This article is one of a series that describes how to disassemble, work on, and reassemble the Road Star engine. This particular document describes how to install the engine's clutch, shift-shaft, primary drive gear, pickup coil, and oil-pump driven gear assemblies. See the Complete Engine Tear Down, Orientation article in this website for details.

Be sure you refer to the service manual through all phases of this project.

Take picts of the engine’s left side.

Bolt on the primary drive gear assembly, including its key, pickup coil rotor, and spacer washer, but do not torque the bolt yet.

Installing the Oil Pump Driven Gear Assembly

Install the oil pump driven gear assembly, including the brass oil-delivery tube. Remember to include the three, little O-rings for the oil-delivery tube. See photo above.

Installing the Shift Shaft Assembly

Next, install the shift shaft assembly.

Tip: I forgot to install the shift shaft assembly until after my clutch was completely in (Not one of my better moments). But I was able to get the shift shaft assembly installed without having to take the clutch back out. To do this, I used a little wire-tie on the shift shaft, to pull the lever clear. Then I just snipped off the wire-tie once the shift-shaft was in. See photo below.

Install the clutch assembly. Refer to the, How to install the Barnett Clutch with new Oil Pump Gear article in this website for details.

Tip: I do have one suggestion, however. Rather than purchase a one-time-use tool like the Yamaha clutch basket wrench, I wrapped a nylon-webbing, hold-down strap around the basket. One end is tied to the frame. The other end is just wrapped around the basket, overlapping itself. The webbing does stretch. But as long as you wrap it in the right direction (see photo below), it will tighten on itself nicely.

I thought about using the folded over copper washer trick, to hold one gear against another, but the service manual does not suggest this. I assumed it was because of the amount of torque causing possible damage to gears or bearings.

While you have the Yamaha clutch basket wrench or nylon-webbing in place, torque both the clutch boss (aka basket) nut and the primary gear (aka pickup coil rotor) bolt. The clutch boss nut takes 50 ft-lbs, and the pickup coil bolt takes 85 ft-lbs.

Do not install the clutch cover yet. You can want access to this area as you assemble the engine's right side.

Take picts.

To access related articles, refer back to the Complete Engine Tear Down, Orientation article in this series to see which additional articles best address your situation.

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DISCLAIMER: This information and procedure is provided as a courtesy and is for informational purposes only.  Neither the publishers nor the authors accept any responsibility for the accuracy, applicability, or suitability of this procedure.  You assume all risks associated with the use of this information.  NEITHER THE PUBLISHERs NOR THE AUTHORs SHALL IN ANY EVENT BE LIABLE FOR ANY DIRECT, INDIRECT, PUNITIVE, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OF ANY NATURE ARISING OUT OF OR IN ANY WAY CONNECTED WITH THE USE OR MISUSE OF THIS INFORMATION OR LACK OF INFORMATION.  Any type of modification or service work on your motorcycle should always be performed by a professional mechanic. If performed incorrectly, this procedure may endanger the safety of you and others on your motorcycle and possibly invalidate your manufacturer’s warranty.

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