Help! Flywheel, stator and pulser experts get in here!

[Jimbo45]

Ok, so I found my "jetting" problem (sarcasm) I think.  I was getting an intermittent loss of power after running for just a few minutes.  I took of the left side case cover and this is what I find (see pics).  Mind you, I tested the stator and pulse generator before pulling the cover, and both fell into spec, as far as ohms go.  This looks bad to me.

My questions:

-What do I need to replace here....Flywheel?  Stator?  Pickup coil?  All of it?  Can I clean up/ sand the flywheel and or pickup coil and reuse them?

-What special tools do I need? What kind of flywheel puller?

I need this quad to be reliable, and this is the last of the electrical system I have checked.  Looks like I need to spend more money.....

[thesmith87250r]

oh hell that is rusty

[Pumashine]

Looks don't make much difference. Hell, they run fine with water in there. Just clean the pickup and any loose junk and give her another try. Before you use a fly wheel puller you will need to clean the rust off the left hand threads in the flywheel.

[Jimbo45]

Looks don't make much difference. Hell, they run fine with water in there. Just clean the pickup and any loose junk and give her another try. Before you use a fly wheel puller you will need to clean the rust off the left hand threads in the flywheel.

Will do Tony.  But, don't I need to pull the flywheel and clean inside too?  I imagine it is a rust bucket under there too....

[2ndmoto]

Before you shell out more money. Clean it and and give it a whirl. I would soak the flywheel nut in pb blaster. Next day impact it off. Soak the end of the crank and inner flywheel threads. Clean the inner threads with a wire brush.

muriatic acid works really good for cleaning rust, but I am not sure what it will do to the magnets. I am fairly confident it will turn aluminum inner swiss cheese. So if you use it, be extremely careful.

Try threading in the puller, if it doesn't seat all the way then reclean. Thread and impact away. I would use the impact gun lightly and slowly creep up in pressure.

I endorse an use motion pro pullers. I needed one for a motorcycle I was rebuilding recently. I was over budget on the bike so I went cheap and bought a Tusk. It came cross threaded out of the package. Never again

Good luck
Best regards
-Jason

[2ndmoto]

PS,

You might want to start looking for a stator though. My experience, stators and flywheels work fine after derust. Stators not so much... But it is worth trying.

[Pumashine]

PS,

You might want to start looking for a stator though. My experience, stators and flywheels work fine after derust. Stators not so much... But it is worth trying.

I have a few stators. So I can hook you up easily for cheap.

[Jimbo45]

THanks guys.  I ordered a motion pro puller just now.  I will pull it all apart and clean it up as well as I can.  Tony, I may be hitting you up for a stator......

[broken1]

After you clean all the parts for re-use check them periodically because the rust will come back & don't use sealer on the gasket for ease of inspection down the road.

[dem3500]

Just clean it up. I've had rusty stators on a few different bikes in the past. It all works on magnetism and it takes a lot of rust to mess that up. But like others said, get the rust completely off the crank threads before you take the bolt off! If not you risk tearing all the threads off the crank and that's not cool! Lol

[2ndmoto]

After you clean all the parts for re-use check them periodically because the rust will come back & don't use sealer on the gasket for ease of inspection down the road.

I used to ride the Oregon coast dunes quite a bit, so rust was always a concern. One flywheel I had was really rusty. Cleaned it and hit it with a little rustoleum. Cleaned the threads, tabs and mating surface of residual paint. Never had a problem again.

And I too agree with checking up on components. It's part of the fun.

Best regards
-Jason