Wow.. after 9 years of owning/riding and maintaining 2 roadstars one of them finally broke down!! The transfer case drive pulley spun out on the main shaft and both are stripped out.. and the nut was not loose as we all know happens sometimes..has anyone replaced the main shaft because of this ?? I am quite mechanically inclined and a machinist by trade but i dont want to get in over my head. Looking at the manual helps but someone with experience is priceless..anyone else have this problem ??

Its about a 4 or 5 beer job. The hardest part is just like the clutch replacement, scraping the gaskets Yamaha made changes between 05 and 06 to the shaft nut that holds the pulley on and the 2 shafts are NOT interchangeable, so make sure you get one from the appropriate years for your bike. My 06 I bought in February had that happened with a loose nut, bought the bike for $1000.00, bought a complete Transfer case assembly minus the pulley on Ebay for $140.00 shipped to me. Had the parts installed in just a few hours. Your time involved may vary (Ive had my 02 down to the frame 3 times now )

Make sure you replace the small little O-ring on the end of the shaft. I would replace the seal on the pulley side and also I always replace the Tab lock washer with a new one (when appropriate)

Rod

Thanks for the heads up on that..this one is an 05...

Stripped my drive pulley a few years ago. Replace the pulley only, left the drive sjaft as it was after a clean up and installed a heavy duty clutch. 30k kilometers, no problems.

Wow....guess I should check mine....it's an 06 as well. Has anybody determined the cause of this if the nut is still tight?
Poor quality pulley material?

Yeah, did that a couple of years ago. You'll have to pull the right side cover and unbolt the drive sprocket and remove the chain to pull the jackshaft.
I found one (final drive box actually) on pinwallcycles but you can check suncoastcyclesports also.
I would replace the seal and bearing while I was in there, but for sure right side gasket, seal and o-ring.

no luck finding another middle gearbox used.. its a longshot but if anyone has one for an 04-05 or knows where i can find one please let know..gee..wonder why they changed the design in 06 ??

It is a lot more work, but if you found a complete 06 or newer transfer case, you could swap housings and all. Just cant put the old/new shaft into the new/old transfer case.

Rod

Hey Nightstar, I sent you a PM.