buy a banshee, 250r, 4o0ex,450r,raptor or any other name brand with these new 450's, can am has a new 08 gg bike and i hear a new outlaw 521 is coming out in 08 [img]i/expressions/face-icon-small-smile.gif[/img]

 

you have to find someone that knows how to tig weld...i can weld anything ...but then i have been welding for 34 years..lol

 

<div class="FTQUOTE"><begin quote>Originally posted by: STRAIGHTUPDAHILL

you have to find someone that knows how to tig weld...i can weld anything ...but then i have been welding for 34 years..lol</end quote></div>

So you can weld cast aluminum? If so, why is everybody I talk to so scared of it? Are they wimps? I had an old chevy K5 Blazer that had a cast aluminum tramsmission in it and after too much abuse the bell housing cracked all the way around. I took it out and tried to find somebody to weld that up for me with no luck. They told me cast aluminum gets contaminated so easily its hard to weld it. Did they just not want to mess with it or what? I am familiar with stick and MIG welding on steel, but I have never done any TIG or aluminum welding.

 

aluminum is a mystery to most welders...


most welders can't weld aluminum

 

<div class="FTQUOTE"><begin quote>Originally posted by: N.F.S.

Hello,

First of all I'm Connor Reyes, I'm new to this forum.

I have a 1999 Yamaha Warrior.

A little while ago i wasa quading and i happened to get stuck on a branchy busy that had been lying on the ground. I went to reverse off of it but when i shifted the quad into reverse the clutch popped and the chain managed to catch the side of the engine casing. What ended up happening was the chain got wrapped around a piece of the left side of the engine casing and riped a piece off. The piece ripped off tore a small hole in the engine exposing the internal bearings. The rest ripped off only tore partial connected pieces of the casing off. I was devistated when it happened. [img][/img] Since the accident the warrior has sadly been sitting in my shop. I have called around to professional welders about patching the hole and it can be fixed alright. I must take apart the entire engine and bring them the only piece that needs to be welded. I Was wondering if there is any specific way that the engine must be taken apart, and once it is apart i figured i might as well clean out everything internally, and is there a specific way to clean out and restore the engine. I realize that i'm asking alot but i dont specificly know how and what to do to complete the process of fixing my quad, and i love it to death so i want to make sure everything is done right. [img][/img]



Thanks,



Connor.</end quote></div>

Alright, sorry to get off topic with the whole welding thing. Are you going to do all of the work yourself? If so, Ive heard there is a certain way you have to split the engine cases. For starters, if you don't have the engine laying on the correct side when you pull the halves apart, the transmission will fall everywhere. There's too many little pieces in there for me to deal with, I usually let somebody else do it for me. The last time I had it done it cost me $40 in labor. So it was worth it to have his trained eye spot a few pieces that were worn out. The Warrior lower ends are nearly bullettproof, so usually there is nothing you should have to replace other than gaskets and maybe crank seals if you want. You may want to just check the shift forks for wear and there is something on the reverse mechanism in there that has a tendency to wear out you may want to check. Other than that new oil and a new oil filter and you should be all set.

 

If you do plan to pull the motor appart get a clymers repair manuel for the Warrior, because you will need it by your side. I've done three Warrior engines, they are not hard at all. I would go on ebay and look for a mint set of cases instead of welding, Warrior cases can be welded, my friend had his done but I'd rather have a mint set. You will need a few special tools or you could take the left half after you've pulled the enging appart and have the dealer pull the flywheel and press the crank out. To reinstall the crank (don't laugh it works, Mickey Dunlap of FST told me to do this) just put the crank in your freezer for a few hours and with a propane torch just lightly heat the bearing area (not to hot) and the crank will slip right in. Just follow what the book says and the trans will be fine.

 

hot ice and an oven works great