Diffucult lenghty start - Page 2 - Yamaha ATV Forum
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post #21 of 26 Old 08-16-2019, 07:16 PM
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is the timing chain tight? warriors break exhaust studs pretty often check that but if they are good sounds like you might have to tear it down and look at the crank and rod
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post #22 of 26 Old 08-20-2019, 05:54 PM
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when the cam mark is lined up it is at TDC compression stroke. that is where you adjust the valves. I would not run it with loud tapping, something is coming apart.
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post #23 of 26 Old 08-21-2019, 09:57 AM Thread Starter
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I took it our riding over the weekend and hit up the mountains. After about 5 hours of riding, It seemed to be running great still despite the noise. Didn't get louder or didn't go away. Only issue I am having is that it dies out when I come to a stop about half the time.

Also another thing, I NEVER had neutral in the shifter since I got the thing. I have always had to put the forward/reverse lever in the middle to be in neutral. Do you think this would a clutch issue or start looking somewhere else?

The quad was basically free but sucks getting something so old that you have no idea what was done to it in the past or what other issues have come up. I just want to hit the mountains in confidence!

BTW I was out with my 9y.o. son this weekend while he had his 96 PW80. Got about 6 miles from the staging area and about +2000 ft elevation up a mountain and his rear tire blew!! HEHEHE that was fun.
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post #24 of 26 Old 08-22-2019, 10:12 AM
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did you ever adjust the valves? its not likely a clutch issue and i am not sure how that is possible. the only clutch related thing i could think of is if it is not adjusted properly and is dragging it can be hard to hit neutral it will skip right over it. but if you can hit first and second neutral should be there. does it jump when you put it in gear. the light should at least flash as you go by neutral. test the switch. be very careful using that method as neutral. there is no neutral there it is just splitting those 2 gears and could easily drop into one or the other
when my boy was 5 he crashed about that far out, what an ordeal. i cant count the flats and such we have had together. good times
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post #25 of 26 Old 08-23-2019, 10:09 AM Thread Starter
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The valves seem spot on still, so no idea there. Maybe I can take a shot at seeing if it is the timing chain. Just interesting this was never a sound before the valves were adjusted, but also before the valves had no gap at all.

As far as neutral goes is beyond me. I can sit there with the clutch in while running (F/R switch engaged) just fine. If the bike is off and F/R switch engaged either direction, I can not start it without it trying to pull forward (or reverse), nor can I just pull in the clutch and push it while off. Both starting and pushing the thing requires the F/R to be in the middle. I have found neutral (using the shifter) a few times but they were all accidental and random (maybe 5 times total). The quad never came with the Neutral/reverse light bezel. I did however purchase one and installed it with no luck. The lights worked when putting external voltage to them, but when installed and hooked up to the correct wires, they never worked. Took my trusty DMM to the leads as well and seen no voltage. I took the bezel off. Seems like unless it is running, the clutch has issues.
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post #26 of 26 Old 08-23-2019, 10:26 AM
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the clutch is dragging. first try to tighten the cable, my bet is its adjusted to the max and you will need a new clutch but that is easy and cheap. if adjusting it does not work you can tip the machine up on its left wheels and let it set for a second or 2 and they you can pull the clutch cover for inspection without draining the oil.

as to the neutral light is the baby blue wire hooked up to the brass plug switch by the shifter? if not hook it up. if it is test the switch, they commonly go out. the power should come from the cdi through the light bulb and then to the switch. the switch should be normally open and go to ground when in neutral. this ground the neutral/start relay and allows power to the start solenoid.

pull the cam cover off and see if the chain is loose. i am pretty sure those have an automatic timing chain tensioner. pull it out and make sure the spring is good and it is good and clean. if that does not stop you noise it is probably the bottom end and you will either need to tear it down and inspect it or ride with a buddy and a tow strap
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