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MadMax made it thru 10 hours of surgery to replace the tranny gears and to rejet the carbs and sync them with the YICS tool that Dr.Rago made as per this website.And while most of this is pretty straightforward...not everything went the way it should have..but it the final analysis it did.
The first thing to be addressed was the final drive filler cap that wouldn't budge...Even with the allen head stripped Dr.Rago managed to heat the housing up around the bolt then was able to get an allen tool to hold onto the head and Lo and Behold that satisfying crack when you break the toque of the bolt!Final drive gear oil drained...next thing we did I think was to take out the left rear turn signal as we were going to lay Max down on his left side.Between the help of Randy and my Brother we were able to flip Max without the need of a 2 x 4...Max is finally on his back...we then proceeded to dissassemble the clutch and basket etc... which we were supposed to do before flipping but it really did not make any difference.From this point on dis-assy of the clutch basket and springs and removing the shift pawl and the other things we did as per the "Procedeure" went uneventfully.When it came time to reinstall all but the 5th gear..is when the problems began.It was just a case of getting all the gears to mesh while lining up the shift dogs/forks..easier said than done...but between the 2 of us we figured it out.Took nearly an hour and a half just to get the shift forks back into place.We reversed the "Procedeure"in re-assy of everything...and flipped Max back to his normal posture.
Next up were the carbs...while I went to the local Advanced Auto to buy engine oil and gear oil(25 mins) by the time I came back Dr.Rago had already finished the carbs...but his prognosis was mixed.While he was able to get all the main jets out and replaced...all but one of the Pilot jets were stripped and were not coming out so none of the pilots were changed.Float bowls were adjusted up to try and compensate for the lack of larger pilots'.So now we reinstall and reconnect the carbs for synching with the YICS tool.Inserting the tool into the port the first time it was in but the tool wasn't together tight enough and perhaps it was loosened inadvertantly...net result was that parts on the end of the tool came apart inside the port.Luckily my brother had a magnetic drill dit the was able to get the parts out!But Oh boy that was an oh-S### moment.Once the Yics tool is fixed then we start to reassemlbe the battery and put the oil into the engine.Dr Rago then brought out this wild looking device that he uses to sync the carbs with...consisting of 4 glass pipettes that have Mercury in them.Connecting to a portable gas tank all hoses connected...its time to turn the key and fire this baby up....nothing happens...ok check kill switch...engine in neutral but no neutral light...Dr. Rago the jumps the bike via a scewdriver acrpss the termials on the starter solenoid and the bike cranks...but only when we had the sidestand up...but bike was in neutral but no light...so somewhere the circuit was not complete.We then had problems with getting spark ...problem traced to corrosion in a wire connector.Once we got spark it wasn't getting any gas to the plugs...figured that out and started cranking the motor via the jump method..eventually Max fired up and he was revived!Dr Rago then synched the carbs.After that we started to clean up having completed to two main objectives.But still leaving the problem of the bike not starting via the starter sw.So our resident Electrical Guru troubleshooting the switch...its good...pulled the connetor for the solenoid and it too was good.Reconnected everything and I was the first to notice the green neutral light was back on so I tried the starter sw. and Lo and Behold another miracle.I did leave a few details out but overall this was a most rewarding day!
I want to Thank Randy for being so generous of his time and efforts to help me.His patience and skill working on m/c's is admirable.I learned quite a bit today.I also want to Thank T.C for posting the link to the Tech article that I have Ken Talbot to Thank for as well.The information and the comraderie of fellow XSives helping each other out....PRICELESS.Thankyou all for your patience in reading this stuff too.....Pics to follow.....Ben
The first thing to be addressed was the final drive filler cap that wouldn't budge...Even with the allen head stripped Dr.Rago managed to heat the housing up around the bolt then was able to get an allen tool to hold onto the head and Lo and Behold that satisfying crack when you break the toque of the bolt!Final drive gear oil drained...next thing we did I think was to take out the left rear turn signal as we were going to lay Max down on his left side.Between the help of Randy and my Brother we were able to flip Max without the need of a 2 x 4...Max is finally on his back...we then proceeded to dissassemble the clutch and basket etc... which we were supposed to do before flipping but it really did not make any difference.From this point on dis-assy of the clutch basket and springs and removing the shift pawl and the other things we did as per the "Procedeure" went uneventfully.When it came time to reinstall all but the 5th gear..is when the problems began.It was just a case of getting all the gears to mesh while lining up the shift dogs/forks..easier said than done...but between the 2 of us we figured it out.Took nearly an hour and a half just to get the shift forks back into place.We reversed the "Procedeure"in re-assy of everything...and flipped Max back to his normal posture.
Next up were the carbs...while I went to the local Advanced Auto to buy engine oil and gear oil(25 mins) by the time I came back Dr.Rago had already finished the carbs...but his prognosis was mixed.While he was able to get all the main jets out and replaced...all but one of the Pilot jets were stripped and were not coming out so none of the pilots were changed.Float bowls were adjusted up to try and compensate for the lack of larger pilots'.So now we reinstall and reconnect the carbs for synching with the YICS tool.Inserting the tool into the port the first time it was in but the tool wasn't together tight enough and perhaps it was loosened inadvertantly...net result was that parts on the end of the tool came apart inside the port.Luckily my brother had a magnetic drill dit the was able to get the parts out!But Oh boy that was an oh-S### moment.Once the Yics tool is fixed then we start to reassemlbe the battery and put the oil into the engine.Dr Rago then brought out this wild looking device that he uses to sync the carbs with...consisting of 4 glass pipettes that have Mercury in them.Connecting to a portable gas tank all hoses connected...its time to turn the key and fire this baby up....nothing happens...ok check kill switch...engine in neutral but no neutral light...Dr. Rago the jumps the bike via a scewdriver acrpss the termials on the starter solenoid and the bike cranks...but only when we had the sidestand up...but bike was in neutral but no light...so somewhere the circuit was not complete.We then had problems with getting spark ...problem traced to corrosion in a wire connector.Once we got spark it wasn't getting any gas to the plugs...figured that out and started cranking the motor via the jump method..eventually Max fired up and he was revived!Dr Rago then synched the carbs.After that we started to clean up having completed to two main objectives.But still leaving the problem of the bike not starting via the starter sw.So our resident Electrical Guru troubleshooting the switch...its good...pulled the connetor for the solenoid and it too was good.Reconnected everything and I was the first to notice the green neutral light was back on so I tried the starter sw. and Lo and Behold another miracle.I did leave a few details out but overall this was a most rewarding day!
I want to Thank Randy for being so generous of his time and efforts to help me.His patience and skill working on m/c's is admirable.I learned quite a bit today.I also want to Thank T.C for posting the link to the Tech article that I have Ken Talbot to Thank for as well.The information and the comraderie of fellow XSives helping each other out....PRICELESS.Thankyou all for your patience in reading this stuff too.....Pics to follow.....Ben
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