Powerdynamo MZB INSTALLATION ON A KX500

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Brakes, Suspension, Carburetor, Bottom end, Top end, Chassis, Discontinued parts, Wheels, Plastic, Tools
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Powerdynamo MZB INSTALLATION ON A KX500

Post by Sandblaster » Wed Aug 21, 2013 10:44 pm

MZB INSTALLATION ON A KX500

I'd like to start by thanking Alward25 and Motorrad for their insight and tips for making this installation a complete success.
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Re: MZB INSTALLATION ON A KX500

Post by Sandblaster » Thu Aug 22, 2013 9:47 pm

Directions.
DIRECTIONS PAGE 1.JPG
DIRECTIONS PAGE 1.JPG (743.13 KiB) Viewed 3617 times
DIRECTIONS PAGE 2.JPG
DIRECTIONS PAGE 2.JPG (246.47 KiB) Viewed 3617 times
DIRECTIONS PAGE 3.JPG
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Re: MZB INSTALLATION ON A KX500

Post by Sandblaster » Thu Aug 22, 2013 9:51 pm

Fly wheel puller
FLY WHEEL PULLER.JPG
FLY WHEEL PULLER.JPG (53.98 KiB) Viewed 3616 times
Fly wheel
FLY WHEEL.JPG
FLY WHEEL.JPG (79.04 KiB) Viewed 3616 times
Stator
STATOR.JPG
STATOR.JPG (167.9 KiB) Viewed 3616 times
MISC1.JPG
MISC1.JPG (115.55 KiB) Viewed 3616 times
MISC2.JPG
MISC2.JPG (77.46 KiB) Viewed 3616 times
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Re: MZB INSTALLATION ON A KX500

Post by Sandblaster » Mon Aug 18, 2014 9:56 pm

So now that we have the preliminaries out of the way, we need to be able to move the piston to top dead center and then roll the motor back .086" and install the flywheel.
So how can you get the timing exact?
Just need the right tool.
I used a dial indicator and a old hollowed out spark plug.
The first pic here is of my cut away motor.
I am seeing if I have enough travel in my dial indicator to zero the indicator out when the piston is at top dead center, and then still have enough travel to back the motor off to .086".
This is the set up:

[attachment=1]kx500 mzb ignition 1.JPG[/attachment]

In the next pic I rotated the crank so that the top of the piston is at top dead center and zeroed out my indicator.
Then I rotated the crank so that the indicator is not touching the piston at all and got a reading of .132"
Looks good even when we factor in the gasket thickness that is not on the mock up engine.
However, it is really close so I may have to modify my spark plug adapter some to gain some travel in the indicator.
Why?
As Motorrad is fold of saying, every motor is a snowflake...
That's right, stacking tolerances are a killer.
So, when I get this set up on my engine I will run the same procedure and see if we have enough throw.
If not, I can add a little to the bottom of my indicator such as a drop of epoxy or I can cut down the thickness of my adapter.
We will just have to wait and see... :shock:

[attachment=0]kx500 mzb ignition 2.JPG[/attachment]
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kx500 mzb ignition 2.JPG
kx500 mzb ignition 2.JPG (39.63 KiB) Viewed 3307 times
kx500 mzb ignition 1.JPG
kx500 mzb ignition 1.JPG (62.38 KiB) Viewed 3307 times
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Re: MZB INSTALLATION ON A KX500

Post by Sandblaster » Wed Aug 20, 2014 7:33 pm

Just for grins I weighed a stock KX500 flywheel and it is approx 2.6lb.
The flywheel I used comes in at 1.6lb.
That should make it go Wheeeee! a bit faster :-)

Use fine lapping compound and lap away...
KX500 2001 MZB INSTALLATION 1.JPG
KX500 2001 MZB INSTALLATION 1.JPG (76 KiB) Viewed 3294 times
I didn't get any pics before I started but the tapered flywheel ID was bright and shiny.
After applying some fine lapping compound and spinning the flywheel back and forth, round and round, it should be dull..
KX500 2001 MZB INSTALLATION 1-1.JPG
KX500 2001 MZB INSTALLATION 1-1.JPG (40.19 KiB) Viewed 3294 times
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Re: MZB INSTALLATION ON A KX500

