robs400

Getting the Banshee back together slowly...got around to putting the foot pegs and nerf bars back on the banshee last night. The original bolts were all bent from the previous owner and just not in great shape. I cleaned the threads up on the frame and purchased some new metric bolts from the hardware store (8.8). They are only a regular hex head bolt tho, I could not find any flanged head bolts like I pulled out. I tightened things up as best I could and the pegs still feel solid when standing on them, but if I look at them, things still deflect. Is this a common problem for those bolts to break? Should I try to find stronger bolts? Thanks.

I'm glad to hear it running too. Just called and ordered those plugs. The guy wasnt sure if they were metal or not, but either way its the factory part I have ordered and I'll get them in there one way or another. It seems odd that they both fell out. Something that is meant to retain fluid like that I would think should have a positive means of being securely fastened. Unless the previous owner had them out for some reason and simply forgot to put them back in. Any suggestions on first mods I should get? Its still all stock...not too worried about power right now...I like reliable. I was thinking a case saver as it sounds like those are a good idea to get. Any other suggestions on things I should check or purchase? It does not see much abuse as I dont drive it too often due to where I live...but I do take it back to NY occasionally and would like it to be in working order with no worries. Last year I drove 5 hrs to get 5 minutes of ride time...and then another 5hrs back...no fun.

Are these known for falling out or would have had to remove them and not replace them? Hopefully thats all it is.

I FINALLY got the banshee back together last week. I found this site in early spring after I had some issues with what I thought/hoped was only my clutch. After getting everything back together it seems that the clutch is what was making that horrid noise. Took it up and down the dirt rd here a few times tonight and its running great. Hasnt started since last thanksgiving, and it started up second kick! Anyways...the initial noise the banshee had, I believe was due to the fluid getting low and messing up the clutch plates. So after I changed the clutch and figured out that was the cause of the noise...I need to find out where the fluid went. Banshee is all stock - 2004, low hrs. It has a new clutch cover gasket so I dont believe that is leaking, and the old one looked to be in good shape. I did notice fluid on the other side of the engine tonight tho. It is wet around the drive gear coming out of the case. It does not appear that the case was ever hit with a broken chain, but there are two small cavities below the drive sprocket on the case. Inside of those cavities look like pins...sitting in about a 1/4" or so. There is bright red fluid there, it looks fresh. I looked in the manual this evening, and it looks like those pins are actually rods that hold the shift forks on the other end...and that where I see the fluid seeping thru, there should be a plug. There are no plugs there currently. It looks like it is just a push in plug tho...will that really hold fluid behind it...is it common these fall out? Or am I looking at a bigger problem with a possible warn part causing fluid to leak there? Thanks for the help!

What is that in your vise? Is that just a piece of thin metal that is bolted to the case or something??

Appreciate all the help guys. It isnt the cooling tube o ring, I know that because I just ordered that one and its in a different exploded diagram...AND this I ring I am talking about is much bigger...its probably an inch smaller on diameter of the OD of the clutch housing. What I dont understand is that I see no means other than friction to hold that o ring into the house (if thats where it goes). So that means its meant to stay there on its own. I would have had no reason to pull that o ring out of that groove so it either was not on there when I pulled it apart, or I am missing something. Due to the weird noise the thing was making in the first place I want to make sure this thing goes back together right.

Looking at the setup it does not seem like there should be an o ring where it is shown. I dont have a camera here at work. Anyone else with a clymers manual??? pg 156.

Not exactly sure what you are asking for. The clymers manual shows an exploded view of the entire assembly. There is a groove on the back side of the Clutch housing (towards the engine with the gear on it), and on that side there is a groove that the o ring looks like its supposed to sit in. When the clutch housing is installed it does not seat up against anything in that area, so I am unsure what this o ring is for. I am not even sure what would hold it in there.

Removed the clutch assembly a while ago in my banshee (04) and a bunch of projects came up in the meantime that resulted in all my parts getting moved around my garage. Well I finally went to start putting things back together last night and realized I was missing 2 parts right away. The first is the ball on the end of the pushrod. They have one at my local shop that I am picking up today. The second piece is an o ring on the back side of the clutch housing. My clymers manual calls it out as item 17 pg 156. The local parts start has the official yamaha assembly diagram and its not shown on there. Looking at the part, I dont see what the o ring does. Does anyone know if this is available somewhere? Or if its something that is not needed?? Thanks for the help.

I greased everything and checked the fluid levels before I put in my truck to make the 3hr ride to NY....drove it for about 5 minutes and my parents house...let it sit over night...and took it further north to ride...which is when I had the issues. I will now check it EVERY time I ride Here are some pics of the clutches for reference...probably cant tell anything by them anyways. Been talking to another guy here on the forums having the same issue...he thinks it the clutch on his so I'm hoping mine will be fixed with that too.

I'm new to the banshee, but after taking it apart...the noise that it was making does sound like something that a clutch that ran dry would make. Where should I go to get new clutch plates? Should I get the basket as well? I'm not sure where the oil ended up going that was in there...it sits in my garage in the same spot...never a drop underneath it. Once I get the problem fixed I can clean everything up and keep an eye for anything leaking. Anything else I should check for as preventative maintenance? Thanks guys!

Clutch Chatter? Not sure if I am describing the noise correctly...this is pretty damn loud this noise, almost like a screeching...I cant imagine this being normal...especially since it wasnt doing it before. I was told by the guy at napa (not saying hes an expert) that regular motor oil would be bad for the clutch plates...however diesel oil is often used in gear cases ...I was in the middle of no where at that time and just wanted to see if the noise would go away if I filled it back up to a normal level...it didnt. What would you recommend putting back in there?

Did some searching this past weekend and found this forum, hopefully you guys can help me out. This is my first fourwheeler so if I'm missing some of the obvious please excuse me....heres a pic of it for reference I'm the third owner of this 04, pretty much unmolested banshee. I bought it from a friend of mine that barely used it, and I have owned it for a little over a year now, but due to me moving and a bunch of other things, I have no had much seat time on the thing. There is a small sandpit across the street from me that I put around in every once in a while and the few hours I have ridden it, it started great and was trouble free. I took back home to NY over thanksgiving to go riding up north with a friend...we drove 1.5hrs to the spot we were going to ride....unloaded the banshee...and within a few minutes all of a sudden a loud noise developed. As soon as I pulled the clutch lever in the noise would go away. I turned the machine off quickly, ran to the napa that luckily was across the street and filled the case back up to where it should be with some diesel oil to see if the noise would go away. I started it right back up, kicked it in gear and as I let the clutch lever out the started moving forward but the noise was also still there. The noise was very much like a wearing/whining type noise. Jump to this past weekend...I finally got a chance to look at it (its been winter here for a while). I figrued it might be clutch related so pulled the cover off and checked out the clutch plates and they "looked" fine. NOt sure where to go from here and am looking for some input... Also while i have you guys here...can someone give me any important things to check or know about with a banshee? ie common upgrades or issues with these things? Thanks for the help guys!

Hello - New here, went looking on the net this past weekend trying to see if anyone was having a similar issue I am having with my banshee, and I was directed to this site. Did you figure out what was wrong with yours? Aside from making the noise being pushed in neutral (I didnt try that) The issue sounds very similar to what mine is doing. I stopped mine almost instantly after it started making the noise. Checked the fluid, it was pretty low, so I added some fluid to see if it would go away, and it didnt within a minute or two so I parked it and got to tearing it apart this past weekend. A friend of mine helped pull the clutch cover off and we pulled the clutch apart...everything looked okay in there. No metal I could see in the oil I drained, altho it did look like there was a little water in it. Any info would be appreciated. Thank you!