Sorry but this will be somewhat lengthy as I need some help/advice...I have an '05 R* with 16k miles. Due to weather my trip this weekend got canceled but this gave me a chance to install the 33t front pulley I purchased from another R* owner. My first indication of a problem was when I pulled the bottom bolts from the cover to discover they were covered in oil. What i found was the nut for the pulley was very loose (half way off) and the locking washer was broken with the bent tab almost broken off. This has been like this long enough to measureably wear the pulley teeth by about 20% - 25% and wear the shaft splines to where there is a noticeable notch in each one. the old pulley was so loose it would wobble in all directions.

I know if I don't replace the middle driven gear shaft this new pulley won't last long. How difficult is this to do? I have the shop manual and it looks like I could do it. How much do you think a new shaft would cost? What would you do - repair or trade?

I can't believe how easy a maintanence item this is to have been overlooked. Everyone should check their pulley condition at least once or twice a year!

Love these forums and everyone's help. Thanks!!

Bump

Hey,

I'm ditching my entire transfer case on my Roadstar and going RSD...
So, If ya need an entire case let me know...
It may be a while 'til I get to parting out my Roadie...a month or so at least...Perhaps you would be interested? Easier than pulling yours apart!

I think the Yamaha part number for the output shaft is
#5vn-1755a-oo-oo and it lists for $201.69
(Don't quote me, I'm a little rusty at the parts fisch.) LOL

-WARSTAR

What is RSD and why would you ditch the transfer case?

Roland Sands Design?

RSD = Right Side Drive

Doc

I thought you meant Royal Star Deluxe...thanks for the offer but I can't wait a month or more. I get really cranky and depressed when I can't ride everyday. Waiting a couple weeks is going to be bad enough...how much do you want for everything?

oldroadstar, I had the same thing happen to my 05 R*. I got a shop manual (you should have one anyway), I asked a few questions here, and a friend at the dealers, bought a inch lb torque wrench and followed the manual. The parts cost me around 300 to 350.00. That was the final drive shaft, gaskets, o rings, and pulley. I had about 12,000 miles on at the time. The chain and front gear were still good.The dealer wanted 600.00. I just took my time and it took about 5 hrs, including lunch and a couple of breaks. The mechanic at the dealer that helped me and gave me a couple of new lock washers from a tranny recall kit he had laying around. If you can change your oil, spark plugs, adjust your belt tension and have a moderate mechanical ability,,,, do it yourself. The guys here are great and can help you if you run into problems.

Anyone have the link to the Right Side Drive? Seeing this about the front pulley has me worried so I'm gonna check into it. If I do before one is posted I'll do an article on it.

I've called Yamaha Tech line to discuss the transfer case...
The box is a 1:1 ratio,and the output shafts are the same
spline. The pulley should slide right on,fastening and spacing
could be another issue. I have not performed this procedure,YET.
Also, I'm just 'flipping' the rear wheel and re-spacing to keep the belt running true...this also means rear caliper relocation to the left.
(Not an afternoon job.)
I have not found any 'kits' either...let me know if anyone does find info on this subject.
I'm planning on moving the rear axle forward the amount of the transfer case shaft offset when I build the frame...and use the stock length drive belt.I want shorter...and lighter.

Meanwhile,still thinkin'...

-WARSTAR

Why not just go with a chain?

Or do you want to shorten the wheelbase?

Doc