Kawasaki EX500 - Flywheel Replacement (RMStator)

[@bcolby4392]

Holy smokes, this is precisely the video I considered creating for others, but grateful this guy saved me the trouble. I ran into every single one of these issues. This video is right on the money.

[@matttriestodothings]

Don't let it stop you from making a better one man. Niche motorcycle videos and old school forums are some of the last good remaining parts of the internet! I'm glad to know I wasn't the only one that hit these stumbling blocks. What I thought was going to be a straightforward simple 2 hour thing obviously turned into several days. Cheers man.

[@paullambert7110]

Only video so far I seen showing somewhat what to do appreciate u

[@matttriestodothings]

Thanks Paul.

[@SativaWraith]

Thank you taking the time to make this video.

[@matttriestodothings]

For sure. Hopefully it was useful.

[@SativaWraith]

Got a good condition white gen 1 I'm keeping & a tatty gen 2 I'm going to sell cheap. Thinking of being cheeky & swapping the chain tensioners & guides over xD

[@SativaWraith]

Assuming the flywheel isn't a straight swap though. That would make things too easy.

[@matttriestodothings]

@@SativaWraith eh, it's pretty much a straight swap besides me messing up the threads a bit.

[@matttriestodothings]

@@SativaWraith The 1st gen tensioners I'm told are a ticking timebomb, so swapping to a gen2 was advised to me.

[@mikeyyoyo6464]

Hi. Is that the same engine as the KLE 500? I’ve just bought a 1995 model with 27,000 miles on it & I’ve seen other videos about that part failing, the bike is in good condition for it’s age but it’s looking like I’m going to have to do this for peace of mind, unless it’s already been done as it’s a lot of miles on the original? Engines could be slightly different but those flywheels definitely have the same issue, good video 👍

[@matttriestodothings]

Interesting--I'd never heard of a KLE500, but I see that it was essentially the same engine as the EX500/Vulcans with some minor top-end changes. If it has the same flywheel, I'm guessing it could have the same potential problems as this one in the video. Peace of mind is probably the primary reason I'd consider doing the swap. Though it has proven itself for over 30 years already. But you just never know.

[@alielabdimarras7965]

Looks like you've got a stainless exhaust header on it, did not know there was an aftermarket replacement

[@matttriestodothings]

If thats the case I'm guessing the Muzzy exhaust must be a full system. I'm not an expert on these at all so just trying to figure it out on my own and whatever info I can get from the ex-500 forums.

[@surek0959]

nice work

[@matttriestodothings]

@@surek0959 thanks man.

[@lucasmorehouse7352]

Thank you for this! What size tap was it? Just want to be prepared. Great video

[@matttriestodothings]

The one I ordered had the description of "M10 x 1.25 HSS Metric Left hand Tap"

[@lucasmorehouse7352]

@@matttriestodothings I do have another question about the flywheel puller. Recommendations for the tool?

[@matttriestodothings]

@@lucasmorehouse7352 I don't have too much experience with flywheels pullers. I felt like the one that I ordered for this was 5mm too short which is why I sought out a slightly longer bolt. I do think that if I would have gone around with a soft hammer and tapped on the flywheel during stages of pulling that it would have come off easier though.

[@lucasmorehouse7352]

@@matttriestodothings you rock man. Thanks for all the help!!

[@alielabdimarras7965]

Sounds the Japanese way of doing thinks, the first fine thread in M10 that comes to my mind is M10 x 1 @@matttriestodothings

[@Gneeznow]

Is this the same engine that's in the EN500 and LTD454 ? I've got some weird noises coming out of mine lol

[@matttriestodothings]

LTD454 I believe was the predecessor to this engine.

[@Gneeznow]

@@matttriestodothings Thanks, it looks very similar, I'm guessing they are 80% the same

[@surek0959]

hi . I bought the exact same flywheel But there is no TDC marking on the flywheel at all How can I adjust the valve clearance if I change to this flywheel?

[@matttriestodothings]

Realistically, you can just make sure the cam lobe isn't pushing on the valve. It doesn't necessarily have to be at TDC in order to check clearances. It's "correct" to use the markings, but not imperative.

[@brendenc.2683]

My 91's flywheel grenaded apart on me the day I bought it at 15k miles. Good thing you did that beforehand. I have an 03 now, & haven't checked into the flywheel. Do you know if it's the same on the 2nd gen?

