2002 Yamaha Road Star Warrior Problems

What owners report

Owner complaints for this model year center almost entirely on the transmission recall that was announced in late 2003: many riders describe waiting months for repair parts with the bike parked. A smaller set of complaints covers stalling or sudden engine shutdown traced to sensors and fuel plumbing, plus a handful of individual brake, speedometer and fuel tank items.

1. 1
   Transmission and drivetrain

   Transmission recall parts unavailable for months

   • 60 complaints (71%)
   • median 3,975 mi at 2.4 yrs old (18 state mileage)
   • filed 2004

   Owners describe receiving a recall letter covering a transmission circlip or pinion gear concern and being told not to ride the motorcycle until the work was done. According to the complaints, dealers repeatedly said the repair kits had not been shipped and could not say when they would arrive, placing owners on waiting lists. Some also report that only the part carried a limited warranty and that labor was not covered, and that recall notices arrived months after the campaign was announced. Mostly reported in late 2003 and the first half of 2004, often on motorcycles with only a few thousand miles.

   Recall 03V309000

   What to check: Ask whether the transmission recall work was completed and obtain the repair paperwork; confirm the parts were replaced rather than just inspected.

   2 excerpts from owner complaints in NHTSA records

   “Recall of 2002 Yamaha roadstar warrior. Just learned Yamaha was notified of need to recall in august of 2003...however I only recently received a notice and have been informed by my local Yamaha dealer that Yamaha does not have parts for the fix and doesn't know when they will be made available. Yet Yamaha continues to manufacture new models of my motorcycle. In my opinion, this is wrong.”

   NHTSA complaint #10060295, filed 2004-03, 5,500 miles

   “I own a 2002 Yamaha roadstar warrior which is involved in a recall which I have not recieved a letteror phone call from Yamaha or my local dealer I only found out after I called. The they told me they had no idea when Yamaha was sending the parts so they put me on a waiting list. The lack of comunication is unacceptable when my safty is involved. Now they say when they fix the bike the labor is not covered under the warranty and the parts are for90 days. …”

   NHTSA complaint #10060780, filed 2004-03, 1,100 miles
2. 2
   Transmission and drivetrain

   Transmission locking up and rear wheel locking

   • 6 complaints (7%)
   • median 23,634 mi at 1.7 yrs old (1 states mileage, few)
   • filed 2003–2004

   Some owners describe the transmission locking while riding, with the rear wheel also stopping and little or no warning, at speeds from around 45 mph upward. Others describe hearing about lock-ups through owner groups and treating the recall as a reason to stop riding until repaired. Complaints refer to abnormal wear of internal transmission parts and a retaining circlip that can break. Reports span low-mileage bikes up to roughly 24,000 miles, with at least one lock-up described between 45 and 50 mph.

   Recall 03V309000

   What to check: Ask about any prior transmission noise, jumping out of gear or rear-wheel lock-up, and whether the recall repair has been documented.

   2 excerpts from owner complaints in NHTSA records

   “The parts to fix the recall were not supplied to the mechanic so I have not had the use of my motorcycle for 28+ days. Yamaha motor corporation, u.s.a., has determined that a defect which relates to motor vehicle safety exists in 2002 and 2003 xv17pcp, pcpc, pcr, and pcrc ( Road Star Warrior ) motorcycles. In affected motorcycles, certain transmission components may not meet Yamaha quality-control standards, which could allow abnormal wear that eventually results in a broken retaining circlip. …”

   NHTSA complaint #10064096, filed 2004-03

   “It is with the utmost concern that I, as an owner of a 2002 Yamaha road star, provide this communication to you and the Yamaha motor corporation, USA. It has been known that a problem exists with the transmission, whereby at unexpected times the transmission locks, which can and has caused loss of control by the rider, thereby endangering the safety and life of the rider, passenger, and other vehicles, passengers, and pedestrians in the area. …”

   NHTSA complaint #10025860, filed 2003-07
3. 3
   Fuel system

   Stalling from fuel quick-disconnect and tank plumbing

   Mentioned in 4 of 60 sampled complaints

   Owners describe stalling when pulling away or at low speed after the fuel line quick-disconnect moved off its seat, cutting flow from the upper tank to the pump. Another complaint describes a fuel filter elbow sleeve separating and releasing fuel near a hot engine. A further report describes fuel leaking at the tank mounting bracket after the tank-mount recall work had been done. Reported from a few hundred miles up to roughly 28,000 miles, with the quick-disconnect stall noted during stop-and-go riding.

   Recall 02V181000

   What to check: Inspect the fuel tank bracket area and the quick-disconnect fittings for cracking, looseness or fuel smell, and ask whether the tank-mount recall was performed.

   2 excerpts from owner complaints in NHTSA records

   “The fuel filter assembly to the front of the tank will release the inner sleeve at the elbow spilling fuel all over motor. If motor is hot, can result in fire and has happened in the past. I was fortunate to have just started riding when it happened to me.”

   NHTSA complaint #11219092, filed 2019-06, 28,000 miles

   “I have a Yamaha roadstar warrior motorcycle and the recall (id# 45939 - fuel system, gasoline:storage:tank assembly:mounting) was performed. This was to prevent the tank from cracking at the mounting bracket. My tank is now leaking gas from that mounting bracket. I took it to the dealer, they called Yamaha USA and they said they would not fix the problem. It is obvious that either the recall did not work or that the tank started to crack before the recall was performed and finally grew big enough to start leaking gas. …”

   NHTSA complaint #10255342, filed 2009-01, 27,450 miles

Buying note. Check the recall history carefully, since the transmission campaign dominates the record for this model year, and confirm the repair was completed with documentation. A pre-purchase inspection covering the fuel fittings, rear brake drag and sensor-related stalling is worth the cost on a used example.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.