Powerdynamo MZB INSTALLATION ON A KX500

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Admittedly, it took me a few tries to get it right.
The first thing I noticed is that my crank stuck too far out into the flywheel hole

KX500 2001 MZB INSTALLATION 3-1.JPG (22.45 KiB) Viewed 7827 times

But, the kit came with 3 washers that were perfect for the job... Almost like they knew I would need them..

KX500 2001 MZB INSTALLATION 3-2.JPG (21.83 KiB) Viewed 7827 times

So I put the washers on then slipped the flywheel on with just a light smear of blue (Weak) retaining compound.
With the dial indicator at .087" reversed rotation from TDC I put the nut on just a few threads.
Then I took my Makita and ran the nut up on the flywheel fast to drive the flywheel on and set it in position.
Makita...

KX500 2001 MZB INSTALLATION 3-4.JPG (48.42 KiB) Viewed 7827 times

Because the flywheel moved when I did this (About .010") I had to figure something else out.
So, I read the directions
It says to use a block of wood to lightly tap the flywheel on and then set the nut.
I tried it by the directions and the flywheel moved again!
So after talking with Alward25 I tried another tactic...

KX500 2001 MZB INSTALLATION 2-4.JPG (27.68 KiB) Viewed 7827 times

Yes, I greased the face of the nut and one of the washers.
I got everything set and the drove the nut on again with my Makita.
Success!!!

By the way, the guy holding the parts is a professional hand model and is available for hire

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With the flywheel set, I rolled the engine completely over and made double sure that with the line on the flywheel and the dot on the stator lined up the indicator is still at .087"... Yep.... Poifect! (Spelling error intended)

The next thing I did was use some Black RTV Silicon around the stator wire where it is leaving the case.
I did the inside and the outside to be sure it is well sealed.
Now it is time to install all the other goodies.
I started with the coil.
I wanted to install it where the old coil went.
I looked at doing a bracket to mount it to and a few other ways.
Then I decided the easiest way to mount it was to slot the coil plate as shown..

[attachment=3]KX500 2001 MZB INSTALLATION 2-2.JPG[/attachment]

I did this on both sides.

[attachment=2]KX500 2001 MZB INSTALLATION 1-9.JPG[/attachment]

[attachment=1]KX500 2001 MZB INSTALLATION 2-1.JPG[/attachment]

I made the first slot and did a test fit.
With the first slot the coil just barely touched the gas tank.
I didn't like it so I made a new slot and tested it.
Beautiful.
If you use the 20mm and 27mm measurements to cut the slots it will mount just where you need it.
Mounted and looking good.

[attachment=0]KX500 2001 MZB INSTALLATION 3-3.JPG[/attachment]

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If you take a good look at the last pic, you will see a HUGE ground wire on the lower right side.
I do not like grounding issues so all the grounds on the system all go to the same place.

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The new style regulator mounts where the old CDI went.

KX500 2001 MZB INSTALLATION 2-3.JPG (56.28 KiB) Viewed 7823 times

It's held on with one bolt at the top.
Seems to be enough but may have to add another..

Put the stator cover on and we are ready to run the wires.

KX500 2001 MZB INSTALLATION 2-5.JPG (52.62 KiB) Viewed 7823 times

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Wire it up....
The only thing that seemed a little wiggy on the directions was there was two black wires on the CDI/COIL and two from the Stator that are suppose to hook to one another.... but which went where? it didn't make squat for difference.
All the grounds went to the same place on the coil mounting bolt and plate.
Drum roll!!!

Started it right up.
Put the volt meter to the battery at idle, 13.4 volts.

Ok, time for a ride.

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Idles a little smoother... It was pretty smooth before...
Take it for a couple of laps around the block to get the water temp up.... (My bike runs cool)
Finally got it warmed up and wicked on the throttle.
With a flywheel that is 1 lb lighter then stock, it revs up quicker and smoother then ever before.
The really cool thing is MY LIGHTS WORK AWESOME!!!
No more having to charge the battery every 45 minutes of ride time.

So far, I'm smiling.

Total installation time?
It took me 6 hours.
It could be done a lot faster if your competent which I'm not.
That being said I could do another much faster the second time around