[@matttriestodothings]

Jeeze man, sorry to hear that. What a welcoming introduction to the EX500 you had. Yea this one was just in my head based on all the reports and recommendations I'd heard to swap the flywheel because of the poorly adhered magnets. Thanks Brenden for helping me to feel better about the money spent. Hope you were able to find something soon after to ride or get the ex repaired!

[@matttriestodothings]

Second Gen I'm told resolved the issue. Common swap is to modify a second Gen to go into first because second Gen resolved the issue. I didn't feel confident enough in myself to shave the second Gen and have it balanced so I went aftermarket.

[@brendenc.2683]

@@matttriestodothings Good to know, thanks for the fast response! I had to replace the flywheel and stator coil, and it ran great for awhile, but It developed an electrical issue after a few months. Only gets spark on the first initial crank. Couldn't figure it out. I'm thinking ignitor because I replaced the coils but I'm not sure.

[@brendenc.2683]

@@matttriestodothings And thanks for the fork rebuild video! Very helpful I just finished rebuilding the forks on my 03. And I put in the recommended 352 for 2nd gen because the forks are slightly bigger. But basically the same.

[@matttriestodothings]

@@brendenc.2683 I'm not sure why we love these two wheeled machines so much. I suppose it's those moments in between fixing the damn things that makes it all worth it! I'm starting at a tire on the floor right now that's refusing to spoon on and im considering arson in my own house. But I know that's not the right idea and once I get it seated it'll be worth it, haha.

[@unokarpa4405]

чтобы не повредить резьбу подкладывай шарик от подшипника под винт

[@matttriestodothings]

Rough translation "in order not to damage the thread, put the ball from the bearing under the screw"? I agree that a puller screw with some type of ball or spherical surface would be a lot better at not damaging the threads. I didn't know any better at the time, unfortunately.

[@unokarpa4405]

@@matttriestodothings нет необходимости покупать дорогой специальный инструмент, достаточно иметь обычный съёмник и обычный шарик из старого подшипника

[@matttriestodothings]

@@unokarpa4405 Thank you for the advice Uno. I think I have a bunch of ball bearings from the steering head of my Honda VF500F! I will use one next time.

[@matthew1990xy]

so my manual says to put molybdenum disulfide grease on before the flywheel, did your manual say the same thing?

[@dylanm5397]

Yes I did that and it’s been running perfect

[@garrettwilliams4180]

Where the hell did you get the left-handed tap? I need

[@matttriestodothings]

I bought it on Amazon. According to my buy history in 2022, it was a M10 x 1.25 HSS Metric Left Hand Thread Tap Pretty certain that was it.

[@garrettwilliams4180]

It says the bolt is a 10-36

[@matttriestodothings]

@@garrettwilliams4180 10-36 sounds like an SAE bolt. This is definitely metric.

[@jedmeans1263]

Whats the specs of the tap cause I slightly messed up the threads on my crankshaft and I need that specific tap

[@matttriestodothings]

M10 1.25 left handed is what I see in my Amazon purchase history.

[@rn.85]

Man, I'm trying to take the cover off my alternator right now and it's not even budging. Any suggestions?

[@matttriestodothings]

Soft taps with a soft hammer and keep working it around. I've had to drive a wedge (blade) in super stuck ones before... It sucks. I'd probably go around with a head gun if the soft hammer isn't budging and try again. Not a torch just heat gun.

[@rn.85]

@@matttriestodothings thanks for the reply. i got it off with a good thump from a mallet. is there supposed to be any engine oil in that side? my stator is doused in it...

[@matttriestodothings]

@@rn.85 Awesome--glad it came off. Some of them can be absolute nightmares to get off. Yea, there will be oil in there. In the video I had drained the oil which is why it probably doesn't look as messy.

[@shaughnparker2545]

Where did you buy the tap tool?

[@matttriestodothings]

The left-handed thread tap? Amazon for about $15. Item listed as "M10 x 1.25 HSS Metric Left Hand Thread Tap"

[@koyval22]

Hey bud is it a rm250 or rm450?

[@matttriestodothings]

The info I can find in my email confirmations is: "Kit Flywheel + Gasket + Flywheel Puller for Kawasaki VN 500 Vulcan / 454 LTD / Ninja 500 1985-1996 SKU: RMS900-104872" Not sure if that means rm250 or rm450. If you reach out to their customer service, they were really helpful with me when I was searching.