Gwbarm

The picture of the shaft and seal I sent yesterday, it looks like it was put in yesterday I get more oil than that on a seal just installing it. I don’t think it has been run since this work was done, if so very slightly, maybe they didn’t get everything back together right and it locked up, I know wishful thinking. My plan as well was to get this side cover off, just planning how to do it without everything falling out in my lap, I think I will jack that side up and put it on jack stands

Nooooo not the strip down I was sure you would have a secret formula hit the clutch side 4 times with hammer and stator 2times and it would come loose. Just kidding I think I have known for a while it needed to come out, just not sure if I have enough a$$ left to lift that engine by myself.

Glad to hear you are making good progress, how’s the head

Good ole WD 40

I was working the foot shift and hand shift , put it in L and shifted the foot shifter , put it in high and shifted the foot shifter, I can definitely feel it shifting 3 times didn't really go all the way to 5, tried to find the false neutral you were talking about by putting in different places along the length of the hand shift still no movement at drive shaft. Went back to where neutral should be with foot shifter and tried pulling up a little bit, sometimes neutral is hard to find between low and first, still nothing. If you look closely all of the linkages look like they have been changed out, they look newer than the rest of the bike. IMG_3857.mov This shafts and linkages look like they has been changed also with new oil seal, so previous owner threw some money at this and I guess gave up. Probably sold it just to get his money back

Tried the L,H,R shifter in all different places still nothing moving, tried the foot shifter again still not moving, I think this one is going to be fun.

I think you are good to go, I just brought back one of those engines they are very tough, I was very impressed with how tight and smooth everything was after so many years of neglect.

Thanks! I will try that.

I have not used the supertech oil from Walmart, but I did buy the prime brand that Sams sells, I use it in my lawnmowers, didn't really notice any difference, may have burned a little more oil, it did seem thinner and clearer than other oils.

There should be some side to side play, but shouldn't be excessive, their shouldn't be any up and down play, once you get oil back in the bearing side play should be minimal.

Castrol has always been one of my favorites for using in motorcycles, but I had never heard of this one. Thanks for the reply.

Checking valve clearance would be a good thing to do, but it sounds like a carb problem to me, I would clean the carb jets again, don't forget the one down in the hole, gif you are using ethanol fuel it has a tendency to collect water in the bottom of the carb that eventually turns to jelly. Something to look at, also inspect the vacuum slide carefully for pin holes.

The whole cable is supposed to turn, if its not turning the screw the cable must be broken under the plastic cover, follow it back to the carb and you can get the screw out with a pair of pliers, but I have never seen one break.

Just an observation, i was just checking out the trans, with it in high or low, I can shift through all the gears , as I go up in gear the play gets a little less prominent,but never goes away, like you said if it was seized bearing no play at all, trans seems to be working fine, when I move hand lever shifter to reverse, no shifting at foot shift.

I use eBay for discontinued parts Rockymountain ATV for OEM parts and Amazon for aftermarket parts.

I have worked with it a little bit, sprayed it down several times with PB Blaster, it is not frozen up so solid anymore, I can get a little movement and it now feels like it's stuck in gear. If you listen closely you can hear the click click as I turn it back and forth with my hand. I haven't started it yet I may have to clean the carb to get it to start its been sitting about 8 months. Thats next on my agenda. IMG_3854 2.mov

Sorry to hear this happened, please be careful, if you get to feeling bad, headaches and brain cloud, even after 3 or 4. days please go to the ER , head hitting concrete can be very serious.

Souds like a nice project, looking forward to it, keep us posted. I would flush the bottom end with some type thin oil maybe even diesel and put it back together with new parts. OEM parts are expensive but for this I would go with them, also check the cam and chain for proper specs.

From what I know of Yamaha wiring I would guess the W/G and W/R would go to your pulser coil, but according to the diagram you posted it should be Blue/Yellow haven't looked at schematic yet, are the cut wires on the CDI. end of the harness.

To release pressure that might build up in their places. I know for sure on the final drive, my suzuki has a bellows attached for that reason and my yamaha has the breather hose. Like yours.

It sounds like your coming along well , one thing you could do to make sure its completely shifting correctly, is jack up the rear wheels shift to first, turn them to get movement and see if it goes through all the gears, you can feel by how the wheels turn to tell that's its shifting to a higher gear. Just a thought.

I am trying to figure out the best way to proceed. Hook the driveshaft back up with the rear wheels off the ground, crank the engine and try to shift the 5 speed, and the high, low and reverse shifters you suggested, and see what happens. Or take the stator side cover off first, and see if everything is in place , and inspect to see if anything is going on in there. I can tell that the side cover has been off before, not even sure if all the gears are there.

These breather hoses just hang out in the grommet attached to the air intake duct, hooks to final drive, carb, and brake, and do not attach to anything on the other end. You might have already known that and I misinterpreted your question. Thats what mine does and it appears yours does also by looking at the diagram.

KP which oil did you buy at Walmart for your ATV. My Walmart the shelves were pretty bare, but they did have Rotella T5 and T6 diesel oil, I wasn't sure if that was good enough For ATV.

I had this happen to a yamaha, never did figure out why , but ended up using a small fiber washer and o ring to stop it, even thought the oem parts diagram showed neither one.