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Discussion Starter #1 (Edited)
EDIT: solved woodruff key issue, now I’m looking for spark,


Got that all switched out, tried to fire it up after an oil change, I’m not getting any spark

If I did the flywheel mod wrong, will that prevent spark? I believe I had spark before the starter sprocket broke.

I was careful with measurements but the tool slipped and I took a small chunk out of the corner of the timing stripe

I might put the 1st gen with a thrown magnet back in to test.

Ive got new plugs, checked ignition wires and caps, tested coil resistance, all checks out

How do I test the stator pickups? I read the guide but did not understand

I got the bike to run around the block once before the starter sprocket broke. That is good now so I’m on to the next issue

Also considering the cdi is bad, not getting much readings with the multimeter.
I have the red prob in the pin connector and the black on the battery or frame ground, is that correct ?

Thank you

Looking forward to putting some miles on this old machine”



Edit: have a 1993 bike that wouldn’t start. After troubleshooting I determined the starter wasn’t engaging.
Took off the stator cover and removed the flywheel.

Now I’m stuck, the washer is stuck on the crankshaft behind the extruded key.

How do I get it off / around this?
Will the sprocket also slide off, it’s broken from the weld

I have a new flywheel,washer,clutch,sprocket, and gasket coming this week

thank you for any and all help
 

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"extruded key."
That should be a removable woodruff key.


52814


52815


If it sheared, you can dig it out using a small punch.
 

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Search Google: digging out woodruff key

"I always try to take a small punch and tap one end down into the keyway.
There's a good chance the key will rotate enough to get vise grips on the other end and pull it out."

Also consider applying some heat.

Search YouTube:
Yamaha Warrior - Snapped Woodruff Key
 

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Discussion Starter #5
T
Search Google: digging out woodruff key

"I always try to take a small punch and tap one end down into the keyway.
There's a good chance the key will rotate enough to get vise grips on the other end and pull it out."

Also consider applying some heat.

Search YouTube:
Yamaha Warrior - Snapped Woodruff Key
Thank you , got it out.


If I have a 1st gen frame, but second gen motor, do I need to modify the new second gen flywheel or will it be fine since the
 

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Discussion Starter #7
Got that all switched out, tried to fire it up after an oil change, I’m not getting any spark

If I did the flywheel mod wrong, will that prevent spark? I believe I had spark before the starter sprocket broke.

I was careful with measurements but the tool slipped and I took a small chunk out of the corner of the timing stripe

I might put the 1st gen with a thrown magnet back in to test.

Ive got new plugs, checked ignition wires and caps, tested coil resistance, all checks out

How do I test the stator pickups? I read the guide but did not understand

I got the bike to run around the block once before the starter sprocket broke. That is good now so I’m on to the next issue

Also considering the cdi is bad, not getting much readings with the multimeter.
I have the red prob in the pin connector and the black on the battery or frame ground, is that correct ?

Thank you

Looking forward to putting some miles on this old machine
 

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Discussion Starter #8
Any ideas? Still no spark, just tried a new computer/junction box,

going to put the original flywheel back to test that
 

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Check the pickup coils.

Test1: from the Manual: about 400-490 ohms resistance between the leads, and infinity to ground.
Test 2: from experience: AC Output with starter spinning the engine; don't know a specification for this test, maybe 15, 20 AC Volts? Maybe someone can check it on theirs?
 
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