dry clutch, they sound almost like a Guzzi!
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post #7 of 14 (permalink) Old 4-11-2019, 8:06 AM
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those flywheels are good but are still a fair chunk of bucks. I don't know why some are wary of doing the gen 2 mod it's not that hard. in fact quite simple. the original piece [in the how to] looks complicated with all that measuring with a Vernier. but assumes you don't have the gen 1 flywheel to hand. if you have it's easy. I have recently done this mod, cost $20 and one hour of time.

all you need is both flywheels off the bike.
a fine tipped marker.
flat level surface to work on.
a tee square.
a small hacksaw.
and something to grind the triggers. you can do this with a file if no grinding equipment is at hand.

procedure. first mark both flywheels on the outside edge where the timing marks are. T.F.C. with a fine marker.

place both flywheels on the flat surface one on top of the other [either way round]

line up the marks on both flywheels. check with the tee square. that they are all in line on both flywheels.

mark the start of the little trigger on the gen 1 onto the long trigger on the gen2. you will notice the end of both triggers are in line [or should be]

using hacksaw cut along the line of the gen 2 flywheel so it matches the gen 1.

measure the length of the trigger on both flywheels, they should be the same [30mm]


if they are mark this section on the gen 2 fly wheel with the marker[ so you don't forget which bit you have to keep.


then grind/file off all the rest of the triggers left on the gen 2 flywheel. that includes the long and short one on the back of the flywheel.


what you should be left with is two identical triggers 30mm long.


that's it your done. not hard at all and saves you loads of bucks.


edit. just found some photos of the last one I did.
Attached Images
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File Type: jpg 100_1209.JPG (245.2 KB, 13 views)

Last edited by yorkie; 4-11-2019 at 4:55 PM. Reason: to add photos
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post #8 of 14 (permalink) Old 4-11-2019, 3:14 PM
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My only concern is balance - think of 11,000 RPM way out there on the end of a flexi-flyer crankshaft which is supported by marginal cases. Much of the weights that the flywheel was balanced with being ground off.

My perspective is, as stout as they are, I managed to break a small block Chevy crankshaft - but it did not have the potential to spit me onto the pavement.

Just saying.

I finally figured out why I like Ducatis: With their exhaust note and dry clutch, they sound almost like a Guzzi!
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post #9 of 14 (permalink) Old 4-11-2019, 5:18 PM
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if you look at the position of the hole in the side [the only balance part of the flywheel] you will see it's not that far off centre as it was on the gen 1 flywheel. suppose if you wanted it to go racing. it could be re-balanced . but on a road bike. as far as I know this mod has been done hundreds if not thousands of times on exposed magnet flywheel bikes. yet no one has reported a crank failure. or even increased vibration.

FOG put this out years ago I believe. an out and out racer if that isn't testament to it's success I don't know what is.

the other thing to consider most do not do this until after the gen 1 flywheel has shed some magnets. if the engine is robust enough to survive that and probably been run in that state a fair while until it stops working . a little hole moved 15mm isn't going to do it.


just my view of course.
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post #10 of 14 (permalink) Old 4-11-2019, 5:40 PM
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2 is 2. For those unable or unwilling to locate and pay for a gen2 wheel and mod it, the aftermarket unit is a very viable option. At almost $50 off the shipped from Belgium price, it caught my eye.


I'm calling to mind here the number of members who can identify a wrench, but have never turned one. Some of those befuddled gents in the carb section will also have to deal with a flywheel. If 5 or 6 teardowns cannot get the carbs put right, what on earth are they going to do with a flywheel?



Just saying.

I finally figured out why I like Ducatis: With their exhaust note and dry clutch, they sound almost like a Guzzi!

Last edited by po18guy; 4-11-2019 at 5:45 PM.
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post #11 of 14 (permalink) Old 4-11-2019, 8:58 PM
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Now I wish I had a Gen1, so I could get in on this.

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post #12 of 14 (permalink) Old 4-11-2019, 10:12 PM
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Quote:
Originally Posted by bpe View Post
Now I wish I had a Gen1, so I could get in on this.

no you don't. you have a gen 2 so never have to worry about the flywheel exploding
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post #13 of 14 (permalink) Old 4-11-2019, 10:17 PM
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Point being made is that there are options. If you lack Dremel, drill motor or Bridgeport, it may seem a task too daunting. However, it can be done with a hand file if absolutely necessary.

I finally figured out why I like Ducatis: With their exhaust note and dry clutch, they sound almost like a Guzzi!
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post #14 of 14 (permalink) Old 4-12-2019, 8:46 AM
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the thing is these bikes are old. the ones that are around most likely are going to need a new flywheel at some point soon.

it was said by a senior member once "it not a question of if the magnets drop off but when they will drop off" indeed it is fair to say many of the gen 1's being bought to restore have been left to rot for many years because the flywheel has disintegrated the cost of a new one the main reason this has happened.


indeed even Kawasaki knew of the issue and is why the gen 2 has enclosed magnets. so given that all early flywheels are suspect what is the best way to eliminate the issue when this occurs.


new ones are expensive probably it would cost more to replace than the bikes is worth. that is if you can get a new one. in many part of the world this is impossible as they are no longer available. buy a aftermarket one yes good idea but these are still expensive and may be the cost prohibitive for use on a bike with a limited life span.


or convert a gen 2 one to run on the gen 1 electrics. this can be done in two ways. modify the flywheel or leave it as is and change the electrics to gen 2 spec it is possible just time consuming.


a lot will depend on the degree of competence you have to do either. one thing is for sure the issue will not go away until every gen 1 has been fixed and the problem will keep arising. however you decide to fix the issue is entirely in your own hands, most just want the cheapest option. if so the information is there what you do with it is up to you.

Last edited by yorkie; 4-12-2019 at 9:03 AM.
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