The Yamaha Road Star Warrior Forum

I am in need of your help... I did a search and found other people and threads with this problem, but no one really got to DIY fix. Almost everyone gripped about it, or took it to the dealer.

So if anyone can help and give me hints, tricks, tips, or steps it would be greatly appreciated

Thanks a ton

The part you have is the middle shaft outer seal and located behind the front drive pulley. I suspect that you have a loose front pulley and there's lots of press on this subject. This is a common failure on the '04-05' models IMO and also misdiagnosed as a leaking seal. You'll want to read the enclosed threads regarding the inspection of the splines on the pulley and middle shaft as well as the proper torque of the frt pulley nut when reassembling.

The transfer case leakage is commonly from a small o-ring (Item 26) between the spacer (Item 27) and the inner race of the middle shaft outer bearing (Item 5) and not from seal (Item 25)

This is not a difficult task and most likely you'll be able to remove the pulley nut by hand because it is loose.

Here are some threads & you'll want to order Item 80 - splined tabbed washer - qty: 1

Re: Sprocket Issue's (anyone else?) http://rswarrior.com/forums/p/20832/324166.aspx#324166

http://rswarrior.com/search/SearchResults.aspx?q=user%3aalanh&tag=Middle+shaft&orTags=0&o=Relevance

What AlanH said.

Assembly tip: The sleeve (item # 27) has a bevel on the inside diameter at one end only. Install the sleeve with the bevel facing the center of the bike.

Thanks for the awesome info guys...

But AlanH You have me dreading do it now if fear of seeing the "red rusty residue"

I just ordered the other parts from the dealership and I think I am going to tackle it this weekend. We will see if anyone has other tips in the time being.

Thanks again

 Z-Warrior....good luck with this.  i willwatch as you work thru it.  I do not have a problem with mine, but it is an 05, so I am very interested in what you find out.

Thanks AlanH, I will check out those threads too.

While I don't have any advice, I can say I bought an '04 Indigo Warrior exactly two years ago.  Got it home and had the exact same problem...oil on the garage floor from a loose front pulley nut.  When I torqued it back down, the leak stopped.  But, I had the dealer replace that seal anyway.  Hasn't leaked since...

Z-Warrior:

Thanks for the awesome info guys...

But AlanH You have me dreading do it now if fear of seeing the "red rusty residue"

I just ordered the other parts from the dealership and I think I am going to tackle it this weekend. We will see if anyone has other tips in the time being.

Thanks again

FYI ... i just edited the 2nd link in my prior post to be more specific. Try it again here: http://rswarrior.com/search/SearchResults.aspx?q=user%3aalanh&tag=Middle+shaft&orTags=0&o=Relevance

Also, red residue/dust will not occur if you are running an Aluminum Frt Pulley ... Here's an earlier thread: http://rswarrior.com/forums/p/26393/903168.aspx#903168

AlanH:

Sat, May 3 2008 7:25 PM
Red dust - Heads Up

Keep in mind the Red Dust is the tail-tale from (2) dissimilar Ferrous alloys and/or differing hardness and represents the metal fatigue!

An aluminum front pulley will not exhibit the red dust

Just want to say thanks AlanH.

You are awesome!

I am feeling pretty confident on what I need to do now, and don't feel as lost.

Thanks again man!

AlanH, and everyone else that has helped and added info

Sending PM to AlanH as well

So I have been bad and have not changed this seal yeat, I have been too busy adding mods and enjoying riding. I tried a couple weeks back but did not have a 36mm socket. I now have the socket and am going to do this tonight. I will post my plan, and please let me know if anything should be added, or seems not kosher.

• 1. Pull off Front Pulley cover
• 2. Un-bend the tabs on the lock wahser
• 3. Breaker bar and 36mm six point socket and get the nut loose
• 4. lift up bike so I do not have to loosen the rear wheel/ belt/ and rear brake bolt
• 5. Remove Nut
• 6. Remove pulley (pray that the spines aren't trashed and not red dust) a couple weeks ago I saw a tiny bit of red dust but not a real abundance
• 7. pull off the sleeve and o-ring
• 8. pull out seal
• 9. replace with new seal
• 10. replace with new o-ring
• 11. Put back sleeve bevel facing in
• 12. put back on pulley
• 13. replace new lockwasher
• 14. blue locktite on nut
• 15. Make sure belt is seated properly
• 16. put back on front pulley cover

I guess my biggest worry is the red dust and spine but anyone with wisdom is greatly appreciated.

Thanky ou everyone for your help