Bike started sputtering at times, suspected carbs. Rebuilt carbs, forgot to replace valve needle and seat gasket. Gas filled the cylinders and caused instant hydrolock, which then caused starter idle gear to break multiple teeth. Simple carb project got bigger real quick.
Split case to begin gear replacement. Used down time to replace carb float needles/seat gaskets, petcock rebuild, starter rebuild, fuel filter replace, shift kit, and a bunch of other smaller things here and there. So this weekend comes, scored 4 days off in a row and had all my parts ready at hand... Or so I thought! Upon putting the new starter idler gear in I moved the crank around some to see how it spun, and things felt ok except in two spots. There is a 2nd idler gear that is on the actual main shaft/starter clutch that seemed to take some damage as well. This is where my big project got bigger.I used the tear down guide from the old forum to get to where I was and now I wonder if this has been something that may have been overlooked by anyone that's had to replace that single gear. I managed to find the gear for $45ish on some random site out of Ohio. Yamaha dealer locally sells it for $109! I'll throw some pictures up here so you all can see what gear I'm referring to. Also: I've been taking shots during this whole process to continue to further the progress on the FAQ being built. This way every one can learn from my mistakes! YAY!
Split case view. Yellow is where the first starter idler gear normally is that touches the starter motor directly.
Another Case View. Yellow is where the first idler gear goes that the starter motor touches directly.
Starter Clutch Assembly.
Bent teeth on 2nd idler gear.
Comparison of good and bad teeth.
Sad gear teeth
Looks like they got chewed in 2 different spots on the sprocket.
