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 1 
 on: July 06, 2020, 07:57:29 
Started by jewls - Last post by Dave Milnes
When the engine is clear from the frame the oil needs draining and the filter removing then take off the black water pump cover so you can turn the pump. The front exhaust pipe needs twisting in it's clamp to give a bit more room to extract the cover. Mine turned without having to actually undo the bolts after a soaking in penetrating oil.
Then around the outer edge of the cover are around 10 8mm bolts of various lengths to remove then there are few difficult to spot ones, one up under the oil filter flange, and a couple down holes. Once all are out the cover should pull away from the side of the engine. There is no need to dismantle any of the actual engine parts.
The stator is bolted to the inside of the cover and the wiring routed under a plate and out via a grommet in the cover flange.
Clean all the old gasket off both the cover and the crankcase and use a new gasket. I applied a thin smear of red Hermatite to the crankcase face and stuck the gasket on then by the time I was ready to re-fit the cover it stayed put and made it easy. You have to rotate the water pump so it engages the slot on the shaft and the cover then sits flush. The coils sit inside the concave flywheel so it's important to centre the cover perfectly and also fit the new coils carefully as it's a blind fitting so you can't tell it's not right until the engine starts up, then it's all to do again!

 2 
 on: July 05, 2020, 11:28:09 
Started by jewls - Last post by jewls
Hi, how do I split the to halves to get the cover free?


 3 
 on: June 21, 2020, 15:04:17 
Started by jewls - Last post by Dave Milnes
Strange it's the stator causing the problem as mine failed at 2 years old but the bike still ran until the battery died. A jump start had it going again for 20 miles to get me home. Unlike the smaller motors the 500 doesn't have a spark trigger winding on the stators, it's purely a 3 phase charger. The engine should run with it disconnected if the battery is good.
It's an engine out job as you cannot extract the cover with the engine in place as the frame is in the way, also the water and oil need draining and the filter removing plus you need a new gasket for the cover and water pump.

 4 
 on: June 21, 2020, 09:31:14 
Started by jewls - Last post by jewls
Hi Dave,
I have checked the generator and I have found its knackered, what sort of a job to change it? Do I need any special tools at all, I have not done this thing before any help would be gratefull.

Julian

 5 
 on: June 20, 2020, 14:17:39 
Started by jewls - Last post by jewls
Hi Dave,
I have changed the coil, starting relay and checked or changed any fuses that require, new spark plug, second hand rectifier, second hand rear brake lights and got power to the rear brake lights, checked all the switches on the handle bars all ok.
But there is still no spark!! ,
Could it be the 3 phase generator causing the problem?

Julian

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