1st Sled Purchase Nightmare Gets Worse!!!! Please Read!!!!

thstorms said:
I installed the new oil pump, and the new waterpump shaft/pulley, and balanced the old clutch weights(without rivets) and reinstalled them.....

"note to self... buy a clutch puller so I dont have to remove clutch weights surgically..."

fly weights are a huge pain to change while the Primary is still mounted to the motor!!!!

My rpm's now max out at 8100-8200, it feels awesome!!!! shift seems to be somewhere around 5500-6000, engagement is about 4000..... excellent power at low mid and high range.... should I play with my spare set of weights to try to get the rpms down?????

Oil pump is working great!!! day one I burned 5-6 gallons to about 2" of oil(5-6oz) Im guessing..... today I burned 3/4 tank of gas to about 1/2 tank of oil.... seems like a bit much, I started with both tanks full today next time I ride I plan to measure both tanks refill capacity and figure out my ratio!!!! should be 50:1 right????
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c"mon ..flyweights are'nt that bad to change ...its easy with the clutch on....Did you remove the cover first?
 
To measure the belt deflection:
Using a spring scale (fish scale), hook it over the end of a suitable sized piece of metal or wood that can be used to push down on the belt through the check hole.
Measure the distance between the belt and the top of the check hole while pushing down on the belt.
When the belt has moved 5/16 inch (8mm), the scale reading should be the specified amount in the service manual.
If the shims are changed, turn the engine over with the clutch a couple times before rechecking belt tension.

I have a manual for a different model. I do not know if it ever changed in later books, but only 5/16" movement seems like it would leave the belt too tight.
 
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I always liked them on the loose side of spec to ease bearing fatigue,thats why i use 10mm or 1/2"

good way of doing it tho PZ if one want to be precise.
 
PZ 1 said:
I see that you had 17.6 pounds - I thought what I had was the same, my numbers are for a 1997 500. I have changed it.
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hold the phone here ur right i was looking at the wrong year here.

94-96 is 17.6

97 up is 22-31

why it's different i have no idea thats strange it's the same type drive set up.
 
yammy said:
c"mon ..flyweights are'nt that bad to change ...its easy with the clutch on....Did you remove the cover first?
Click to expand...

of course not..... I dont have a torque wrench....
 
PZ 1 said:
To measure the belt deflection:
Using a spring scale (fish scale), hook it over the end of a suitable sized piece of metal or wood that can be used to push down on the belt through the check hole.
Measure the distance between the belt and the top of the check hole while pushing down on the belt.
When the belt has moved 5/16 inch (8mm), the scale reading should be 17.6 to 31 pounds -best to keep it closer to 17.6 .
If the shims are changed, turn the engine over with the clutch a couple times before rechecking belt tension.

I have a manual for a different model, but the spec is probably the same as what daman listed. I do not know if it ever changed in later books, but only 5/16" movement seems like it would leave the belt too tight.
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Im really shocked!!! for the first time someone has mentioned a specialty tool that I have!!!! A FISH SCALE
 
I appreciate all the help and different ideas!!!

Looks like I get to pull it apart again...... I know the belt is super tight!!!

at least all these little things keep improving the sled a little more each time, you guys wouldnt believe some of the places Exaust springs were routed and connected the first time I tore it down!!! when I replaced the OP and WP shaft I figured out all but one place where there were springs linked together to make it work.....

durring all the repairs I noticed the pull cord...(you know the thing that starts it) was a little worn, may as well replace it now that I have to pull the recoil AGAIN... should I use a special rope or will any nylon rope work????
 
if that sled could talk ....the storys it could tell ....i am thinking the drag theory....if the oil pump was helped out ...whats to say the bore wasnt helped out til it blew and the stock top end went back on and it went bye bye ...all i can say is CARMA ...i know it has passed several hands but someone was with holding info..now you are left cleaning up the mess ...guess the next sled you buy cant be anywere near this bad knowing what you know now ..thats the school of hard knocks there....feel for you man .........
 
The good thing about all you gone through:
-you have learned a lot!
-met some incredible people!
-you now know what is right with your sled!

Pick up some proper recoil rope...its more expensive but it is stronger and lasts longer.

