Replacement Flywheel - CDI - Coil

torgo · Post by **torgo** » 09:37 pm Oct 12 2016

Well I have an 1980 KDX 175 I am trying to restore to do some vintage racing. Like a lot of these older bikes the magnets on the flywheel have come off. After some extensive internet searching I found a place in Germany that makes a complete kit to replace the flywheel, CDI and coil all the while adding a charging coil and regulator/rectifer to get 100W DC.

https://www.powerdynamo-shop.com/shop/s ... cts_id=939

Has anyone heard or used one of these kits? With the exchange rate it looks like it will run me about $300. For that you get the flywheel, CDI, Coil, Reg/Rectifer.

I don't think that is too bad since the flywheels are Unobtainium and the available CDI are all used.

Comments?

Thx

Post by **KDXGarage** » 09:55 pm Oct 12 2016

Surely that stator with all those coils is not the correct one, is it?

The lower left piece says Czech Republic.

torgo · Post by **torgo** » 11:38 pm Oct 12 2016

I emailed them and asked if it will fit the USA bike. What it looks like is that it fits the SR model. I'll keep you posted.

jeswinehart · Post by **jeswinehart** » 07:31 am Oct 13 2016

How bad is your flywheel magnets Torgo ? Can you post up pics of them please ?
I rework Kawasaki flywheels. Mostly Tecate but have done other models too.

john

torgo · Post by **torgo** » 04:56 pm Oct 13 2016

I don't have any pictures (until tomorrow) but two have just come loose and the third has come loose and is broken in half (clean break).

I was thinking they could be reglued and I was going to try it, but I would gladly let someone with experience give it a try.

I have not taken them out of the flywheel so the North/South orientation is still good. I would be happy to send it to you to give it a try.

Worst case I will have to go with the Powerdynamo setup.

jeswinehart · Post by **jeswinehart** » 05:54 pm Oct 13 2016

The broken one is useless for sure. Once they break they become 2 magnets each with north + south poles and they will not go back together.
Is your a 4 magnet or 3 magnet type ? If it is the 4 magnet I can definitely be of help.
http://s1122.photobucket.com/user/jeswi ... ort=3&o=47

torgo · Post by **torgo** » 06:43 pm Oct 13 2016

Well that sucks, mine only has 3 magnets. I don't suppose that you might have a third magnet? Maybe I can see if someone has one. Otherwise I think I am going to look into the PowerDynamo thing.

Thx

jeswinehart · Post by **jeswinehart** » 06:49 pm Oct 13 2016

No, I wish I did have a magnet for you,,,, darn it. Yeah, if you can find one I can take care of the rest of reinstalling and encapsulating all of them so ,,, no more loose magnets.
Any replacement magnet you get will need to be the correct polarity or flywheel will not work. I (or you) would just about need a intact one to see what the polarity lay out is. When I ask for pictures I ask the keyway be facing towards top (and visible) just to know what I am looking at.

torgo · Post by **torgo** » 08:25 pm Oct 14 2016

Here are a few pictures of my flywheel.

Edited

I filed small notches on the rim to mark where the ends of the Magnets were at. I also numbered them and used arrows to indicate how they go back in.

[img

][/img]

torgo · Post by **torgo** » 11:05 pm Oct 14 2016

I edited my post so the pictures work now. I also JB Welded the magnets back in after using my dremel to clean all the rust and old glue off the inside of the flywheel and magnets.

I cleaned up all the connections and am going to put it all back together tomorrow and see what happens. If this doesn't work I am going to give the Powerdyanamo a shot.

Thx

jeswinehart · Post by **jeswinehart** » 08:47 pm Oct 15 2016

Any luck Torgo ???

torgo · Post by **torgo** » 11:54 pm Oct 15 2016

No luck yet, had to work 16 hr shift yesterday. Put it together Sunday afternoon.

torgo · Post by **torgo** » 07:40 pm Oct 16 2016

I got it back together and i have spark and it is better than before, but still not great.

torgo · Post by **torgo** » 06:16 am Oct 19 2016

I have ordered the Powerdynamo unit and will install it as soon as it arrives from Germany.

torgo · Post by **torgo** » 10:31 pm Oct 20 2016

Totally amazing. I ordered the Powerdynamo on the 17th and it arrived today the 20th. From Germany to Iowa. I'll be installing it on Saturday.

Post by **KDXGarage** » 10:38 pm Oct 20 2016

WOW!!

mwoj · Post by **mwoj** » 04:39 pm Oct 25 2016

Let us know how it goes.

torgo · Post by **torgo** » 12:31 pm Nov 02 2016

I didn't take any pictures, but it was pretty straight forward except the timing. The Powerdynamo flywheel doesn't have a keyway in it so you can time the bike any way you want. The instructions say to refer to your manual for the correct position for ignition timing. The manual I have doesn't list the deg or mm for timing. The new stator has two pickups so I figure that is how they configure the advance. I made a piston stop out of an old spark plug with a 3/8" bolt tapped in it so I could rotate the crank and have it stop exactly where I wanted.

I set static timing to 1.2mm BTDC. The systems comes with a new CDI/Coil combination unit and voltage reg. The new stator puts out 12VDC so I had to change all the bulbs in the tail light and headlight.

Other than that the the bike runs great. It starts first kick warm and 2-3 kicks cold. It idles smooth and it is nice to have 100W for lighting. All in all it works and now I can concentrate on fininshing the rest of the bike.

Post by **KDXGarage** » 01:54 pm Nov 02 2016

WOW! Thanks for the report!

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