Powerdynamo MZB INSTALLATION ON A KX500
- Sandblaster
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Powerdynamo MZB INSTALLATION ON A KX500
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.
I'd like to start by thanking Alward25 and Motorrad for their insight and tips for making this installation a complete success.
If bikes are for kids I'll never grow up.
- Sandblaster
- Posts: 6313
- Joined: Thu Jun 07, 2012 3:50 pm
- Location: Eugene, OR
- Contact:
- Sandblaster
- Posts: 6313
- Joined: Thu Jun 07, 2012 3:50 pm
- Location: Eugene, OR
- Contact:
Re: MZB INSTALLATION ON A KX500
Fly wheel puller
Fly wheel
Stator
Fly wheel
Stator
If bikes are for kids I'll never grow up.
- Sandblaster
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- Joined: Thu Jun 07, 2012 3:50 pm
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Re: MZB INSTALLATION ON A KX500
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...
[attachment=0]kx500 mzb ignition 2.JPG[/attachment]
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...
[attachment=0]kx500 mzb ignition 2.JPG[/attachment]
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- kx500 mzb ignition 2.JPG (39.63 KiB) Viewed 11218 times
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- kx500 mzb ignition 1.JPG (62.38 KiB) Viewed 11218 times
If bikes are for kids I'll never grow up.
- Sandblaster
- Posts: 6313
- Joined: Thu Jun 07, 2012 3:50 pm
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Re: MZB INSTALLATION ON A KX500
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...
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..
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...
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..
If bikes are for kids I'll never grow up.
- Sandblaster
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- Joined: Thu Jun 07, 2012 3:50 pm
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Re: MZB INSTALLATION ON A KX500
Here's how the crank looks..
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...
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...
If bikes are for kids I'll never grow up.
- Sandblaster
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Re: MZB INSTALLATION ON A KX500
Just to make sure, I put some grease on the end of the bolts and did a test fit.
Sure enough that was the problem.
After I ground the bolts shorter the stator went right in with no problems.
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
Sure enough that was the problem.
After I ground the bolts shorter the stator went right in with no problems.
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
If bikes are for kids I'll never grow up.
- Sandblaster
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- Joined: Thu Jun 07, 2012 3:50 pm
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Re: MZB INSTALLATION ON A KX500
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.
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...
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.
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...
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.
If bikes are for kids I'll never grow up.
- Sandblaster
- Posts: 6313
- Joined: Thu Jun 07, 2012 3:50 pm
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Re: MZB INSTALLATION ON A KX500
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"
But look a bit closer.... Notice the small red numbers?
Reading the small red numbers it's .086".... PERFECT!!! **** CORRECTED INFO NOW IT'S .086" ****
(The dial indicator is reading .013" because we had a change in timing... Use .014"
But look a bit closer.... Notice the small red numbers?
Reading the small red numbers it's .086".... PERFECT!!! **** CORRECTED INFO NOW IT'S .086" ****
If bikes are for kids I'll never grow up.
- Sandblaster
- Posts: 6313
- Joined: Thu Jun 07, 2012 3:50 pm
- Location: Eugene, OR
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Re: MZB INSTALLATION ON A KX500
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
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
If bikes are for kids I'll never grow up.
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