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Discussion Starter #1
Hi all.
I am looking for anyone that has had the Middle gear shaft break on the 1100 Vstar. Yamaha is telling me that they cannot warrranty it for me, on my 06. I feel that it should not have broken. Any help on this will be greatly appreciated.
Ride safe
Doug
 

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Power shaft

There was a discussion just over a month ago here. Look second page back titled power shaft broken.

Another responder also had the same problem. I mistakenly thought that by power shaft he meant drive shaft but, I think you are speaking of the same shaft.

Apparently they are a weak link but, I don't think it is something that happens often.

Aparently as with most manufacturers free of defects in manufacturing for one year does not mean free of defects. Also not sure if any hot dogging was in this picture.
Dave
 

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Discussion Starter #4
I realize this was a thread a short time ago. I am trying to find out how many shafts have broken lately. Maybe I can pursuade Yamaha to do something about the issue. To replace the shaft the cosst is between $1500 and $3000. that being said.
When the shaft broke I was riding along at about 25mph (city traffic). and developed a whine (sounded like tire whine). noise followed speed, could only hear it during decelleration (loud pipes). Noise gradually got louder. Loud crunch was heard when nut holding u-joint to middle gear dislodged and busted speedo pickup.
 

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my o5 had 53000 when this happened but after a lot of reserch i have found out that this is happening in a lot of the 11oo's of all years and milage from 8000 up.i have already repaired mine and it only cost me 14 bucks and about 8 hours time.the cause of the breakage is that yamaha uses a cast forged shaft which they finish machine and heat treat.After examing the broken shaft under magnification you can really see how uneven the heat treatment was but back to the fix,if you remove the swingarm you can easily get tothe end of the broken shaft where any competent mechanic or machinest can drill the end of the shaft and tap it,install a proper hardend steel bolt to hold the universal yoke to the shaft.thats the basics of the fix but can give a more in depth explanation if anybody needs it
 

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Discussion Starter #8
Thanks for the information, I am having a private shop replace the gear shaft. I want to try and get Yamaha improve the gear and maybe with any luck do a recall.
 

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Good to hear that you are getting it taken care of. What kind of money and time were they talking? The nearest shop for me that can do that sort of work is several miles away. I hope you pursue the idea of a recall on that. If Yamaha put out a defective part, then by all means, they should recall and fix them all, otherwise would be quite a blackeye, don't believe Yamaha would want that. Would be nice if they give this attention.
 

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Discussion Starter #10
I took the engine to a private shop 14 miles from home. I think I am going on 4 weeks now. The shop said it could be as early as the end of the week. with a total of around $1600. I was quoted 12hours labor. The local dealer said they could do it in 6 hours. I have to wonder what corners where to be cut. I don't mind paying for a little more labor if the job is done right the first time.
I will definently persue Yamaha on doing a recall.
doug
 

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Discussion Starter #12
Just an update on the saga of my broke bike. Called the shop today and was told that they needed to order another tool and bearing carrier for the middle shaft. Destroyed tool, retainer,and nut during removal of old nut. Oh well what can you do? Should have the motor back in about 1 1/2 weeks.
 

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Discussion Starter #14
I stopped by the shop today I should have my engine back tomorrow. YEH.:):) Now I just have to find the time to but it back into the frame. Anyone want to help?
 

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Doug, really, before you starting postin on this problem I had not heard of it, or didn't pay attention or something, really glad you are on the way to runnin again, glad you about got it, it seems it's been a lot of grief gettin there, good luck with it all, and thanks for keepin after it.
 

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DMTJOY,
Not sure if it is the same shaft, but the output shaft broke on my 06VSTAR Custom at the end of Sep with only 30,000 km on it. As I bought it used, I can't speak for the original owner, but do not believe it was abused. The original quote to repair was over $4000. Not happy with that, I trailered it back to my original dealer 3 hrs away. At the same time I called Yamaha Canada, but they shot me down. So, I wrote a formal letter to Yamaha and my dealer worked with the field services rep in the area to determine what they would do to help. At the end of the day, it cost me $1300 to fix. Yamaha's formal response to me was that they left it with the dealer to determine if they would cover some of the cost. I'm not buying that! Yamaha has not acknowledged that there is a problem with the output shafts, but I believe there is. I have spoken to 3 dealers and they have all had at least two VSTARs with the same problem. Further, when the replacement output shafts come from the manufacturer, they are slightly larger and more solid. That indicates to me that there is a problem with their product.

Jeff
 

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Discussion Starter #17
The output shaft and Middlegear are the same shaft. Yamaha calls it the middle gear. I just got my engine back this morning $1600 later. :( I also noticed that the new shaft and nut are larger. I realize that you live in Canada but would mind filling a complaint with the NHTSA. http://www-odi.nhtsa.dot.gov/ivoq/index.cfm
If we can get enough complaints maybe Yamaha will have to do a recall.
Thanks
Doug
 

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Doug,

Already done! I saw the link last night and took a few minutes to fill it out. Best case scenario is that they eventually have a recall and we can get some (or all) of our money back.

Jeff
 

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Discussion Starter #19
Thanks Jeff,
Got my bike back on the road this week. Glad to be riding my Vstar again. After the first of the year I plan on going to Calif. to visit Yamaha USA headquaters, maybe I can get some satisfaction.
Doug
 

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Hey Doug, I hope you are able to do that, it would be pretty neat to show up with documentation(and maybe the used parts) in hand. I'm looking foward to hear what they have to say to you in person.
 
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