Whats your diagnosis? 2005 Kodiak 450

[waltinbatonrouge]

Hi all. I spoke at length with the young guy who owned it....He said, "I put some big tires on it, ran it for a couple of weeks, then it wouldn't go into High gear. It would run in Low but would click, click, click as i rode it. My dad put it up on jackstands and ran it. He used a stethoscope and listened to the clutch side of the engine. He said "The secondary gear is ruined, put it in the junkpile", or pay someone $1000 to split the cases and rebuild the transmission.""

I bought the basket case 2005 Kodiak 450 for what I thought was a ridiculously low price.

Do you agree with his diagnosis?? There was no metal filings or pieces in the clean engine oil.
I don't want to split the cases for a maybe
please offer your thoughts, opinions as to whether you agree to the "secondary gear failure"
I've done a lot of Yamaha waverunner, BMW auto and electronics maintenance work, but just don't want to pull the cases apart on a hunch..

I have the factory Yamaha books..
thanks much Walt in Baton Rouge

[~Muckboy]

If you havn't done it before, and you dont have somebody with you who has, I would suggest you bring it to the shop.

They can also give you a realistic price on what your in for....

[waltinbatonrouge]

Hi Muckboy. I've done quite a few yamaha waverunner engine rebuilds, BMW and MB engine work as well...
check out the pictures in the Kodiak 450 basket case thread.
Thats the condition of the Kodiak.

Since I saw NO metal residue in the crankcase I'm thinking that there may not been internal engine damage.
The dealer wants $250 to open the case.

I'm just trying to get some information that may be able to suggests what might have caused symptoms as described earlier. thanks much walt

[jake72]

make sure shift cable is adjusted properly first

[Mad Mike]

yep check all the easy stuff first. There is someone on this site that just had to split the cases on a 700 do to reverse going out. There was an updated part so look on some parts diagrams to see if they have an update for the 450 if so most likely the problem. cases arn`t that hard to split make sure you keep all the spacers and shims in the right place.

[waltinbatonrouge]

Hi mad Mike..I'll check on an "updated part" for the Kodiak 450. Any idea what the part was/did? thanks again

[keith20mm]

What did you find? Split the case?

[Mad Mike]

I would like to no what he ended up dong also.

[keith20mm]

Originally Posted by Mad Mike

I would like to no what he ended up dong also.

I'll proxy his findings.

In pm discussion with him, what he found was that the low middle wheel had gall-welded onto the drive axle due to insufficient oil. Once it seized, a tooth broke off of the wheel. The gear wheel did not have any needle bearing against the axle, as in the old design. Sufficient oil would have precluded the failure. The new gear wheel runs on a needle unit onto the drive axle. So he's getting a new axle, gear wheel, and needle unit.

[4welynn]

Bummer, could be worse. Hope everything else is OK.