Gwbarm

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.

Looks bad I think you are right about no oil, hate to see that happen to one so new. I use rockymountainatvmc.com or motorsport.com have used partzilla no problems, the others are usually cheaper.

I did jack up the rear end today drive shaft unhooked I can turn the wheels by hand and drive shaft moves with no noise a little wear there because I can move the wheels a bit before the driveshaft moves, but that is not my problem. I tried turning the shaft coming out of the engine there and no movemeant what soever, but do get movement from the shaft coming out of the front of the engine going to the front wheels. I tried shifting with the foot shifter and it does shift and feels like it's going into gear. So something has the backshaft frozen solid. IMG_3848 1.mov IMG_3853 3.mov

So glad you got it figured out without splitting the case, I hadn't abandoned you , I have been keeping tabs on your progress, just got kind of busy, Mech is so good with transmissions I thought you were in good hands.

I did look and I came to the same conclusion there should be a little play there. Thats why I was thinking it may be a seized bearing, I even thought even if the gear had broken off and jammed I should get a little movement one way or another.

I haven't messed with it lately, but I think I remember that I was getting no movement whatsoever at the engine, I jacked the rear end up and I was getting a little back and forth movement, but I just think it was from the final drive, once I unhooked the drive shaft from the engine I could roll it around, so I assumed the final drive was OK. I am going to get out tomorrow and do some more evaluating and testing and see what I come up with. I was going to get a big wrench and see if I could gently move the drive shaft at the engine, at that time I was thinking it could be a seized bearing. I decided not to do that until I took the cover off and take a look at the gears, whatever is going on has not locked up the engine because it runs, but I didn't run it very long. Then shortly after that the Big Bear followed me home and you know the rest.