[Amoore117]

Hello,

I was wondering if anyone can point me in the correct direction. I recently purchased a 93 vulcan500 and it has a charging issue. I removed the stator cover and found the magnets on the magneto have left their home without permission and proceeded to wipe out the whole charging system. I want to upgrade the magneto to the “enclosed model ”

can i use a rotor from a 94-09 ex500 ninja and modify as outlined in the how to i found on this forum?

thank you guys in advance!
-alex

 

[yorkie]

yes you can it's a standard upgrade. if it's wiped out the stator you can use one off any model with this engine fitted. but you will have to retain the outer cover that has the two ignition triggers. (assuming it wired same as the gen 1 and has 2 triggers).
don't forget to make sure you have removed all the bits of broken magnets even if that means dropping the sump to make sure. drop the oil and change the filter also.

 

[Amoore117]

yes you can it's a standard upgrade. if it's wiped out the stator you can use one off any model with this engine fitted. but you will have to retain the outer cover that has the two ignition triggers. (assuming it wired same as the gen 1 and has 2 triggers).
don't forget to make sure you have removed all the bits of broken magnets even if that means dropping the sump to make sure. drop the oil and change the filter also.

Thank you so much!
Yes it’s very ugly 70% magnets have been hammered. Here is a picture

 

[yorkie]

man that's ugly. good clean required not seen one that bad in long time must have been ran quite a while with the magnets being slowly consumed.

 

[Amoore117]

I agree. I was disappointed to say the least but I am crossing fingers that after a good clean out

all new charging parts

and a half dozen or so oil system flushes, I will be able to save the motor from exploding because of all magnet parts that may be stuck in the oil pathways.

 

[ducatiman]

I'd suggest pulling the oil pan, examining/cleaning the oil/screen inlet filter.

 

[Amoore117]

Is this something that the motor needs to be pulled to do?

 

[ducatiman]

no

 

[Amoore117]

than in only makes sense with all the carnage.
thanks!

 

[yorkie]

I agree. I was disappointed to say the least but I am crossing fingers that after a good clean out

all new charging parts

and a half dozen or so oil system flushes, I will be able to save the motor from exploding because of all magnet parts that may be stuck in the oil pathways.

I'm afraid it's one of those ticking time bombs for all gen 1 type engines. engine dismantling not required just a thorough clean out as it been suggested drop the sump wash it out clean the strainer. should be good to go with new generator parts.

edit. just to add this a very common issue, as of yet no-one has reported a blown up engine because of it.

 

[Amoore117]

I'm afraid it's one of those ticking time bombs for all gen 1 type engines. engine dismantling not required just a thorough clean out as it been suggested drop the sump wash it out clean the strainer. should be good to go with new generator parts.

edit. just to add this a very common issue, as of yet no-one has reported a blown up engine because of it.

Overall it runs good if you ask my “half trained” ear. I am on the fence on if I’m glad I didn’t find out about this until after I bought it because I may not have. I think I spent more on charging parts than I did on the bike itself. I have worked on cars and atvs and basically anything for over 20 years now but this is my first bike I finally pulled the trigger and bought. So I just worry when I think of relatively small oil passages and magnetic pieces in the quantity I found behind the cover. there would really be know way of knowing how clogged up it may be on the inside even if I tore it all down, which I don’t believe it needs by how overalls quiet the motor is while it runs. I will have to find the procedure to drop the sump and clean it out as good as I can.
would you suggest running and extra magnet around the oil filter after the clean out to try and pick up any debris?

 

[yorkie]

no I wouldn't bother. there is no reason to over think this one. the filter will take out any small particles that's it's job, you could swap it out after a few miles (earlier than usual) and drop the oil. but really the magnet bits are really soft (in metal terms) being made from magnetised compressed carbon dust and there is plenty of carbon dust circulating round the engine normally that does not do any harm.
just remove as much as possible with a good wash out.

 

[bpe]

There are 3 O-rings involved with the R&R of the oil pan. More often than not they fall out during the pan removal and leave members scratching their heads wondering where they came from, and where they go. These are not standard O-rings that you can get at a local auto store. They have a flat side and are directional specific. These O-rings are minimal cost, so I would suggest buying new ones ahead of time and just replacing them. I would plan on replacing the pan gasket also, but that's just me.

I always suggest to anyone working on their bike to have a service manual.

 

[Amoore117]

There are 3 O-rings involved with the R&R of the oil pan. More often than not they fall out during the pan removal and leave members scratching their heads wondering where they came from, and where they go. These are not standard O-rings that you can get at a local auto store. They have a flat side and are directional specific. These O-rings are minimal cost, so I would suggest buying new ones ahead of time and just replacing them. I would plan on replacing the pan gasket also, but that's just me.

I always suggest to anyone working on their bike to have a service manual.

I will need to find them and order them for sure. I do not think the pan gasket i ordered came with them

 

[bpe]

1993 Kawasaki VULCAN 500 (EN500-A4) Crankcase | Ron Ayers
I think (but not 100%) that the ones you need are:
Part # 92055-048 (2 of these) &
Part #92055-074

This particular diagram is a little busy. I can't even find the -074 on it, and just one of the -048's. They list the sizes of the O-rings, so it could be confirmed once the pan is dropped.

 

[Amoore117]

1993 Kawasaki VULCAN 500 (EN500-A4) Crankcase | Ron Ayers
I think (but not 100%) that the ones you need are:
Part # 92055-048 (2 of these) &
Part #92055-074

This particular diagram is a little busy. I can't even find the -074 on it, and just one of the -048's. They list the sizes of the O-rings, so it could be confirmed once the pan is dropped.

Thanks BPE. maybe someone will chime in and confirm the size if not I will when I drop it

 

[po18guy]

The '94-'09 flywheel cannot be swapped in without modification to the ignition triggers. There is a thread here about how to modify them. You can also buy an upgraded Gen1 flywheel that bolts right on, but they are $150-$175. I have a Gen2 flywheel in a box somewhere if you cannot find one to modify.

Here is a used upgraded Gen1 unit ($600 from Kawi!!!) on eBay. I would shoot them an offer and see what they say. Otherwise, new upgraded flywheels from Belgium are about $190 delivered.

eBay item number 115343862647

 

[Amoore117]

The '94-'09 flywheel cannot be swapped in without modification to the ignition triggers. There is a thread here about how to modify them. You can also buy an upgraded Gen1 flywheel that bolts right on, but they are $150-$175. I have a Gen2 flywheel in a box somewhere if you cannot find one to modify.

I found the upgraded gen1 version for like 250 and a gen 2 for 150 so I’m going for the gen2 and will modify as per the write up that FOE (I believe) did. Thanks for the heads up and the offer. If something goes wrong I will keep it in mind. I don’t believe I should have an issue, but I would bet we all know Murphy Unfortunately.

 

[po18guy]

For $180 asking price, the one I listed is a genuine Kawi unit and needs no mods. I have the same flywheel on my '87.

 

[Amoore117]

For $180 asking price, the one I listed is a genuine Kawi unit and needs no mods. I have the same flywheel on my '87.

I don’t know how I missed the bottom of your first listing

if I had not already ordered eBay item number 265197380438 I would have ordered what you gave me here. 🤦🏻‍♂️ Damnit.