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Discussion Starter · #22 ·
I have always soaked the clutch plate in a wet clutch set up prior to assembly. Use motorcycle oil.
Can someone please provide me the Ninja 500r Torq settings for 1) the 3 Starter Clutch Bolts that connect to the flywheel, 2) the 2 Chain Guide bolts, 3) the center Flywheel bolt, and 4) the bolts that attach the Flywheel cover to the engine. The Clymer manual doesn't specify all the Torq settings. Thanks!
 

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not specifically but using my method. 1. as tight as you can with standard hex key plus added thread lock. 2. just nipped up tight'ish there only plate screws. 3. just nipped up it won't come undone (it's a left hand thread) 4. tight enough to seal the seal case but not overdone as they break very easily.
ok not scientific but the bolts on these bikes are made from butter so strip out or break. unless you have top quality inch pounds wrench forget it.
note, 90% of the bolts on both my bikes have been changed for Allen screws tightened up with no more than a stock "T" handled driver nothing ever leaks, breaks, or comes undone.
 

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Discussion Starter · #25 ·
Ok, I'm now at the point of putting the flywheel and attached starter clutch back on the drive shaft. It doesn't slide on easily, like I though it would. I know I need to line up the woodruff key with the flywheel, but you can only go on feel since it's hidden. Even when I think it's lined up I still can't push it in by hand.
Should I use a rubber mallet to get it in. Or, a hammer on a block of wood on the end of the flywheel. Hate to damage the flywheel doing something not recommended. Thanks!
 

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Should I use a rubber mallet to get it in. Or, a hammer on a block of wood on the end of the flywheel. Hate to damage the flywheel doing something not recommended. Thanks!
absolutely not no way, if the flywheel is not sliding on (it's not in line) all it will do is push the woodruff key out of position. both the crankshaft and the inside of the flywheel are tapered so much wider on the inside if that bit isn't sliding on.
try making sure the woodruff key is moving in it's seat and point it down slightly at the front. it helps if the keyway is pointing up. do not use force.
 

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Discussion Starter · #27 ·
absolutely not no way, if the flywheel is not sliding on (it's not in line) all it will do is push the woodruff key out of position. both the crankshaft and the inside of the flywheel are tapered so much wider on the inside if that bit isn't sliding on.
try making sure the woodruff key is moving in it's seat and point it down slightly at the front. it helps if the keyway is pointing up. do not use force.
OK, Got the flywheel with the attached starter clutch back on the bike. By rotating the flywheel in a clockwise direction until the woodruff key aligned was the secret.
Now I'm at the point of reattaching the flywheel (alternator) cover.
I was wondering about applying gasket rtv with the new gasket.
Where do I apply the rtv? I know I should apply it by the wires. But not sure where else.
Do I apply it on both sides of the gasket?
Also, should I take the dowel guides out of the flywheel cover and put them in the engine casing first. Seems like the cover will go on easier if I do that.
Thanks!
 

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you got the flywheel on good job, as for the outer case how you fit it is up to you. providing the gasket surfaces are clean paper gaskets don't need RTV. however you can put it on one side or both if you want it's your bike.
you can even delete the gasket altogether and just use RTV everyone has their own way. dowels don't care where they fit if it's more convenient to put them on the engine fine do that.
don't forget once you offer the case up to the engine the magnets will grab the stator so be prepared for that.
 

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Discussion Starter · #29 ·
you got the flywheel on good job, as for the outer case how you fit it is up to you. providing the gasket surfaces are clean paper gaskets don't need RTV. however you can put it on one side or both if you want it's your bike.
you can even delete the gasket altogether and just use RTV everyone has their own way. dowels don't care where they fit if it's more convenient to put them on the engine fine do that.
don't forget once you offer the case up to the engine the magnets will grab the stator so be prepared for that.
Ninja all back together and running fine. Starts every time and no leaks. Went for a very nice 30min country ride yesterday. Looking forward to many more rides this fall.
Thanks for all your help! Saved me a fortune by doing the job myself. :)
 
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