cycleranger
Generally Ok.
I finally fixed the starter drive. I've had the bike for ten years and I've never used the starter.
When I got the bike I touched the starter button once and heard a terrible sound so I didn't ever do it again.
Since then I read up on it and knew what the problem was so I've kicked it for ten years.
Anyway I thought while I'm there I'll just replace the clutch plates too.
Long story shortened I put everything back together no problem and tightened down the cover.
Then I looked over and saw the large washer I left out.
There my troubles began... because I hadn't paid close enough attention when I took it apart I could not figure out where the washer went. Consult the parts diagram, no help, thanks Yamaha!
Thankfully this forum exists and I found the thread that solved my dilemma.
Anyway, got it all back together and the starter sounds... less horrible now but I'll probably keep kicking it anyway. And the clutch works fine.
Regarding the starter gear fix, since my gear was pretty chewed up I used a new one from Mike's with a NOS clip.
One thing I noticed is the original gear has more of a V-shaped groove for clip compared to the new gear from Mike's that has a more U-shaped groove. Did Yamaha change to this U-shape in later years?
The OEM clip wire was 2.90mm diameter compared to the Mike's clip that was 2.80mm.
The NOS clip fit in the new Mike's gear ok and was in spec for drag without having to squeeze it.
I checked the clip from Mike's for the heck of it and it was a couple of pounds lighter and would have needed a bit of a squeeze get it in spec.
The only other thing of note is that after ~42K miles the original clutch friction plates still measured in spec, which surprised me.
When I got the bike I touched the starter button once and heard a terrible sound so I didn't ever do it again.
Since then I read up on it and knew what the problem was so I've kicked it for ten years.
Anyway I thought while I'm there I'll just replace the clutch plates too.
Long story shortened I put everything back together no problem and tightened down the cover.
Then I looked over and saw the large washer I left out.
There my troubles began... because I hadn't paid close enough attention when I took it apart I could not figure out where the washer went. Consult the parts diagram, no help, thanks Yamaha!
Thankfully this forum exists and I found the thread that solved my dilemma.
Anyway, got it all back together and the starter sounds... less horrible now but I'll probably keep kicking it anyway. And the clutch works fine.
Regarding the starter gear fix, since my gear was pretty chewed up I used a new one from Mike's with a NOS clip.
One thing I noticed is the original gear has more of a V-shaped groove for clip compared to the new gear from Mike's that has a more U-shaped groove. Did Yamaha change to this U-shape in later years?
The OEM clip wire was 2.90mm diameter compared to the Mike's clip that was 2.80mm.
The NOS clip fit in the new Mike's gear ok and was in spec for drag without having to squeeze it.
I checked the clip from Mike's for the heck of it and it was a couple of pounds lighter and would have needed a bit of a squeeze get it in spec.
The only other thing of note is that after ~42K miles the original clutch friction plates still measured in spec, which surprised me.
. I’ll take it to my friend’s place to see if he can do an emergency weld on it. After the rally I think I’ll have my buddy make me a new pedal from billet aluminum.
