Search results matching tag 'Middle shaft'

Re: Middle Shaft Seal

AlanH — Thu, 23 Apr 2009 04:00:00 GMT

[quote user="Z-Warrior"]

Thanks for the awesome info guys...

But AlanH You have me dreading do it now if fear of seeing the "red rusty residue"

I just ordered the other parts from the dealership and I think I am going to tackle it this weekend. We will see if anyone has other tips in the time being.

Thanks again[/quote]

FYI ... i just edited the 2nd link in my prior post to be more specific. Try it again here: http://rswarrior.com/search/SearchResults.aspx?q=user%3aalanh&tag=Middle+shaft&orTags=0&o=Relevance

Also, red residue/dust will not occur if you are running an Aluminum Frt Pulley ... Here's an earlier thread: http://rswarrior.com/forums/p/26393/903168.aspx#903168

[quote user="AlanH"] Sat, May 3 2008 7:25 PM
Red dust - Heads Up

Keep in mind the Red Dust is the tail-tale from (2) dissimilar Ferrous alloys and/or differing hardness and represents the metal fatigue!

An aluminum front pulley will not exhibit the red dust

[/quote]

Re: front wheel pulley oil leak, what parts am i missing?

AlanH — Sun, 21 Sep 2008 04:00:00 GMT

I responded to your problem earlier this year and explained where the o-ring resides http://rswarrior.com/forums/p/115039/935680.aspx#935680

Your hosted photo, even when zoomed in and panning, isn't clear to me as to the chamfers because of the reflections ... it also looks like the back of your pulley has been rubbing the aluminum fins of the middle shaft case housing unless you did that. You also never responded in your earlier post to my request of what 1-1/2" pulley you were using .... GOOD LUCK

Here's a photo from a recent post even though it's the earlier middle shaft the spacer is the same if i'm not mistaken: http://rswarrior.com/forums/p/118963/961669.aspx#961669

This is the proper placement of the hardened spacer w/ the chamfer on the O.D. facing the back of the pulley ... Be sure it goes together exactly like this else you will leak transfer fluid! The small o-ring is behind the spacer between the inner brg race and the spacer which has a small chamfer on the I.D. and seals the fluid from leaking around the middle shaft O.D. The large mechanical seal prevents fluid from leaking around the O.D. of the spacer. You need to remove the spacer and check the small o-ring that is pushed inside against the brg race

Re: Oil leak on trip!!!!

AlanH — Thu, 18 Sep 2008 04:00:00 GMT

[quote user="dbreuer"]

SO here are a few pics of the pulley and shaft, any thoughts? When I pulled the collar off the shaft, around a couple tablespoons of gear oil leaked out and there seams to be around 1/4" play when I push or pull the shaft in/out, is this normal? ... Yes ... when the parts are assembled and tight there is no axle end play ... the loss of residual fluid is normal and can be avoided and or minimized if your bike is level and not on the kickstand.

The middle shaft splines appear to be slightly coined at the pulley contact surfaces based on these photos. It's difficult to see the amount of wear from your photos. I've seen a lot lot worse than this put back in service w/o a problem!

The pulley looks to be just fine!

This is the proper placement of the hardened spacer w/ the chamfer on the O.D. facing the back of the pulley ... Be sure it goes together exactly like this else you will leak transfer fluid!

[/quote]

Re: Spun two bearings in the transfer case

AlanH — Thu, 18 Sep 2008 04:00:00 GMT

[quote user="davidd"]

Yamaha still needs to help us with this issue!! Not to steal the thread, but does everyone still agree that the pulley nut should be torqued to 125ft lbs. We keep hearing about this ussue and a definitive answer from people who have not had probs for many miles would be useful for everyone involved. I replaced my lockwasher this past summer, torqued to 72, no loctite, it has held for 5k, but as we all know it could come loose at any time. Too many posts like this. Good luck getting it fixed, let us know how difficult it really was.[/quote]davidd ..... IMO you need to help youself here and retorque your frt pulley nut to a higher value. You're doing an injustice to your ride @ 72 ft~lbs unless you ride like a wimp ... JK

It has been well documented on this site that the '06' & > Warriors have a newly designed middle shaft, transmission output shaft,retaining nuts , inner brg/brg housing etc to resolve this issue. I can recall one member with an earlier bike upgrading to the new parts as i mentored him with the conversion.

Out of the gate, the loose pulley syndrome appears to be more prevalent and common with the later bikes produce between 2004-2005 that didn't go through the factory trani recall. My rationale is that the technician/mechanics used an impact gun on reassembly of the nut during the recall campaign

My hands-on here: http://rswarrior.com/forums/p/20832/324166.aspx#324166

Re: Spun two bearings in the transfer case

AlanH — Thu, 18 Sep 2008 04:00:00 GMT

[quote user="megawatt"]

[quote user="Bladerunr"]

.... Also check the lube system, I remember an oil pump being part of that case. I bet the case is just fine, and bearing mount compound would fix any problems with that bore.

Hope all your luck is, good! [/quote]

The transfer case is just a case that holds gear oil. The gears just sit in a bath of oil, there is no oil pump associated with the transfer case. There is no dipstick to use, only a large screwed in cover about 2" wide that you remove to visually inspect oil level.

The bearing should sit in the housing (look next to #29 in diagram) and the outer race of the bearing should not move. I have the smear marks on the transfer case housing walls that hold the bearing, this indicates the bearing was spinning inside the housing which it should never do. As for the bearing being under lubed.... the level is constant, there is no blowby possible like with engine oil. There is no only a fill hole and a small drain screw, it never was under lubed and when I opened it two days ago it was good.

Jabo - I only heard the noise when unloading the drivetrain (chop off throttle). It was a very quick duration sound, similar to a squeaky rusty spring being compressed.