Prior to installing the new rope soak it in oil, motor oil works good.

But be fore warned...installing a new rope can be a nightmare, its not always a simple job!

If the recoil spring decides to unlatch, break, or the recoil ends up too far disaasembled and you have to replace or reinstall the spring...not fun!

JM.02c
 
Find the belt tension spec for your model sled. It could have changed by year and model. You can ask your dealer.

The recoil rope is hard to find in the metric size that Yamaha uses, it is larger than what is normally found. Otherwise the rope that the hardware store has that looks the same - and may be labeled recoil rope, will work fine. Or pay your dealer the price.

Do not remove the rope pulley from the recoil. It does not have to be removed to change the rope.
 
Thanks for the help on the recoil...... I was hopeing I could stretch out the old rope, hold it from rewinding..... really quick and easy swap to the new rope(you know how it always goes..LOL), install the new one and let it wind back up! Perfect, and simple, THE FIRST TRY!!!! LMAO

Great tip that the pulley doesn't have to come off!!! I probably would have gone for the BIG bolt right in the center first, the spring would have sprung, and I would have been sitting on my bucket in my unheated garage wondering if it was even worth crawling around on my hands and knees looking for all the parts or not...... :o| #$%&* :o|
 
I think the oil pump I baught is the evil opposite twin of my old one sent from the future!!!!! Or a '97 pump....... with the marks lined up I used 26oz oil to 8 gallons of gas..... I backed it off as lean as it would go and which put it about 2mm off from lineing up, this time I burned 17 gallons and 30oz oil!!!!!!!

she's got a little bit of a miss on the low end now...... you guys think it could be plugs??? LOL

I need ANOTHER oil pump!!!! :o| :o| :o|
 
I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! I LOVE THIS SLED I'M GLAD I BAUGHT IT!!!!! :o| :o| :o| :o| :o|
 
thstorms said:
I think the oil pump I baught is the evil opposite twin of my old one sent from the future!!!!! Or a '97 pump....... with the marks lined up I used 26oz oil to 8 gallons of gas..... I backed it off as lean as it would go and which put it about 2mm off from lineing up, this time I burned 17 gallons and 30oz oil!!!!!!!

she's got a little bit of a miss on the low end now...... you guys think it could be plugs??? LOL

I need ANOTHER oil pump!!!! :o| :o| :o|
Click to expand...


Just a second here:

Your original oil pump setting:

26 oz / 8 gallons

8 x 4 = 32 quarts
32 x 32 = 1024 ozs
1024 `/. 26 = "39: 1"

40 : 1 is pretty well perfect for the Yamaha twins...LINE THOSE MARKS UP AGAIN

JM.02c
 
sideshowBob said:
Just a second here:

Your original oil pump setting:

26 oz / 8 gallons

8 x 4 = 32 quarts
32 x 32 = 1024 ozs
1024 `/. 26 = "39: 1"

40 : 1 is pretty well perfect for the Yamaha twins...LINE THOSE MARKS UP AGAIN

JM.02c
Click to expand...

I thought it needed to be 50:1...... I will check it again just to be sure
 
Clutch ????'s

Both of my clutches are hot after riding pretty hard..... I can hold my hand on them but only for about 5-10 seconds.....

is this normal???

should I try winding my secondary a little tighter????
 
thstorms said:
I thought it needed to be 50:1...... I will check it again just to be sure
Click to expand...

The 600 twins were never real easy on oil, you don't have power valves to gum up, so a little extra oil use like 40: 1 is not a bad thing.[helps the very hard working crank + rod bearings]

JM.02c
 
thstorms said:
I think the oil pump I baught is the evil opposite twin of my old one sent from the future!!!!! Or a '97 pump....... with the marks lined up I used 26oz oil to 8 gallons of gas..... I backed it off as lean as it would go and which put it about 2mm off from lineing up, this time I burned 17 gallons and 30oz oil!!!!!!!

she's got a little bit of a miss on the low end now...... you guys think it could be plugs??? LOL

I need ANOTHER oil pump!!!! :o| :o| :o|
Click to expand...

It was way lean on the oil.

-almost got a chance to rebuild the motor again!!! :mrgreen:
 
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