Chain case problems

[RippinV]

Hi all, was wondering if I could get some help? At the end of last season my track blew out and I took my 2005 RX-1 to a local dealer in CT to get the new track installed. They installed the track and I put the sled away for the summer. I took the sled out this season and went to Canada for a 400 mile trip. Sled ran great, then I went back up last week and started out a four day trip, two days in and 400 miles later I smell the most nasty smell coming from my sled. Then I hear the chain slipping, I try to tighten and the bolt goes essentially all the way in . I check the oil, no oil! I add oil immediately, it leaks right out the bottom near the gasket! I limp it back to the truck adding oil every 50 miles. I get it back to CT and to the shop and they want to charge me $1200.00 to fix it?

I am picking up the sled in pieces tomorrow and was wondering if you all could advise me on what parts I am likely going to need to replace.

Also, is their a download for the repair manual so I can get all the specs and rebuild schamatics?

I am very mechanically inclined and would have done the work myself the first time if I had the time. Unfortunately I trusted a Yamaha dealer to do the work and this is where i am at.

Thanks in advnace

John

 

[givemeaboost]

Sounds like it's time to find a new dealer to me.

 

[Swiss Sledder]

You have to buy the service manual from an authorized Yamaha dealer. Since you probably don't want to buy one from your current dealer, try Port Yamaha instead. Good people to work with.

 

[RippinV]

Does anyone have the assembly sheets on the gear box? I need the torque specs as well. My ex-dealer really (*&$*$% me on this one. Anyway, new parts should be here tomorrow and I want to make sure I can get this thing back together.
:exc:
Thanks in advance guys!

Peace!

 

[LazyBastard]

Torque specs are NOT critical here. Loctite nuts and bolts on the INSIDE to keep them from rattling off. Service manual has been seen online - should be a link to it somewhere in the forum. Also, lots of people have copies on CD, myself included. I would send you the applicable sections, but mine is up north.

Probably what happened is they pinched the cover gasket, so all the oil leaked out. Then the chain exploded and took out the front and back of the chaincase. Parts - chaincase front and back, gasket, chain, driveshaft and jackshaft bearings and seals. Maybe also some random bolts and things. If the chaincase blew from the front, make sure that bits of the chain didn't damage the engine oil tank.

For the damages, you should definitely fight. If you can't get anywhere with the dealer, contact Yam directly about it.

 

[RippinV]

Thanks lazy, I actually went through all the parts last night. The chaid seems to be stretched out quite a bit. The gears are black but did not look rounded at all, but to be on the safe side I am replacing all the forward drive gears as well as the main bearings, oil seals, and the tensioner needle bearing. The gasket was tweaked so I am replacing that as well. The dealer lost the spring between the small forward and reverse gear, its a spring likely the size of one found in a pop out pen, but now I need to see if I can find one. All the bolts and stuff are find, the case is in one piece. I have to replact he exhaust pipe though, the flange that meets the header pipe is all cracked, that damn pipe is $250 +. So the hole sled is in pieces but I hope to have it ready for Friday's trip to St Raymond/Chicoutimi.



We'll see, I am just hoping to get my parts covered in some way, Total of $600.00 + without the exhaust, which is not their fault.

 

[Shivesy]

I tore down my chaincase on the Apex to add a different size gear. I took pictures of the tear down and thought this might give you some insight of what to expect. The Apex does have reverse. Hope this helps.

http://www.ty4stroke.com/viewtopic.php? ... highlight=

 

[4Fighter]

That sucks. Definitely file a complaint.

IMO: I'm glad to have the best dealership in MI, in my home town.

 

[RippinV]

Shivesy, you have no idea how helpful that was

Thanks a million

 

[kimoajaj]

Gees man sorry to hear about this.
I guess the reason for your problems has to do with a fautly reassemble of your dealer.
Oil doesn`t disappear just like that.. .

But I guess it will be almost difficult to make the dealer pay the repair.. or will it?.

 

[Meatloaf]

I just went through this. The dealer fixed everything for free. I'd go back and have a chat with them.

 

[race24x]

I would have a talk with him too. A right hook to the nose. Go in find there biggest truck and drain all of the oil out of the differtial in the middle of the night, put the cover back on nice and neat like and dont make a mess under the truck. See how they like it. Not that I have ever done this before cough cough