jelliott wrote:
well the pulley itself is not damaged, the drive shaft gear/splines have slight damage.
I have a slight movement when I put the pulley on in the middle of the shaft gears.
Just wish yamaha would have made a key way slot and some type of pin so the nut would not
have backed off.
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Hey,with that thought in mind it makes me wonder if someone was good enough with a small die grinder or some kind of metal cutting tool to grind a keyway in the shaft and have machinest cut keyway in drive pulley.

Then use a hard stainless steel type or hardened steel key that wont easily sheer.

Or another thought would be to drill & tap drive pulley in 2 places (inbetween teeth) for recess type stainless steel allen head screws .

And at the same time your drilling the 2 holes on the drive pulley also drill 2 corrisponding /matching shallow/not too deep maybe 1/8" holes or nice flat areas in the driveshaft at same time that the 2 allen head screws can seat in.

Then install the SS or hardened steel recess type allen head screws with red max strength loctite
and see how that does.

Now if you could setup/cut some kind of key way system too work with the allen head screws i bet that would work even /hold even better.

Could save a lot of time/money ($200 + for parts or $600-700 for repair at the steeler) esp if the bike isnt ridden real agressive & doesnt have high power/trq mods.

Scott

does anyone know if you can use a 07 middle drive gear (shaft) to replace a 05 shaft?

jelliott wrote:
does anyone know if you can use a 07 middle drive gear (shaft) to replace a 05 shaft?

I just did a search on the middle drive gear and the part# for the Road Star is 4wm-1755A-00-00 and the part# for the Warrior is 5px-1755A-00-00 so they may be the same except for the first part of the part# maybe distinguishing the road star part from the warrior but being the same part. There is a different bearing and bearing housing you have to use because of the different design of the newer shaft if it will work.

thanks gilly, just didn't want to put the sane stuff back in it so it might happen again, or pull the pulley cover off every few months to check.

The Warrior has a separate bearing housing that you can change to accept the 07 bearing from an 05 but i do not see the housing in the 05 Road Star at all. The 05 Road Star carries a different bearing than the 07 but does not list a bearing housing for either bearing. The Warrior lists the 07 bearing as the same as the 07 stock Road Star bearing. So if the Road Star does not have the replaceable bearing housing to change the bearing size to the 07, i do not see how it could work without changing the transfer case to an 07. I could be wrong about this but it does not look good for the swap. but hopefully someone with more knowledge will be able to help.

here's a link to this same discussion on a stratoliner forum. photos of the nut tie-wired on the shaft
http://forums.delphiforums.com/n/main.asp?webtag=starroadliner&msg=25759.21
you need to go to the start of the thread

i would say about 2 hrs. did you try pinwall cycle on ebay? they may have one. it's not a hard job.
http://www.ebay.com/itm/04-Yamaha-Road-Star-XV1700-1700-TRANSMISSION-TRANNY-SUB-MIDDLE-DRIVE-/200825357898?pt=Motorcycles_Parts_Accessories&vxp=mtr&hash=item2ec21fc64a

Do not attempt to weld this shaft!!

Even an expert welder would not do it.
There is no way to get it straight.
It cannot be welded in one pass.
The weld zone will get past 1600º.
It would require removing the shaft from the engine.