Motorcycle Repair: Maintenance on 1994 Yamaha Kodiak 4x4, yamaha kodiak 400, engine gaskets

Question
Mark,

I have a 1994 Yamaha Kodiak 400 4x4.  The bike has been parked for about 4 years.  Before it was parked, it ran, however the starter had gone out so it had to be pull-started.

I am ready to take it out of mothballs and get it running again.  I am fairly certain that it is going to take some work to get it running.  I wanted to let you know what I am planning on doing, and see if you had any advice on any additional steps I might take.

1. I am going to take the gas tank off and clean it out.  In addition to the tank, I am also planning on replacing the fuel lines and in-line fuel filter.

2. I am going to take the carb off and clean it out.  I am pretty sure that it is going to be gunked up.

3. I am going to change the oil and the oil filter.

4. I will probably go ahead and replace all of the engine gaskets.

5. I may try to see if the battery will take a charge, but will probably end up buying a new one.

6. I would like to replace the starter, but this is not crucial at this time.

This is my game plan.  If you have any further advice on other things that I should do to get the bike up and going again, please let me know.  

Thanks,
Dale
dalehurst2000@yahoo.com

Answer
Hi Dale,

1. I am going to take the gas tank off and clean it out. In addition to the tank, I am also planning on replacing the fuel lines and in-line fuel filter.

A:  Good idea. Clean the petcock of any accumulated varnish, too.


2. I am going to take the carb off and clean it out. I am pretty sure that it is going to be gunked up.

A: Yup.


3. I am going to change the oil and the oil filter.

A:  Yup. Avoid storage with old oil. Loaded with acids from combustion. May harm bearing and metal surfaces over time. Change oil prior to storage.


4. I will probably go ahead and replace all of the engine gaskets.

A:  Nope. Leave these alone. They should be fine even after much longer periods of storage.


5. I may try to see if the battery will take a charge, but will probably end up buying a new one.

A:  Batteries usually have a useful life of about three years when in regular operation. A defective battery may harm other electrical components.


6. I would like to replace the starter, but this is not crucial at this time.

A:  Remove, disassemble, and inspect prior to replacing. It may need cleaned and new carbon bruses installed.

I'll send tech files to your email address. Thanks!

Respectfully,
Mark Shively