The Yamaha Road Star Warrior Forum

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Originally posted by JamesD

OK, completely off topic but how do you have a five year old bike with only 5k on it??

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Shoot, I had 1500 on mine after three days of ownership. My break in ride was a 1400 mile ride to the mountains in Arkansas.[]

I seccond DFW Warrior. When I got my 06 I had the same noise dirtydan says. I saw the nut couldn't rotate, so I discarted that. Then I loosen my belt a little and the noise went away. Turns out the belt was over tensioned from factory.

I have an 04 with 18,000 mi. The one year warrenty is long gone. My drive pulley nut came completely off two months ago and had to be replaced. I got the new lock washer then. When I took my bike in for the cps recall, the driveshaft was cooked as well as the pulley.
I got my bike back yesterday. Yamaha DID pick up the cost of the drive shaft and pulley, parts only. I had to pay the labor charges. They agreed that I had done everything that I could to keep the nut tite, so the failure was due to the lock washer / nut design. I had had the mech at the dealer check and torque the drive pulley nut at every oil change, but that wasn't enough to head this problem off. It took a while to get the parts, but my baby's home now! Both Yamaha and my dealer stepped up and took good care of me on this one.

Well looks like I got the Gremlin shaft.
http://www.youtube.com/watch?v=KbINNq2VAJs

I had my rear tire off the ground and happened to turn it and discovered a disturbing sound coming from the drive shaft area.

As you can hear the sound in the video, you can see the pulley nut is loose and the pulley rocks on the shaft.
There is a redish sludge around the pulley and red oil at the bottom of the cover.

The real pisser is the dealer where I purchased the bike (Capitol Yamaha, Sacramento) won't take my bike in there shop, because of the after market pipes, AIS removed and PCIII installed. Their afraid of the EPA.

So looks like I'll have to search out another dealer to have this looked at.

Good thing I purchased the extended warranty.


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Originally posted by akitadog

Well looks like I got the Gremlin shaft.
http://www.youtube.com/watch?v=KbINNq2VAJs

I had my rear tire off the ground and happened to turn it and discovered a disturbing sound coming from the drive shaft area.

As you can hear the sound in the video, you can see the pulley nut is loose and the pulley rocks on the shaft.
There is a redish sludge around the pulley and red oil at the bottom of the cover.

The real pisser is the dealer where I purchased the bike (Capitol City Yamaha) won't take my bike in there shop, because of the after market pipes, AIS removed and PCIII installed.

So looks like I'll have to search out another dealer to have this looked at.

Good thing I purchased the extended warranty.

I didn't think they could do that. Especially concidering the fact that the mods you have listed have nothing to do with the problem you are having.

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The only way they would have to worry about that is if they were the ones who modified it. You would think you ripped the tag off your couch pillow or something.[]

Mark... IMO the problem stems from the Factory Recommended Torque spec of 72 ft~lbs which just ain't enough. Your problem started along time ago based on the wear to the pulley which is considerably harder than the shaft. My guess is that your middle shaft was no good at 12,000 miles, but i've been wrong before. Had you inspected it at 12,000 i suspect there would have been the tale-tail red dust that has been discussed numerous times on the forum.

Check out my saga in this thread if interested and also my Homepage url Yahoo photos where there is a Folder titled Middle shaft showing the replacement: http://rswarrior.com/forums/p/20832/324166.aspx#324166

Just my .02, but i would think that the inner & outer middle shaft brg inner races could be worn from spinning on the middle shaft after the pulley loosened up as well as the hardened spacer behind the pulley.

Good luck

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Originally posted by akitadog

I'm more concerned as to why this is happening?
My pulley is stock and has never been removed before.
The nut lock is still bent up to lock the nut in place.

It's obvious the pulley or shaft is bad since the pulley rocks on the shaft.

I guess I should consider myself lucky since I have 24k miles on the bike and some have had less before this has happened.

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Hey there y'all! First post here...but not my last by any means....

I was riding around this afternoon, when I heard this terrible grinding/binding/squealing from the gearbox area. I rode immediately home and checked a few threads here on the forums...

I removed the front pulley and found that one of the 9mm allen bolts (part# 60 - 91317-10050-00 - BOLT (5) for those of you looking at the diagram) used to hold the stay (part #58 - 5PX-17613-00-00 - STAY) had come loose and was grinding against the inside on the back of the pulley.

No damage to the pulley, the little "teeth", I guess you could call them, on the head of the allen bolt were gone...but no serious damage. Tightened all 5 of the allen bolts and threw the pulley back on with a little dab of lithium-grease...and NO SQUEALS!!!

Thanks to all who posted how to remove the 30mm nut holding the pulley in there...that was a b**** to get off...but with some force...a breaker bar...and an impact wrench...it came off no problem.

So for those of you who are having the grinding/binding/squealing noise upon slowing down and pulling away from a stop...take some time (1 hour or 2) and check to see if one of your 5 9mm allen bolts is loose and just grinding the inside on the back of the pulley...

LATER![] And happy riding!

I noticed a small spot of oil under the front pulley...removed the cover and UGH!!! Oil and red goo (dust with oil) and the nut is loose. I've got 20k+ on my 2005. I've had no "tell-tale" noises. Oh joy!!!

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Pull the pulley, I'd bet it looks similar to mine.
I had 24k on mine before I discovered the issue.

DFW....Good point on belt tension and us checking it. MUCH more important is to check it after it comes back from the Dealer. They like to make them tight it seems.

I had the same wear problems at about 21K so i dont think it was my belt being too tight. At 7K I had this wear problem and belt tension checked when this topic surfaced because I didnt want to have to address this. In the end, I still had too. Yamaha paid for the parts and I had to pay for the labor. Not right but that was the best deal I could get out of them.

Well just a follow up on my shaft ordeal.
They are not going to replace it under the warranty.

They claim the other dealer (No longer in business) that last serviced it tensioned the belt incorrectly and this caused the pulley to wear this way.

So it looks like I'll be doing it myself!

It looks like I may have the pulley problem also.Last nite I pulled my fabbed up cover off the pulley nut to get ready for my 31 tooth install and saw the red dust.I had noticed a "binding" feel/noise when I spin the back tire.How much does the shaft cost and how hard to replace?I also gotta to admit that I have never adjsuted the belt it always seemed fine nor do I know the correct tension for it.

 I called Yamaha or should i say Star motorcycles today to complain about the issue and they said hmm not a common problem, thanks for the call goodbye......