[/quote]Joe .... Bladerunr is correct as there is a transfer case pump built into the transfer case housing. There is a small hollow splined shaft that fits into the geared side of the middle shaft that is also splined. If you look closely at your photo here you will see that there is a small gallery hole for the case oil to escape and lube the the 2-middle shaft ball brg's The pump is driven by the middle shaft and operates only when the wheel is in motion.

Suggest you inspect and clean the mesh strainer for this pump that is located at the bottom left side when viewed from the frt and do your due dilligence when inspecting all the rotating parts that are worn because of spinning on the middle shaft. IMO, it's very critical that the perpendicularity of the parts are retained when torqued. So check the pulley nut, drive pulley, small o-ring & hardened spacer and observe the proper installation of the spacer.

I don't agree with Bladerunr's observation regarding the outer brg. The outer race is very shinny & polished in the photo which is indicative that the brg was spinning in the transfer case aluminum housing so your transfer case could be worn. Else, the brg O.D. would display the fine grinding marks from the centerless grinding

Here's the gallery cross-drilled feed hole visible in your photo, RIGHT SIDE

Re: Oil leak on trip!!!!

AlanH — Wed, 17 Sep 2008 04:00:00 GMT

Gear oil leaks at front pulley? http://rswarrior.com/forums/p/21621/961041.aspx#961041

This is the Final Belt Drive ... The Primary Drive is the Cranshaft to the Transmission Input shaft via a spur gear under the clutch cover

[quote user="AlanH"]

Here's an 'A' typical loose pulley failure and loss of differential fluid. As the middle shaft splines become coined and worn from the hardened frt pulley, the fluid begins to seep and leak around the small o-ring seal on the middle shaft between the spacer and brg behind the frt pulley. The leak is not from the mechanical seal... i repeat... the leak is not from the mechanical seal . To get this bike back on the road we removed the naked pulley adapter plate (improperly installed), inspected prime components and tightened the $hit out of the front pulley nut

[/quote]

Re: Spun two bearings in the transfer case

AlanH — Wed, 17 Sep 2008 04:00:00 GMT

Joe .... i'm very sorry to read about your recent middle shaft & transfer case problems brought about by running with a loose pulley. Without defending myself, i too supported Chris's prior diagnosis of a loose belt causing the 2-UHMW rollers to produce a noise (32T pulley) when backing off on the throttle in a coast situation. It was my understanding at the time that you tightened your belt and the chirping disappeared. I also assumed at that time that you were cognizant of the loose pulley syndrome and that the factory spec 72 ft~lbs torque was the root cause of the failure.

Regarding the metal fatague between the ferrous and nonferrous frt pulleys & red dust there have been warnings to the members by this writer.

I challange your diagnosis of the middle shaft markings adjacent to the splines to be from the hardened spacer behind the pulley and the inner race of the adjacent outer brg. These parts when properly torqued to 110-125 ft~lbs are under preload against the small stepped shoulder of the middle shaft. The geared end (opposite side) of the middle shaft is allowed to float in the inner bearing for growth and has a close running fit.

The black smudge/smear on the outer race of the inner middle shaft brg is caused by the aluminum oxide created when the hardened outer race started to spin in the aluminum middle shaft housing mixed w/ oil as a result of loosing the preload from the inner race, spacer, pulley and running loosie goosie IMHO.... just like loosing a frt wheel brg and hub when the brg spins out and enlargens the bored hole.

How about posting a photo of the Yamaha billet pulley!

Once again, i'm sorry to hear of your dilemma and if there is anything i can do pls let me know.

Re: Middle Drive Shaft Assy.

AlanH — Thu, 04 Sep 2008 04:00:00 GMT

[quote user="koolguy"]

Thanks for ALL that info!! But I was just curious how much of a pain in the butt it really is. Churchkey makes it sound so simple. B.

[/quote] ... It is a simple task .... http://flickr.com/photos/15071518@N07/sets/72157602601838714/show/ .... lots of press on this R&R by Redhorse, Churchkey & AlanH

Loose Pulley - AGAIN!!! : http://rswarrior.com/forums/p/12641/195523.aspx#195523

If you don't have an impact wrench, just be sure that you loosen both the frt pulley nut and the transmission output shaft nut (transfer case side) before removing the belt and frt pulley

Re: Front Pulley Again

AlanH — Thu, 24 Jul 2008 04:00:00 GMT

[quote user="94VTEC13"]

Front pulley nut came loose again (3rd time in 7500 miles) last time I torqued to 105lbs plus locktite, this time the lock washer broke and stripped the nut and some threads on the shaft, my question is can the shaft be rethreaded with a die or does it need to be replaced (its not that bad but a couple threads are screwed up) if yes does anybody know what size the die would be/ Thanks, Mark

[/quote]If you have a pre '06' Warrior your middle shaft looks like this except it's missing some threads (only 4-thds) . Even if you turn the frt pulley nut backward with the flat side toward the pulley & existing thd's the impending doom is knocking on your front door. Welding will fail as well.

It's time to come to bat and pay the piper for the req'd parts. I suspect your pulley is N.G. by now as well as other critical parts! There are several good tech write-ups on the replacement. I've included Redhorse's repair below to 357Warrior and mine is here: http://rswarrior.com/forums/p/20832/324166.aspx#324166

Loose Pulley - AGAIN!!!

http://rswarrior.com/forums/p/12641/195523.aspx#195523

Red dust - Heads Up

AlanH — Sat, 03 May 2008 04:00:00 GMT

Keep in mind the Red Dust is the tail-tale from (2) dissimilar Ferrous alloys and/or differing hardness and represents the metal fatigue!

An aluminum front pulley will not exhibit the red dust