PVL troubles

Flywheel has been painstakingly lapped to perfection ! .torqued but not keyed. Going to key it this weekend if possible. Not quite sure what the issue is in earnest with my bike but some small anomaly is causing this flywheel to spin ever so slightly on the shaft....ripping it it today for the final time...

my 400 is a Californian scoot so a motosplat is std

I dont think there is enough thickness in the steel insert of the PVL rotor to cut a keyway. I have never heard of a correctly lapped PVL rotor slipping, there is some other issue going on here.

Guess who told me PVL s are not very good and don't ever recommend them for big bores. PVL reps at Penton imports . I sent in my PVL unit that was
on my Maico 490 for checking. It did not start. Checked perfect. Says we did not recommend are PVLs for open bikes of for any bike that has a slow kick
ratio. So many are also having trouble on their 250s now also.
I would retire that unit and replace.

All my bikes have Electrex units on them now. And about 8+ folks now here on this site have them on their Huskies now. All working fantastic and no kickbacks either

Going with the electrex now myself. Tired of messin with this darn PVL ! Junk IMHO !
Can I ask where you bought your electrex ?

Ah

I would never recommend a PVL for a 250 or above, I made that mistake myself once 10 years ago with my Maico 440, but I have 6 on various brands of 125/175s and they work flawlessly on the small bikes. I would recommend the MZ/B-Powerdynamo for a 250 or above.

However, the PVL flywheel should not come loose no matter what size bike it is on, I suspect something was wrong with that particular flywheel or his crank snout.

I couldn't agree with you more. I have PVL's on a few 125's with zero issues but on anything bigger than a 175 forget it....the crank end was the issue. It's since been corrected and a MZ has been added. Perfect now on all fronts.

Depending on the 250, like a Maico with a relatively heavy crank, you could use a PVL but any 250 like the Japanese bikes, and especially the Penton/KTMs, have light cranks so they need an external flywheel. My Mag 250 has a PVL on it and with a '78+ kicker it starts fine and runs great, but with the stock kick lever you just cant spin it fast enough to generate good spark. After my frustration with the Maico 440 I'll never put a PVL on an open class bike.