Yamaha Bear Tracker 250 Where to start?

[payne]

That thing is tiny, lol. Does it last long enough to crank on it for awhile?

[Frank Angerano]

Yep and its powerful.  

[MarkinAR]

Sorry to jump in about a dozen conversations behind but if the relay is clicking and it's not reliably starting it's most likely the solenoid.  The relay clicks closed and throws electricity to the solenoid to close it.  If it's not closing reliably then voltage doesn't get to the starter.  My oldest runs through solenoids constantly because of mud and water.  They get wet inside and corrode in days and then they're trashed.

[Frank Angerano]

A little late but better late then never !!!  Sounds like its all good for now. Cant wait to see pics.  

[payne]

3 hours ago, MarkinAR said:

Sorry to jump in about a dozen conversations behind but if the relay is clicking and it's not reliably starting it's most likely the solenoid.  The relay clicks closed and throws electricity to the solenoid to close it.  If it's not closing reliably then voltage doesn't get to the starter.  My oldest runs through solenoids constantly because of mud and water.  They get wet inside and corrode in days and then they're trashed.

Seeing as the parts are so cheap, I'll probably get a new relay and solenoid 

[Frank Angerano]

Fresh spark plug as well. 

[payne]

15 minutes ago, Frank Angerano said:

Fresh spark plug as well. 

Already got a new one in it. Next problem.....how to remove the bolts for the header. Very rusty!

4 hours ago, MarkinAR said:

Sorry to jump in about a dozen conversations behind but if the relay is clicking and it's not reliably starting it's most likely the solenoid.  The relay clicks closed and throws electricity to the solenoid to close it.  If it's not closing reliably then voltage doesn't get to the starter.  My oldest runs through solenoids constantly because of mud and water.  They get wet inside and corrode in days and then they're trashed.

Seeing as the parts are so cheap, I'll probably get a new relay and solenoid 

The exhaust is swiss cheese, so it needs removed.

[Frank Angerano]

Ok here's where things can go horribly wrong. 
You have to spray them down good with penetrating oil spray. Do it once and again every 6 hours for 24 hours. 
Warm the engine up and then try to back them out. 
You will get some smoke from the oil burning off.   

They will snap off and then its a whole new ball game.  

[payne]

Them breaking off is what I'm worried about. Is there any sort of repair wrap that I could use rather than removing it?

Think propane torch would heat them up enough to loosen? I dont have cutting torches. 

[Frank Angerano]

Yes, in fact that's what i always use is a propane torch.  I hate to recommend it if the user is not familiar with it so i tell them to warm the engine up.  
 

Heres what i do: Soak them with penetrating spray and let it sit for 4  hours. Go spray again and let sit overnight. 
Next day hit it one more time with the spray and get the torch. Warm the bolts up but do not over heat. All you want to do is heat the metal enough to expand.  I try going both ways with the bolt.  
If bolts are shot when you get them out replace. 

[payne]

I'll give it a try. I wish they were bolt head, not allen.

[Frank Angerano]

It works if you go slow. Rushing = broken bolts. It will come loose and when it does as it comes out go back in and out etc until its comes all the way out. The rust comes off the bolt as you back it out and can ruin threads so go back in if you feel the bolt is not coming out and spray it while doing so.  

 If by some chance the Allen head strips you can always grab the outside with a vice grip. 

Also if the exhaust pipe is shot then cut it off with a sawzall to make access a little easier to your bolts.    

[payne]

On 3/9/2020 at 9:32 PM, Frank Angerano said:

I do recommend a way to clean them up. 
Take a look at this last project i did. 
 

 

Water sand and apply a clear coat thats flexible and durable to chemicals.  

Let me know what you think. 
 

What clear coat did you use?

[Frank Angerano]

Oxidized or faded plastic body parts By Randel1, December 9, 2019 in General Talk - Anything Goes! 
Original Content From:

 

[payne]

Bottom one came out fine. Top one broke.  I may have rushed that one or not hot enough. What should I do next?

[payne]

I have these 

[Frank Angerano]

Go and  buy an easy out kit and drill it out with the approximate size bit and back it out.  
Heat will be key here so tread lightly.  Drill out the center of the stud carefully and go in with the easy out.   

[payne]

16 minutes ago, Frank Angerano said:

Go and  buy an easy out kit and drill it out with the approximate size bit and back it out.  
Heat will be key here so tread lightly.  Drill out the center of the stud carefully and go in with the easy out.   

I posted a pic of the extractors I have. Aren't those easy outs?

[payne]

Drilled and taped for a new bolt, all good.

[Frank Angerano]

Nice work ! 
Personally i would have used stainless steel bolts.  Same exhaust?  
 

[payne]

I had that bolt laying around, started to use the ezout, but felt like it was gonna break. I just loosely bolted the same header pipe on to see if it worked.

I found a used one for $30 on ebay

[Frank Angerano]

Thats a good price for the pipe. 
So were you able to get the bolt out at all or did you have to completely drill and tap? 

Edited March 13, 2020 by Frank Angerano

[payne]

I tried to remove it, but felt like it ezout was going to break off, so I just drilled the whole thing out.

I have this clearcoat that's for motorcycle plastic i believe. Wonder is this would work for the plastics? More importantly,  wonder if its flexible?

 

[Frank Angerano]

This is the one i use.  It was recommended by a paint rep for a few reasons.  Worked great.  
 

[payne]

I actually think I have some of that.

[Frank Angerano]

Its great because it's flexible.  

 

Edited March 13, 2020 by Frank Angerano

[payne]

Did the rep specify gloss over satin or semi gloss?

Did you sand in between coats?

I have one can of satin.

[Frank Angerano]

No difference in anything other then the finish.  The gloss was too shiny for my liking.  
I water sanded first and and sprayed two coats.  15 min in between coats while it was still tacky.   
 

[payne]

Wonder how a satin would look?

[Frank Angerano]

Thats whats on the big bear i showed you.  
Worst case if you don't like the satin you can hit it with a can of gloss as a third coat.