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I'm gonna tag this thread with Foreman 500 secondary gear reduction. Im doing that because on the 500s the secondary gear reduction is accomplished by changing the gear on the output shaft and the smaller gear directly above it. So this could be very useful for someone doing that procedure as well. So let's start from the beginning. It was a great day to ride at Highlifter, and we set out into the woods. Not long after a heard a huge clunk and the bike lurched forward when giving it gas. I was able to engage 4wd and the front tires pulled me back to the trailer. There was some awful noises along the way however so I knew something was torn up pretty good. I cut the driveshaft boot off and found this: So I went ahead and took the swingarm off and this curious little guy fell out: When I dumped the swingarm out, this was in the driveshaft tunnel: I also noticed the output shaft was bugared up, and the rear case was cracked a little, so I ordered up some parts. Output shaft 23611-HP0-A00 $43 Rear crankcase cover 11340-HP0-A10 $136 (comes with 91201-965-000 o'ring pre-installed) Kickstart cover gasket 11396-HP0-A00 $11 Rear cover gasket 11395-HP0-A00 $13 Output shaft seal 91205-HM7-003 $10 Optional but I did not order: Kickstart oil seal 91202-HP0-A01 $8 --------------------

Good morning. I have had this 2000 KingQuad since new - it has 2500 miles/hours on it. it appears that the front out put shaft yoke seal is leaking does anyone have any experience in replacing this seal and O-rings as described in the service manual? Also, can it be removed and replaced WITHOUT disassembly of the engine?

I replaced the rear output shaft seal a year ago and it's leaking badly again. They are a pain to do because of the yoke being bolted to the shaft and the nut behind it. Has anybody seen this happen routinely to know if there may be something contributing to it like a bushing worn out on the output shaft that allows play? Also, any helpful hints as to how to get the nut off easier? Thank you.

Hi All, i have a yamaha beartracker which is not charging and I'M looking to test the elecrical output fom the stator/rotor to check if all is well in that department. just wondering if anyone can tell me what readings for voltage/current I should be getting if the electrics are healthy? also could some one direct me to a wiring diagram on the net or post one if possible? Any help would be greatly appreciated. Regards Chrisok1