Clutch Issues Maybe? - Page 2 - Road Star Warrior Forum : Yamaha Star Warrior Forums

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Old 08-12-2019, 09:38 PM   #11 (permalink)
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Based on the video it sounds like an issue with the clutch housing or clutch boss.
The transmission is still operating in 1st/2nd so I don't believe there is an issue with it or the shift forks.

I would do the following:
  • Pull the front pulley cover for a visual inspection of nut though I don't believe that's the issue as there is no belt movement at all.
  • Dump the crankcase oil only (not the tank) and check for foreign particles
  • Pull Clutch Cover and inspect for failed parts

There have been 1 or 2 cases of a loose boss (basket) nut but not your issue your year.
  • ADDED:
    Clutch Boss/Basket Nut to Transmission Input Shaft (Basket is Splined)
    2004 and later use a conical washer and crush/stake nut to retain the basket.
    2002-2003 use a tabbed lock washer and nut!
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Last edited by alanh; 08-13-2019 at 08:59 AM. Reason: Added jpeg & note, corrected typo :>)
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Old 08-14-2019, 01:37 PM   #12 (permalink)
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Front pulley free spooling??
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Old 08-14-2019, 06:51 PM   #13 (permalink)
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Finally had a chance to get in the garage and see what's what with my ride. I took the Front Pulley Cover off and immediately noticed an issue. There were metal shavings in the case and the bolt didn't look right. As I was pulling the bolt off, the front pulley was wobbling back and forth and was obviously not seated properly! Currently in the process of dropping the rear tire to get the belt off and see whats wrong with the front pulley.
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Old 08-14-2019, 07:11 PM   #14 (permalink)
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Was the front pulley removed when replacing the drive belt?It's not common for the '06' & > to have issues with the front pulley coming loose.

Suggest you post some photos of the middle shaft and pulley splines.
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Old 08-14-2019, 07:52 PM   #15 (permalink)
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I'm fairly certain it was not removed when replacing the belt. But, now that i'm seeing the issue it reminds me that when I had the front pulley cover off, I noticed that the bolt on the Front Pulley was extremely loose. I checked the YSM, made sure it was seated properly and tightened it to spec. Attached are the pics of the inside of the pulley and the shaft, both are worn and I assume need to be replaced.
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Old 08-14-2019, 09:34 PM   #16 (permalink)
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Looks like I need to replace the Middle Driven Shaft Assembly (#8) and the Front Pulley (#78).
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Old 08-14-2019, 10:38 PM   #17 (permalink)
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Quote:
Originally Posted by Zmann View Post
I'm fairly certain it was not removed when replacing the belt. But, now that i'm seeing the issue it reminds me that when I had the front pulley cover off, I noticed that the bolt on the Front Pulley was extremely loose. I checked the YSM, made sure it was seated properly and tightened it to spec. Attached are the pics of the inside of the pulley and the shaft, both are worn and I assume need to be replaced.
I knew it lol. This sounded all to familiar (not me). You'll need another middle drive shaft. Used would be fine.

You still have life left in that shaft but for maybe local riding as it cant hurt much more but deffinetly needs changing.
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Old 08-14-2019, 10:49 PM   #18 (permalink)
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I would also suggest the following on the LH side:
Items #26, #27, #79 & #80

On RH side you'll need the following:
Items #44, #10 & #11
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Items #80 & #27 (hardened spacer) have been compromised IMHO and you should replace Item #26 O-ring.

Items #79 & #44 should not be reused.
You'll want to increase the torque value of the front pulley nut (Item #79) to 110 ft~lbs upon assembly.
You'll also need 80~90 Gear Lube per manual.

Lots of press on this subject if you use the Search Engine and AlanH
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Old 08-14-2019, 11:20 PM   #19 (permalink)
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That middle shaft is chatarra (scrap) and wont work even if you flip the front pulley around. There aren't enough threads on the shaft to torque the pulley nut and go for a ride to 7 Eleven.

The close fit of the pulley & middle shaft splines is very critical as is the torque value so if you purchase used parts you'll want to do your due diligence.

Bottom shaft in photo is new design middle shaft that fits your ride



Middle Shaft Replacement '04' Warrior
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Last edited by alanh; 08-14-2019 at 11:24 PM. Reason: added url
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Old 08-15-2019, 09:09 AM   #20 (permalink)
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Quote:
Originally Posted by alanh View Post
I would also suggest the following on the LH side:
Items #26, #27, #79 & #80

On RH side you'll need the following:
Items #44, #10 & #11
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Items #80 & #27 (hardened spacer) have been compromised IMHO and you should replace Item #26 O-ring.

Items #79 & #44 should not be reused.
You'll want to increase the torque value of the front pulley nut (Item #79) to 110 ft~lbs upon assembly.
You'll also need 80~90 Gear Lube per manual.

Lots of press on this subject if you use the Search Engine and AlanH
Thank you for all this info! I'm really not sure I'd be willing to throw down on this project with out all this help from the forum, I'm truly grateful! Gonna do some research on the service manual and the threads in the forum then start ordering parts and begin the install. I'll keep ya'll posted on the progress
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