I purchased my 2003 Roadstar in late 2002. The transmission recall was performed.in fact, my dealer was unaware of it - I actually had to bring a copy of the recall in for them. I received information from the Internet via third parties, and was never notified of the recall by Yamaha.
While leading a group of motorcycles at a steady speed (70 mph) on a local interstate in 5th gear, I heard a metallic "click" and fifth started acting like neutral. I was able to shift to 4th, which operated normally, but shifting back to 5th was like shifting back into neutral again.
After taking the most direct route possible home, I contacted Yamaha and was advised that "A motorcycle with 30,000 miles is like a car with 100,000 miles - you have to expect things to start breaking." I also filed a report with the NHTSA.
I split the crankcase last weekend and found that the dogs on the 2nd/3rd pinion gear had separated from the gear, thus preventing the motorcycle from engaging fifth gear.
After ordering approximately $500 in parts, I rolled the crankshaft and found damage to the crankshaft and generator shaft gears, proof that one of the dogs had made its way between those gears. After pulling the crankshaft, I found the remaining gear in the crankcase (it had been behind the crankshaft and was hidden from view).
This failure could have easily caused a transmission and engine lock-up at cruising speed, with potentially disastrous consequences for my wife and I, and for the bikes that I was leading.
I estimate that the parts cost will exceed $1,000 for this repair, and if the work were being performed at a dealership, the labor would likely run another $1,000.
I am loathe to trust the local Yamaha dealerships because the closest neglected to tighten my rear axle nut after changing my rear tube on one occasion, and I have noted that after performing the transmission recall, one original gasket was not removed (I'm surprised I didn't develop an oil leak), one bolt in the front head was lose, and the wrong bolt (too long) in the generator shaft cover was installed, thereby preventing the cover from being tightened and resulting in the risk of contamination of the generator shaft bearing. Another local dealer was unable to troubleshoot a vacuum leak after spending an hour with the bike. I suppose the fact that the butterflies on the hypercharger weren't moving was not a very good clue.
I'm a competent motorcyclist with over 25 years of riding experience, and am an MSF-certified RiderCoach. Further, I have over 15 years of aircraft maintenance experience, and have 17 years of quality assurance experience, and performed safety-of-flight inspections on aircraft.
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