Maintenance & Technical > KX500 Original
The Next Rebirth!
Danger4u2:
--- Quote from: dirtball ---Does anyone have a contact number for Stealthy. I am not having much luck
finding info on them.
Thanks
Travis
--- End quote ---
http://www.steahlyoffroad.com/store2003/weights.php?s_make=kawasaki&s_category=Flywheel+Weights
Your Welcome
Danger
Johnniespeed:
Steahly Off Road Products. 3850 Pioneer Road Medford Oregon 97501 USA
1-800-800-2363 1-541-535-4896
Johnniespeed:
By the way, the flywheel weight replaces the nut that holds the flywheel on. There are two threaded holes in the face of the weight that are tapped 1/4 20 sae thread. that is where the installer/remover tool bolts onto. You will need to spin the flywheel weight counterclockwise while keeping the crank stationary. Once you have it off and inspect it you will see how very simple it is. The set screws should be SAE ( non-metric) thread and only need to be loosened a little.
dirtball:
I ended up getting the set screws out with a TINY amount of heat. I didn't use the Oxy/Acetelyne, I used a handheld propane bottle with a brazing tip. I
just barely kissed the flywheel with the flame. I also picked up a 1/4 inch drive 3/32nd hex socket from Snap-On that seemed to deliver a fair amount more torque than a standard L-end hex key.
As for the flywheel removal tool, I took a 1 inch by 3 inch peice of flat steel and welded an extra 1 inch 3/8ths extension. Then drilled holes to bolt it to the flywheel weight. The threads to attach the removal tool to the flywheel weight were 1/4 course standard threads.
I did find once I had the flywheel off, that the flywheel had sheered the woodruff key, and had been sheered for quite some time.
This is a dumb question. The flywheel appears to be one big magnent, aside from being bad for the crank and flywheel surfaces, how does the sheered key change the timing? At what point when the flywheel is passing the coils does the spark get generated?
The sheered flywheel key is yet another factor that was making her such a nightmare to get started.
I can't wait to get her moving again, I can't go any further with splitting the cases until I get a manual.
Between the power valves overclosing, the gunk I found in the pilot circut, and the sheered flywheel key. My 500 dollar KX5 is gonna idle and SCREAM. I can not wait!
Any opinions on Clymer manuals vs the factory literature for overhauls down to splitting the cases?
Travis
KXcam22:
Dirtball,
That sheared key is a good find! Would have given you lots of trouble. On mine I lapped the flywheel to the crank end. Very simple, just borrow a tiny bit of valve grinding compound, place it on the crank taper (no key), put the flywheel on by hand and spin it a bunch. Every so often move the paste back onto the taper. When the two surfaces match you will see a nice even pattern. Hope this helps. Cam.
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