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Discussion Starter · #1 ·
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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Fast Old Guy
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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
 

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Discussion Starter · #3 ·
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?
 

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07 Ducati SS800 '95 Ducati 900SS/SP '19 Honda CBR650R
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yes, reuse stator, test output prior to putting back into service (after replacing FW)
 
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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.

 
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Discussion Starter · #7 ·
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
 

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Fast Old Guy
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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
 

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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.
 

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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
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Where are: the orange coatings missing from some of the other magnets?
 

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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.
 

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Discussion Starter · #16 ·
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
 

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

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One Flywheel Magnet was broken now what should I do

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