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…
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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. YOUR HELP RESOLVING THIS WOULD BE GREATLY APPRECIATED. *TR
NHTSA ODI #10255342
507 miles · Jul 17, 2003
Fuel System, Gasoline
I OWN A 2002 YAMAHA ROAD STAR WARRIOR. THE FUEL "QUICK DISCONNECTS" ARE IN MY OPINION, DESIGNED & ENGINEERED VERY POORLY. THEY VIBRATE OFF THE SEAT. THEY HAVE NEVER LEAKED FUEL, THE LOCKING TAB MAKES IT STAY LOCKED SO IT WON'T LEAK. HOWEVER, WHEN IT IS AGAINST THE LOCKING TAB, IT MOVES OFF ITS SEAT ABOUT 3/16" AND RESULTS IN NO …
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I OWN A 2002 YAMAHA ROAD STAR WARRIOR. THE FUEL "QUICK DISCONNECTS" ARE IN MY OPINION, DESIGNED & ENGINEERED VERY POORLY. THEY VIBRATE OFF THE SEAT. THEY HAVE NEVER LEAKED FUEL, THE LOCKING TAB MAKES IT STAY LOCKED SO IT WON'T LEAK. HOWEVER, WHEN IT IS AGAINST THE LOCKING TAB, IT MOVES OFF ITS SEAT ABOUT 3/16" AND RESULTS IN NO FUEL FLOW FROM THE UPPER TANK TO THE LOWER TANK WHERE THE ELECTRIC FUEL PUMP IS. THAT RESULTS IN A "STALL" SITUATION. I WAS SITTING AT A RED LIGHT WAITING FOR IT TO TURN GREEN, I STARTED OUT AS I ALWAYS DO. I WAS AT 8 MPH & THE BIKE STALLED OUT. THE LADY BEHIND CAME WITHIN INCHES OF REARENDING ME, NO EXAGGERATION. I WAS SCARED, MY HEART WAS RACING. IT WOULD NOT HAVE BEEN HER FAULT, SHE SAW NO BRAKE LIGHT AS I WAS NOT APPLYING THE BRAKES. NO, I WASN'T HURT THIS TIME. BUT IF IT WOULD HAVE HAPPENED, I WONDER IF YAMAHA MOTOR CORP. WOULD HAVE TOLD MY WIFE & DAUGHTER, "SORRY WE DESIGNED A PISSPOOR FUEL CONNECTOR THAT GOT YOUR HUSBAND & FATHER KILLED". THIS ALSO RESULTS IN A LOW FUEL LIGHT SOMETIMES EVEN WHEN THE TANK HAS PLENTY OF FUEL. THIS CONNECTOR NEEDS TO BE REDESIGNED SO AS NOT TO BACK OFF WHEN THE CONNECTOR IS FULLY SEATED. BUT IT WILL VIBRATE ENOUGH TO COME OFF ITS SEAT JUST ENOUGH TO POSSIBLY KILL SOMEONE ALL BECAUSE OF DECREASED FUEL FLOW. PLEASE SHOW THIS TO YAMAHA. I KNOW ONE PERSON WITH A COMPLAINT LIKE THIS WON'T MEAN "CRAP" TO THEM BUT I FEEL IT NEEDS TO BE ADDRESSED. NOT LOOKED INTO BUT REMEDIED. I'VE WORKED ON GENERAL MOTORS VEHICLES FOR 14 YEARS, I'M AN ASE CERTIFIED MASTER TECH SO I'M NOT TALKING OUT OF MY [XXX]. I KNOW A THING OR TWO ABOUT MOTORIZED VEHICLES. I'M NOT GOING OFF OF SOMETHING SOMEONE ELSE HAS SAID. A LOT OF WARRIOR OWNERS HAVE EXPERIENCED THIS FAILURE. TRY RSWARRIOR.COM FORUM & SEE FOR YOURSELF. MY VIN # IS [XXX]. I KNOW YAMAHA DOESN'TCARE! [XXX]. *AK INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
IN THE TRANSMISSION ON CERTAIN MOTORCYCLES, THE SECOND/THIRD PINION GEAR MAY BE INCORRECTLY MACHINED WHICH COULD CAUSE ABNORMAL WEAR THAT EVENTUALLY RESULTS IN A BROKEN RETAINER CIRCLIP.
