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One Flywheel Magnet was broken now what should I do

4075 Views 22 Replies 6 Participants Last post by  po18guy
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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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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
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?
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?
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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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
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
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
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.
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?
Mostly epoxy is gone - but magnets are not far behind.
HT: The bolt holding the flywheel is reverse thread, so it's not lefty loosey, righty tighty; it's the opposite!!
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.
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
Since it didn't exit, it's still in there. So, and oil change or two would be in order.
One Flywheel Magnet was broken now what should I do

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