SMOKNZ
Extreme
Well my 05 warrior met an early end to the season compliments of a rather large rock. I was heading up the bank of a river following a bunch of other sled tracks. The last sled must have kicked up a rock that I met in a head on smack that ended up pealing the rock completely out of the ground. My bulkhead smashed to peices in the very front, and cracked near all the mounts for the A-arms. What kind of job is it to replace the bulkhead. I notice Port Yamaha has an entire front end in the parts breakdown. Is this the way to go or just try to peice together what I need? I have had the motor out of this sled before and am familiar with the alignment procedure. I see the front motor mounts are in the bulkhead. Can I just unbolt these without removing the motor? I assume the whole front suspension needs to be removed. Just looking for some encouragement from some that have been there... Having snow and open trails with no sled is killing me 
Thanks,
Bill
Thanks,
Bill
montanastick
Extreme
bulkhead replacement
That sucks, I replaced mine last year. if you can do a motor you can do this. Only use OEM rivets, they crimp/fold in /compress alittle different than any other rivets. port yamaha has the best deals. for special tools try to get a air rivet gun, This was key to getting rivets in good. (lots of rivets). I drilled most all of my rivets out & used the same hole. Parts I got all used from TY. The motor didn't need to come out. I had about 40 hrs into it, $1500 used parts. L & R full replacement. bulkheads, spindles, A arms, castings, linkage, nuts & bolts, bushing kit. My shocks were OK.
will send you pm
That sucks, I replaced mine last year. if you can do a motor you can do this. Only use OEM rivets, they crimp/fold in /compress alittle different than any other rivets. port yamaha has the best deals. for special tools try to get a air rivet gun, This was key to getting rivets in good. (lots of rivets). I drilled most all of my rivets out & used the same hole. Parts I got all used from TY. The motor didn't need to come out. I had about 40 hrs into it, $1500 used parts. L & R full replacement. bulkheads, spindles, A arms, castings, linkage, nuts & bolts, bushing kit. My shocks were OK.
will send you pm
yamahamaniac
Expert
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So you can replace this just by taking stuff off the front end and letting go the two front motor mounts? I have one of the brackets for the bottom A-arm on the throttle side smasked off... we welded it put with plates and stuff, no aluminum welding just made a plate to go behind the bolt where the washer that connects the two goes and we ran it over to the other side and connected it there so the two sides are strapped together. But I would much rather have it replaced. Taking out the motor isn't an option for me right now so if there is a way around it then I'd greatly appreciate to know.
montanastick
Extreme
bulkhead
I want to take out life ins. on you. NUTS, deathwish,. I made a video of what you will see w/ motor removed. remove a handfull of rivets and it will fall off. it might give you an idea what your infor.
http://www.youtube.com/watch?v=_SsWRsZFcWg
I want to take out life ins. on you. NUTS, deathwish,. I made a video of what you will see w/ motor removed. remove a handfull of rivets and it will fall off. it might give you an idea what your infor.
http://www.youtube.com/watch?v=_SsWRsZFcWg
yamahamaniac
Expert
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You saying that to me? haha Actually I believe that what we have done now is stronger than the stock bulk head because that is only a few smal ears holding it up stock, but on mine there is now a nice sized steel plate connecting the left side to the right, holding both sides up better than the stock ears. I'll try and get a pic to show you what I'm talking about.
