Question about 2004 Yamaha V Star 1100 Custom
I have a 2004 V-star 1100 custom. When replacing the clutch, I managed to get some paper towel lodged deep in that shaft and cannot retrieve it from the clutch housing side of the engine. How can I access the shaft on the transmission side to possible remove the paper?
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2004 Yamaha Star 1100 Clutch Replacement
Yamaha XVS1100 Service Manual
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YAMAHA XVS1100 Owner Manual
Posted on Feb 03, 2017
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Posted on Jan 02, 2017
The bike you are working on has a couple of way to adjust the clutch. Obviously the adjuster on the handlebars would be the first place but actually there is an adjustment on the other end of the cable that has a locking nut on it. You will need to loosen the nut that locks the cable and there should be another nut on the other side of the cable that you can tighten. As you tighten the nut it will take the free play out of the cable.
There is another adjustment on the inside of the clutch cover, it is on the clutch hub. The adjustment for this would be done by removing the clutch cover to access the clutch hub. On the outside of the hub there is an 12mm nut locking down a 6mm adjusting screw, the screw is adcually the first source of adjustment on initial assembly.
Let me give you the breakdown of how this works, your clutch mechanism has the hub adjustment, a ball, and a push rod that goes through the primary output shaft of the transmission. Then it goes to the actuating arm where your cable connects. The reason I'm telling you this is because often the ball in between the hub adjuster screw and the clutch push rod becomes welded to the push rod or it will actually start to come apart. When this happens your clutch adjustment goes away and you have no adjustment available through the cable or the clutch lever. Should this be your case I would recommend you take the clutch cover off, (be sure to drain the oil first), remove the six 10mm nuts securing the clutch hub, (this also holds the clutch springs in place), then you will have access to the push rod and the ball. You may have to tilt the bike over on the right side to get the push rod and ball to come out.
When you go to reassemble the clutch make sure all the adjusters are loose so you can adjust the clutch in the following sequence:
Good Luck! This is a DIY job, you wont need to take the bike to the shop if you are able to do any routine maintenance. Should you have to remove the clutch cover you will need to replace the right side, (clutch cover), engine gasket. If you take it apart I would recommend replacing the ball if it has any signs or wear, it will be blotted, this is a very cheap item that can cause much grief.
Let me know if you need any further assistance.
Posted on Jan 02, 2009
SOURCE: Replacing broken drive shaft
the u joints definitely need lubrication and as far as breaking a drive shaft I personally have never seen one break unless someone has been really hammering it or doing a lot of burnouts
Posted on May 07, 2009
go to this http://www.cmsnl.com/yamaha-rt1-19701971_model8356/partslist/A-09.html and then click on "view big image", this will give you a diagram of the clutch etc,, the adjustment (No. 26) may need looking at, or (No.11,12,) have broken.Basically you turn 26 in (clockwise) untill you feel light resistance then back off 1/2 turn (been years since i worked on one of these!) this should give you freeplay, have you just got the bike?, and do you think it has been stripped lately(ie the clutch). PS I am not affiliated with the web site i offered above, just a handy reference for you maybe? cheers
Posted on Jul 24, 2009
That is a bit strange. Did the previous owner install stronger springs than the stock ones? Compare the effort to pull your clutch handle to what it takes on a new 125. Be sure you have clean 10w40 motor oil in the gearbox. No synthetics or special additives. Replace the rod and the lever assembly. The rod, lever and oil should eliminate the problem assuming the springs are stock.
Can I get a “very helpful” rating on this answer?
Posted on Sep 01, 2009
Testimonial: "Thanks, very helpful because you were right, stiffer springs were added."
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