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Kick Start Installation Advice Needed

3295 Views 10 Replies 6 Participants Last post by TW-Brian, May 13, 2012

d-nix

Discussion Starter · May 11, 2012

One of my first attempts at wrenching my new-to-me 2009 T-dub is to install a kick start kit from North Bay Yamaha. Unfortunately, I'm evidently a slow learner and need a bit of advice.

After removing the pressure plate from the clutch basket, I attempted to use a 24mm socket to allow removal of the clutch basket. No good, the entire bolt spun (probably, I now believe, because the engine was in neutral). At that time, though, I braced off of one of the 4 posts into which the springs and bolts that hold the pressure plate in place. Snapped off the post (btw, a new one costs $54 from the good folks @ North Bay Yamaha).

At this juncture, I can't seem to get the engine out of neutral. Tried turning the engine by hand - no go. Replaced the pressure plate (with the 3 remaining bolts & springs)& turned engine over - likewise, no go.

Any suggestions to 1) Get engine in gear, so I can then 2) remove the clutch basket?

Also,during all this a single large ball bearing (approx 7 mm) appeared on the ground. Any suggestions where this might belong?

Thanks for any suggestions. Learning new stuff is fun. Learning the hard way, less so. Time for an attitude adjusting 12oz., I guess. Happy Friday, y'all.

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TW-Brian

· #2 · May 11, 2012

Hey d-nix,

Sorry to hear about your problems. I put a kicker into my 2005 a month or so ago so I know what is involved. I also have a tool that holds the clutch basket so you can get that big nut off without busting your clutch basket (sorry that I am too late for that).

Here's an offer for you. I have a extra clutch basket that you can have and I would be happy to help you with the install. I'm not too far away from you if you could get your bike up here we could work on it here. If you can't get your bike here then maybe you could swing by and I could show you what to do and send you home with the clutch basket and holding tool.

Try raising the rear wheel off the ground and moving it back and forth while trying to move the shift lever into neutral. The increased leverage may help. I believe that that ball bearing goes on one end of the clutch actuating rod, but I would have to check the manual for sure. That may also explain if the clutch is not disengaging and not allowing you to get it into neutral.

Don't get too discouraged, we've all been there before. Let me know how you would like to proceed.

Brian

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TW-Brian

· #9 · May 13, 2012

Big E said:
When I called North Bay Yamaha to order the broken part, they suggested putting the clutch plates back in, holding the clutch basket with one hand and using an impact wrench. Just tried it and it worked great.

Big E,

Glad you were able to get it off using that technique.

In case you don't happen to have access to an air compressor and impact wrench, here is the tool that I use to hold the clutch boss/basket.

Here is a link on how it works:

http://www.rockymountainatvmc.com/docs/clutch hold instructions.pdf

Brian

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TW-Brian

· #11 · May 13, 2012

D-nix,

I am glad that we were able to get your kicker installed. Mine has already come in handy on several occasions.

It was fun working with you yesterday and the beer and ribeyes were a nice gesture (I guess I owe Brock some thanks for that suggestion!).

Here is the link to the Yosemite ride that my son and I did last weekend. There will be another one coming up in the fall. It is very well organized and they really do a nice job with all the meals, arrangements, etc. We had a great time.

http://www.familyoffroadadventures.com/

Maybe some weekend I can drive over the hill to your place. It sounds like you've got some great places to ride along the coast.

Brian

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