1999 to 2003 XV 1600 Road Star transmission slip and why not to run car tire

[Scott1111111111]

I learned the hard way but have a better understanding would like to share

I picked up a used 2002 XV 1600 Road star miles where under 20,000 if I remember

I am hard on a motorcycle, just the way I ride

Clutch started slipping maybe 25 or 30,000 miles and I didn't know it was by design, made to slip for a reason

Looked up clutch slipping on this bike and found link to Barnett's spring conversion and that was about it, no pro or con information

Put clutch in and slipping stopped, I'm able to pass without any problems and notice big diffrence in response

Started riding 1600 more and started wearing out tires, did not matter the brand would get under 4,000 miles and bald with large chicken strip or part of tire un used. Many interstate miles and I was making tire flat on bottom

Looked up car tire and went all in, could not stand putting new tire on every 2 or three months and one motorcycle tire I picked up metal twice (two diffrent flats same tire) and had to call rollback to get home. No tools or lift to fix tire tube on side of road

All in I sealed rim and purchased car tire known to fit and that was all the information I could find, no idea or knowledge about transmission recall for retainer clips on transmission shafts and did not know if bike had been fixed or recall work done, I got it used 2nd or 3rd owner

about 1,000 miles into wear on car tire and I like the idea or a plug instead or a rollback, no tube and getting more at ease with the ride diffrence, I'm not looking back, on interstate more than anything and bike now like an arrow. Groved 4 lane no longer a problem

Ethanol gas problems and cleanig carb every other month no fun, all pump gas not the same and I'm getting tired or taking carb off to blow things out. Found injection cleaner that worked good enough and would just put up with poping and skipping, didn't think much about it

One ride was difrrent, stopped to get gas and clutch hand was sore.

Out of the blue the clutch became real tight and I had to loosen and just did not feal quite right

let bike sit over night and had to tighten the clutch up, did not think about the day before and how it got tight

I screwed the adjustment in and moved the lever then adjusted but didn't feal quite right

Went to store 20 miles and had to adjust clutch again and adjustment about all the way out, 20 miles back to house and at mailbox I hear something grinding and bike has noticable heasitation

I hear a deep grinding and it sounds like transmission, I can tell by sound and the way it was held back when made noise something broke or came off

Next day I start taking things apart looking for anything cheap and or easy to fix, my gut telling me problem deep and more than I want to mess with and my gut was correct

Yamaha knew they had a problem and slipping clutch is the weakest point in the transmission for a reason, without the slipping clutch the transmission shaft clip on retainers is the weakest point and the case must be split to replace or fix problem

Perfect storm and all my doing

I made clutch stiffer and stopped the slipping and had no idea weakest point became shaft retainers

Put on a car tire and removed any free motion at all, nothing to give or slip I was playing with fire

The clutch became stiffer because the inner shaft holding the clutch basket had moved, it was at normal operating tempreture

The next day it was cool and way too loose, a 20 mile ride only made things move more. All movement inside transmission at shaft, I was lucky things did not lock up

Covers off and see bearings fall out of Barnett's clutch cover, shaft movement and no play plus added stress of car tire ate the bearing but this was not the deep noise

I will park the bike and upgrade to big bore kit and change all of the needed shafts at a later date


The transmission slips for a reason, it is the weakest point

You stiffen things up and the weakest point moves to the clip on retainers on the two shafts inside the transmission that hold things apart and in place

Add a car tire and just a matter of time, something must give and clip retainers are the weakest point


If the clutch slipps and OEM check friction disks and if good just replace the one piece metal spring looks like big bent washer, look at the edge and how sharp it has become

You may save money in the long run, will with out a doubt be safer with something able to give a little

Car tire in this bike with original clutch may work for a little wile longer but know that Barnett's upgrade and car tire may be deadly, transmission may lock up without warning, the transmission shaft retaining clips become the weakest link

If your running a car tire on this bike and clutch adjustment starts changing in an odd way suggest you get ready for something to lock up if you keep riding, stuff inside transmission is moving

[Lug Nut]

Clutch is not an intentional weak point on the bike. You really need to find out if your bike has had the recall or not for the transmission. What you're describing is a very unusual incident. Not at all common with these bikes. I like car tire as well and I like a strong clutch. I have done the barnet conversion with half heavy duty springs and half regular springs on a couple different bikes. I've also done double diaphragm spring on a couple bikes which is a very stiff clutch pull.

[Scott1111111111]

Clutch is not an intentional weak point on the bike. You really need to find out if your bike has had the recall or not for the transmission. What you're describing is a very unusual incident. Not at all common with these bikes. I like car tire as well and I like a strong clutch. I have done the barnet conversion with half heavy duty springs and half regular springs on a couple different bikes. I've also done double diaphragm spring on a couple bikes which is a very stiff clutch pull.

No recall done if going by mark that should be above vin#, will not know if recall parts in untill rebuild

Spring clutch like Barnett's around for decades

Slipping clutch under pressure in high gear only time noticed but clutch weakest point then retaining clips that hold stuff on transmission shafts

Recall changes washer thickness but can not make anything stronger

Jerky motion inside transmission = gear lock up

Gear to gear left side = NO play

Gear to drive chain to gear to belt pully known to strip = problem

Add car tire and slop becomes SLAP, something will give

Would hope front drive belt pully would strip 1st but not weakest point

Wrong transmission washer or not retaining clips weakest point in transmission

Car tire on 1600 Road Star may be very costly mistake recall or not, your rolling dice and may crap out.

[roadiemort]

The Records Stuck!

[MidnightRide]

You should be able to call-in your VIN and the dealership will let you know about the trans recall. Worked for me and several others.

[Scott1111111111]

2019 Yamaha purged system of information related to 1999 - 2003 XV1600

If you have a phone number to information please post the number

[Scott1111111111]

Called dealer and no recall work done

Called several dealers and will not get to working on anything this involved for 5 to 6 months
Information on this site about recall not accurate when in doubt call the dealership about any factory recall

Recall work should be at no coat but ask to remove any doubt

When dealer says will look and see what caused , , , turn and run

Dealer recall work = dealer knows what was wrong

Dealer looking to get paid on top of time involved in recall should not happen unless you REQUEST additional stuff

The 1999 to 2003 XV 1600 has transmission recall for a reason and suggest you call your local Yamaha dealer to see if required work has been done

Grinding noise and hesitation noise deep inside engine letting you know shaft is moving

Clutch not able to stay in adjustment

If upgraded to Barnett's clutch bearing comes apart because shaft in transmission is moving

put bike on stand and in first gear and grabbing and grinding rocks the bike, rear wheel wants to turn with clutch in

Still think car tire = too much for transmission can only hope recall work will be strong enough for hard miles

BAM! BAM!

Says

Goodbye

[roadiemort]

Let the door hit you on the way out! I don't think you will leave on your own accord, the air is too thin where you are, but you will leave if your childish rants continue for any length of time.

[Lug Nut]

Bam Bam and the mma dude with spray painted white bike should form a MC...

[Duke]

You have it wrong. If the transmission was part of your problem due to not being recalled, then it would LOCK UP and not be grinding. It's more than likely that your throw-out bearing has failed.

Remember, the Road Star is a heavy cruiser, and not made to do wheelies or burnouts. Get a Warrior, or a Raider if that's what you are wanting to do.