Post by Sandblaster » Wed Aug 20, 2014 11:24 pm

Here's how the crank looks..
KX500 2001 MZB INSTALLATION 1-2.JPG
KX500 2001 MZB INSTALLATION 1-2.JPG (46.82 KiB) Viewed 3293 times
The next thing I did was test fit the stator.
When I tried to seat it, it rocked back and forth.
No matter how much I moved it, it just wouldn't seat..
Here is the culprits...
KX500 2001 MZB INSTALLATION 1-3.JPG
KX500 2001 MZB INSTALLATION 1-3.JPG (38.34 KiB) Viewed 3293 times
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Re: MZB INSTALLATION ON A KX500

Post by Sandblaster » Wed Aug 20, 2014 11:28 pm

Just to make sure, I put some grease on the end of the bolts and did a test fit.
KX500 2001 MZB INSTALLATION 1-4.JPG
KX500 2001 MZB INSTALLATION 1-4.JPG (47.58 KiB) Viewed 3293 times
Sure enough that was the problem.
After I ground the bolts shorter the stator went right in with no problems.
KX500 2001 MZB INSTALLATION 1-5.JPG
KX500 2001 MZB INSTALLATION 1-5.JPG (64.56 KiB) Viewed 3293 times
I used a dab of Blue Loctite on the bolts.
Probably don't need it but I wanted to be sure I don't loose a bolt and destroy my system :shock:
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Re: MZB INSTALLATION ON A KX500

Post by Sandblaster » Wed Aug 20, 2014 11:31 pm

The next thing I had to do was cut down the length of the grommet that sites between the engine case and the stator cover.
KX500 2001 MZB INSTALLATION 1-6.JPG
KX500 2001 MZB INSTALLATION 1-6.JPG (36.08 KiB) Viewed 3293 times
Turns out the grommet is about an inch too long.
I plan on using some RTV Black Silicon to help seal the wire and grommet.
So now your ready for the flywheel right?
Not just yet.
Remember the dial indicator and the spark plug adapter I showed earlier?
Go ahead and screw in your spark plug adapter into the head, then set your dial indicator with the set screw so that the indicator does not move around.
Next, roll your engine until the piston is at Top Dead Center...
KX500 2001 MZB INSTALLATION 2-6.JPG
KX500 2001 MZB INSTALLATION 2-6.JPG (49.34 KiB) Viewed 3293 times
Once you find Top Dead Center, Zero your indicator out.
Next you want to roll your engine over backwards until you hit .087"
If you are facing the stator side of the engine, that will be clockwise.
If you are facing the clutch side of the engine, that will be counter clockwise.
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Re: MZB INSTALLATION ON A KX500

Post by Sandblaster » Wed Aug 20, 2014 11:56 pm

Note that my indicator reads backwards so if you were reading it normally it would appear to be .014".
(The dial indicator is reading .013" because we had a change in timing... Use .014"
KX500 2001 MZB INSTALLATION 2-7.JPG
KX500 2001 MZB INSTALLATION 2-7.JPG (78.96 KiB) Viewed 3293 times
But look a bit closer.... Notice the small red numbers?
KX500 2001 MZB INSTALLATION 2-8.JPG
KX500 2001 MZB INSTALLATION 2-8.JPG (21.25 KiB) Viewed 3293 times
Reading the small red numbers it's .086".... PERFECT!!! **** CORRECTED INFO NOW IT'S .086" ****
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Re: MZB INSTALLATION ON A KX500

Post by Sandblaster » Wed Aug 20, 2014 11:59 pm

Now you need to install the flywheel.
Remember, there is no keyway in the flywheel.
Why?
Because this flywheel can be used in many different bikes :-)
On this model my stator has a small Yellow dot.
The flywheel has a line on the outside edge.
You need to line the line and the dot up and set it into place while maintaining the .086" reading :shock:
KX500 2001 MZB INSTALLATION 1-7.JPG
KX500 2001 MZB INSTALLATION 1-7.JPG (40.27 KiB) Viewed 3293 times
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