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post #1 of 12 (permalink) Old 09-26-2010, 04:47 PM Thread Starter
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Middle drive gear

Hey guys i haved to change my middle drive gear and was wondering how to split my crank case any info would be great.
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post #2 of 12 (permalink) Old 09-26-2010, 05:16 PM
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Pretty simple, loosen front diff so you can slide it forward and remove front drive shaft, take off the cvt cover and sheaves, remove motor mounts and pull the motor. Once the motor is out, try to keep everything in as big of pieces as possible. Remove both side covers, clutches, flywheel etc, as well as well as the valve cover-head-jug (its good to take reference pictures as you go). Then remove anything that is left, oil lines, etc. Once everything is off take out the bolts 16 or so i think that hold the two halves together and then with the motor laying on its side (flywheel side), lift off the side that the sheaves were on. If its stuck use a rubber mallet to tap it off. You cant really hurt the case as most likely you will have to replace it anyway, just be careful not to lose or forget where the internal pieces went. It took me about 4 hours after the motor was out to get it all the way apart, and that was taking my time and labeling everything as i went. I layed out a 4x8 sheet of plywood and laid the pieces out in order as i took mine apart, which made putting it back together simpler. Also on the covers some of the bolts are different lengths, on these i took a small piece of cardboard and drew a diagram of the part with a marker then stuck the bolts through it this way you know where all the short/long bolts go. The rest of the bolts i had a bunch of small cups and i labeled them and kept with the individual parts. (like head bolts---cvt bolts etc). Good Luck
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post #3 of 12 (permalink) Old 09-26-2010, 07:45 PM
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pretty much what he said only i used zip lock baggies to put everything in. inside the bag i also made up tags identifying everything. i was also able to get my case welded back together. the guy only charged me $50. much better than 600 for a case. its been welded for about a year now and is prefectly fine. he welded in some gussets around the area to help strengthen it.
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post #4 of 12 (permalink) Old 09-27-2010, 12:45 PM Thread Starter
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Quote:
Originally Posted by yota View Post
Pretty simple, loosen front diff so you can slide it forward and remove front drive shaft, take off the cvt cover and sheaves, remove motor mounts and pull the motor. Once the motor is out, try to keep everything in as big of pieces as possible. Remove both side covers, clutches, flywheel etc, as well as well as the valve cover-head-jug (its good to take reference pictures as you go). Then remove anything that is left, oil lines, etc. Once everything is off take out the bolts 16 or so i think that hold the two halves together and then with the motor laying on its side (flywheel side), lift off the side that the sheaves were on. If its stuck use a rubber mallet to tap it off. You cant really hurt the case as most likely you will have to replace it anyway, just be careful not to lose or forget where the internal pieces went. It took me about 4 hours after the motor was out to get it all the way apart, and that was taking my time and labeling everything as i went. I layed out a 4x8 sheet of plywood and laid the pieces out in order as i took mine apart, which made putting it back together simpler. Also on the covers some of the bolts are different lengths, on these i took a small piece of cardboard and drew a diagram of the part with a marker then stuck the bolts through it this way you know where all the short/long bolts go. The rest of the bolts i had a bunch of small cups and i labeled them and kept with the individual parts. (like head bolts---cvt bolts etc). Good Luck
So I have to remove the flywheel?Why would i need a new case?thanks for all your help.
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post #5 of 12 (permalink) Old 09-27-2010, 12:56 PM
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what happens to cause the middle drive gear to go out is that the drive gear support is a weak point from the factory. it breaks and then the mounts on the case where it was bolted to will also break. then the gear goes after that.
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post #6 of 12 (permalink) Old 09-27-2010, 01:00 PM Thread Starter
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Did not notice any of them broke but this middle gear was just done by yamaha and dont even got 100 miles on it.Yamaha wont cover it said my warranty is up!
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post #7 of 12 (permalink) Old 09-28-2010, 03:17 PM Thread Starter
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Well i got it all apart and it is not good lol.Crank case busted where the bearing retainer bolts on,bearing retainer is broke and the pinion is gone to!
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post #8 of 12 (permalink) Old 09-28-2010, 04:20 PM
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case 800, gears 300, retainer 150, bearing 30, gaskets 100, shims 5. Im sure im forgetting some stuff. Be sure to take apart the oil pump and clean the inside of it and also blow compressed air through the lines to the oil cooler to get anything that might have already went through. Chris at benchmark offers 20percent off oem parts. But for the bearing support plate i would go with a aftermarket billet one. I got mine from weller racing but most any are better than oem. Good luck
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post #9 of 12 (permalink) Old 09-28-2010, 04:35 PM Thread Starter
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Quote:
Originally Posted by yota View Post
case 800, gears 300, retainer 150, bearing 30, gaskets 100, shims 5. Im sure im forgetting some stuff. Be sure to take apart the oil pump and clean the inside of it and also blow compressed air through the lines to the oil cooler to get anything that might have already went through. Chris at benchmark offers 20percent off oem parts. But for the bearing support plate i would go with a aftermarket billet one. I got mine from weller racing but most any are better than oem. Good luck
welding the case i know that only gear that looks bad is ring and pinion will deff blow out all the lines and clean the pump.get it back together and buy something new had enough of this thing!
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post #10 of 12 (permalink) Old 09-28-2010, 07:30 PM
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i had about $600 in fixing mine when it went out. just have the case welded up and buy the billet aluminum bearing retainer. when they weld it up have them weld in some gussets to add some strength to it.
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post #11 of 12 (permalink) Old 09-28-2010, 07:54 PM
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Is anyone having this problem with the 700 or is it just a 660 problem?
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post #12 of 12 (permalink) Old 09-30-2010, 08:28 AM
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Just had my 06 660 done. Same thing. Middle gear broke, broke cases, shrapnel in crankcase scored cyl.
I had the motor completely overhauled. Used cases,Weller middle gear supp, new gears, all internal bearings new, cyl honed, new rings, head checked -valve guides-stem seals-seats-sandblasted pathways , new oil pump,the list goes on. Not cheap!
Have to take it back because rings didn't seat. Still burning oil at 180kms. He's going to re-ring it.
Good luck with your rebuild.
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