One Flywheel Magnet was broken now what should I do

4075 Views 22 Replies 6 Participants Last post by po18guy, Jan 1, 2022

HT_Legend

Discussion Starter · Dec 13, 2021

2

I have a 1993 EX500 that I've been trying to fix up, today was my first startup test and the starter wouldn't turn over and all I got was the clicking noise. I decided to remove the old starter but when I took the Stator cover off to get to the starter all I saw was that one of the flywheel magnets was cracked apart and broken. Now due to my lack of motorcycle knowledge IDK whether I can continue using the current flywheel considering it has all its other magnets and a good portion of the broken one or if I need to replace it and the current stator along with it some advice in the right direction would really be appreciated

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fog

· #2 · Dec 13, 2021

Well you have have gen 1 generator and those are or should be replaced with modified gen 2 units (see my piece in the how too section)
you somehow escaped total destruction so you can run it Albiet slowly till a replacement can be found the issue will be balance.
Try to sources a use Gen 2 wheel, last resort is a new $$$$ one

FOG

HT_Legend

Discussion Starter · #3 · Dec 13, 2021

fog said:
Well you have have gen 1 generator and those are or should be replaced with modified gen 2 units (see my piece in the how too section)
you somehow escaped total destruction so you can run it Albiet slowly till a replacement can be found the issue will be balance.
Try to sources a use Gen 2 wheel, last resort is a new $$$$ one

FOG

Ok, ill try to find your piece in the how-to section. How much do gen 2 flywheels generally cost?

HT_Legend

Discussion Starter · #4 · Dec 13, 2021

Also if I put a GEN 2 generator on do I need to replace the stator as well or is it fine without replacing it?

ducatiman

· #5 · Dec 13, 2021

yes, reuse stator, test output prior to putting back into service (after replacing FW)

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po18guy

· #6 · Dec 13, 2021 (Edited)

RM Stator in Loveland Co. sells new upgraded flywheels. Last price I saw was $139. Better buy quick before Brandon's inflation sets in.

Here's the 1987-1993 EX500 page. I don't think the flywheels are listed for the price they give.

Partfinder

rmstator.com

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HT_Legend

Discussion Starter · #7 · Dec 14, 2021

I ended up ordering a FW from a UK company called Electrex World now I'm wondering where I should get a Flywheel tool to remove the old one idk the specs for it

haybaler

· #8 · Dec 14, 2021

HT_Legend said:
I ended up ordering a FW from a UK company called Electrex World now I'm wondering where I should get a Flywheel tool to remove the old one idk the specs for it

Is it this one? https://www.amazon.com/gp/product/B004MB8ZBY/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1

HT_Legend

Discussion Starter · #9 · Dec 14, 2021

haybaler said:
Is it this one? https://www.amazon.com/gp/product/B004MB8ZBY/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1

That's the one I ended up buying its the right one

fog

· #10 · Dec 14, 2021

the flywheel too is just a 18mm bolt. which is the same thread as the spark plugs. go to any auto store and purchase a spark plug thread restore tool for a few bucks.
Hey I never thought till now. a old plug may do the job just break off the electrode

FOG

po18guy

· #11 · Dec 14, 2021

You will need some way of holding the outside of the flywheel so as to keep it from turning. I used a strap wrench. When the bolt is good and tight, coupla ways to do it, but I smacked the end of the breaker bar with a rubber mallet. 2-3 whacks and the flywheel will pop off. No matter if it hits the floor, as it it trash anyway.

haybaler

· #12 · Dec 14, 2021

Well..., 11 posts in, and no one has asked the question. So, almost with an apology to HT, I'll ask.

Where are: the missing pieces of the broken magnet
&
Where are: the orange coatings missing from some of the other magnets?

po18guy

· #13 · Dec 15, 2021

Mostly epoxy is gone - but magnets are not far behind.

haybaler

· #14 · Dec 15, 2021

HT: The bolt holding the flywheel is reverse thread, so it's not lefty loosey, righty tighty; it's the opposite!!

po18guy

· #15 · Dec 16, 2021

Even though they are opposite threads, it is clockwise to remove the flywheel bolt and clockwise on the flywheel puller. Sounds odd, but the whole bike is odd.

HT_Legend

Discussion Starter · #16 · Dec 16, 2021

haybaler said:
Well..., 11 posts in, and no one has asked the question. So, almost with an apology to HT, I'll ask.

Where are: the missing pieces of the broken magnet
&
Where are: the orange coatings missing from some of the other magnets?

i cleaned up the broken magnet bits no idea where the orange epoxy went

po18guy

· #17 · Dec 16, 2021

Since it didn't exit, it's still in there. So, and oil change or two would be in order.

ducatiman

· #18 · Dec 18, 2021

One Flywheel Magnet was broken now what should I do

begs the question.....what DID you do?

HT_Legend

Discussion Starter · #19 · Dec 19, 2021

ducatiman said:
One Flywheel Magnet was broken now what should I do

begs the question.....what DID you do?

my bike is project bike i just recently got it like 3-4 weeks ago and i honestly have no clue why it broke it was my first time even seeing it lol

HT_Legend

Discussion Starter · #20 · Dec 19, 2021

HT_Legend said:
my bike is project bike i just recently got it like 3-4 weeks ago and i honestly have no clue why it broke it was my first time even seeing it lol

But i got the new FW and I'm ready to put it in ASAP but the rain over here is just stopping me

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