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Discussion Starter #1
I took the bike out (06') for a spin yesterday and was leisurely riding some back roads after getting everything dialed in with the PCIII, Ivan's Flash then the fuel leak issues so I wasn't getting on the bike hard or anything crazy just enjoying the weather and a beautiful ride. When I was coming down a hill I gave it a little gas and nothing happened, the engine rev'd but didn't engage and move me forward, I was just coasting. I looked down thinking I broke the belt and it was still intact. I coasted down to where it was flat to give it a better look. While I was stopped, I got it into 1st gear and gave it a little gas and it was grinding and I initially thought the belt came off the front pulley and wasn't catching, I put it in 2nd and got the same result. I got it back down to 1st gear and it caught and everything felt normal. I rode for a bit on my way back to the house maybe another 20min or so. About 3miles from the house on the main road, it gave out again and would not engage. I put it in gear and gave it a touch of gas while looking in at the front pulley and everything looked good there with the belt, pulley etc... There was a grinding and vibration from what I'm guessing is the clutch case, like there are metal parts that are spinning but not engaging and in sync. I adjusted some of my clutch from the handlebars as I knew that was something I needed to do anyways and didn't get any where, I tried shifting up a couple gears and got nothing but grinding and didn't want to mess anything up further. I called for a tow and the bike now sits in my garage.

My initial thought is that the clutch plates are all shot and need to be replaced. I'm all about continuing to learn about my bike and fix things but I'm not entirely sure where to start looking to diagnose the issue and plan the fix and getting into this area of the bike I don't want to mess anything up further that it already is. I could use a little help on where to begin looking in diagnosing, I'm pretty handy but sometime lack the technical language until I've looked at pictures and have done some research with the Forum, the manual and google. Thank you for any help!
 

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Here are a couple of videos to help out....


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By checking and adjusting the cable correctly will eliminate the cable as the culprit. Lets do the stuff that is easy and free then we will throw money at it.
 

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Discussion Starter #3

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I would take the clutch housing off and have a gander first, maybe something came loose on the clutch basket? If your clutch is done for take it down being careful not to loose your intermediate plates orientation, then get a get a new set of clutch plates from Yahama or whoever, Barrnett pressure plate with the three plate mod, you wont regret it
By the way Brian M did a nice video on how to do the three plate mod and Barrnett pressure plate
 

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Discussion Starter #7
I adjusted the clutch and unfortunately everything is the same as before. I took a video of what it sounds like and will try to attach it below but I'm not sure how this will go...

https://youtu.be/zMKg-wVlXOY
 

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I adjusted the clutch and unfortunately everything is the same as before. I took a video of what it sounds like and will try to attach it below but I'm not sure how this will go...

https://youtu.be/zMKg-wVlXOY
Ahh, well that's not cable adjustment issue.
Is the bike in gear and clutch released and no movement?
Or in gear and lightly releasing clutch lever and the noise?

From the sounds of it either way, you may have to open up and inspect the clutch.
 

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Discussion Starter #9
Ahh, well that's not cable adjustment issue.
Is the bike in gear and clutch released and no movement?
Or in gear and lightly releasing clutch lever and the noise?

From the sounds of it either way, you may have to open up and inspect the clutch.
It was in neutral, 1st gear, neutral, 2nd gear then I shut it down. Does it seem like the clutch is the place to start?
 

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Well, let's start fresh. It seems like your splines on your front pulley could be worn down and the middle drive shaft is just spinning and Not turning the front pulley. It's hard to tell from the vid where the sound is actually coming from. I would pull the front pulley cover and have a look at the shaft/pulley unless your for sure it's coming from your clutch.
I'd expect the clutch next if the pulley/shaft is good.
 

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Based on the video it sounds like an issue with the clutch housing or clutch boss.
The transmission is still operating in 1st/2nd so I don't believe there is an issue with it or the shift forks.

I would do the following:
  • Pull the front pulley cover for a visual inspection of nut though I don't believe that's the issue as there is no belt movement at all.
  • Dump the crankcase oil only (not the tank) and check for foreign particles
  • Pull Clutch Cover and inspect for failed parts
There have been 1 or 2 cases of a loose boss (basket) nut but not your issue your year.
  • ADDED:
    Clutch Boss/Basket Nut to Transmission Input Shaft (Basket is Splined)
    2004 and later use a conical washer and crush/stake nut to retain the basket.
    2002-2003 use a tabbed lock washer and nut!
 

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Discussion Starter #13
Finally had a chance to get in the garage and see what's what with my ride. I took the Front Pulley Cover off and immediately noticed an issue. There were metal shavings in the case and the bolt didn't look right. As I was pulling the bolt off, the front pulley was wobbling back and forth and was obviously not seated properly! Currently in the process of dropping the rear tire to get the belt off and see whats wrong with the front pulley.
 

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Was the front pulley removed when replacing the drive belt?
It's not common for the '06' & > to have issues with the front pulley coming loose.

Suggest you post some photos of the middle shaft and pulley splines.
 

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Discussion Starter #15
I'm fairly certain it was not removed when replacing the belt. But, now that i'm seeing the issue it reminds me that when I had the front pulley cover off, I noticed that the bolt on the Front Pulley was extremely loose. I checked the YSM, made sure it was seated properly and tightened it to spec. Attached are the pics of the inside of the pulley and the shaft, both are worn and I assume need to be replaced.
 

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I'm fairly certain it was not removed when replacing the belt. But, now that i'm seeing the issue it reminds me that when I had the front pulley cover off, I noticed that the bolt on the Front Pulley was extremely loose. I checked the YSM, made sure it was seated properly and tightened it to spec. Attached are the pics of the inside of the pulley and the shaft, both are worn and I assume need to be replaced.
I knew it lol. This sounded all to familiar (not me). You'll need another middle drive shaft. Used would be fine.

You still have life left in that shaft but for maybe local riding as it cant hurt much more but deffinetly needs changing.
 

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I would also suggest the following on the LH side:
Items #26, #27, #79 & #80

On RH side you'll need the following:
Items #44, #10 & #11
______________________

Items #80 & #27 (hardened spacer) have been compromised IMHO and you should replace Item #26 O-ring.

Items #79 & #44 should not be reused.
You'll want to increase the torque value of the front pulley nut (Item #79) to 110 ft~lbs upon assembly.
You'll also need 80~90 Gear Lube per manual.

Lots of press on this subject if you use the Search Engine and AlanH
 

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That middle shaft is chatarra (scrap) and wont work even if you flip the front pulley around. There aren't enough threads on the shaft to torque the pulley nut and go for a ride to 7 Eleven.

The close fit of the pulley & middle shaft splines is very critical as is the torque value so if you purchase used parts you'll want to do your due diligence.

Bottom shaft in photo is new design middle shaft that fits your ride :)



Middle Shaft Replacement '04' Warrior
 

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Discussion Starter #20
I would also suggest the following on the LH side:
Items #26, #27, #79 & #80

On RH side you'll need the following:
Items #44, #10 & #11
______________________

Items #80 & #27 (hardened spacer) have been compromised IMHO and you should replace Item #26 O-ring.

Items #79 & #44 should not be reused.
You'll want to increase the torque value of the front pulley nut (Item #79) to 110 ft~lbs upon assembly.
You'll also need 80~90 Gear Lube per manual.

Lots of press on this subject if you use the Search Engine and AlanH
Thank you for all this info! I'm really not sure I'd be willing to throw down on this project with out all this help from the forum, I'm truly grateful! Gonna do some research on the service manual and the threads in the forum then start ordering parts and begin the install. I'll keep ya'll posted on the progress
 
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