Consequence & remedy
Consequence: IF THE CIRCLIP BREAKS, THE TRANSMISSION COULD LOCK UP, WHICH WOULD ALSO CAUSE THE REAR WHEEL TO LOCK UP. THIS COULD RESULT IN LOSS OF CONTROL AND A CRASH, POSSIBLY RESULTING IN SERIOUS INJURY OR DEATH.
Remedy: YAMAHA WILL REPLACE THE TRANSMISSION GEARS AND SHAFTS WITH NEW ONES. OWNER NOTIFICATION BEGAN ON SEPTEMBER 9, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT YAMAHA AT 1-800-88-YAMAHA OR VISIT THEIR WEBSITE AT WWW.YAMAHA-MOTOR.COM.
ON CERTAIN MOTORCYCLES, THE FUEL TANK BRACKET WASHER AND DAMPER DO NOT ADEQUATELY PROTECT THE TANK FROM ENGINE VIBRATION.
Consequence & remedy
Consequence: OVER A PERIOD OF TIME, VIBRATION MIGHT DAMAGE THE TANK WHICH COULD RESULT IN A FUEL LEAK WITH THE POSSIBILITY OF FIRE.
Remedy: DEALERS WILL REPLACE THE FUEL TANK BRACKET WASHER AND DAMPER WITH ONES OF A NEW TYPE. OWNER NOTIFICATION BEGAN JULY 10,2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT YAMAHA AT 1-800-88-YAMAHA (1-800-889-2624).
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1
PE03038 · Unintended Rear Wheel Lockup
Opened Aug 11, 2003 · Closed Nov 6, 2003
Status: closed (inferred from source dates) · Power Train:manual Transmission
SUMMARY: ON AUGUST 22, 2003 YAMAHA NOTIFIED THE AGENCY THAT IT WAS RECALLING CERTAIN MODEL YEAR2001 XV1600 ?ROAD STAR? MODEL MOTORCYCLES TO ADDRESS TRANSMISSION FAILURE IN THOSE VEHICLES.ACCORDING TO THE COMPANY, THE TRANSMISSION WOULD FAIL DUE TO EXCESSIVE BUSHING WEAR ON THE 4TH PINION GEAR.BASED ON ITS ANALYSIS OF FAILED TRANSMISSIONS FROM THE FIELD, THE COMPANY FOUND ?UNEVEN CONTACT BETWEEN THE ENGAGEMENT DOGS ON THE 2ND/3RD PINION GEAR.WHEN IN 4TH GEAR, THESE UNEVEN SURFACES CAUSED UNEVEN BUSHING WEAR IN THE 4TH GEAR BUSHING.THIS WEAR WOULD EVENTUALLY CAUSE THE 4TH GEAR RETAINING CIRCLIP TO FAIL, LEADING TO TRANSMISSION FAILURE.?THIS COULD RESULT IN BOTH TRANSMISSION AND REAR WHEEL LOCKUP AND YAMAHA CONCLUDED A SAFETY RECALL SHOULD BE CONDUCTED TO ADDRESS THE PROBLEM.YAMAHA IS LIMITING THE RECALL?S SCOPE TO THOSE MOTORCYCLES BUILT BETWEEN NOVEMBER 30, 2000 AND JANUARY 24, 2001 BASED UPON THE FOLLOWING:1. YAMAHA U.S. REPORTED FIELD FAILURES (INVOLVING BIKES BUILT IN DECEMBER, 2000) TO YAMAHA JAPAN.2.YAMAHA JAPAN INVESTIGATED AND VALIDATED THE CAUSE DESCRIBED ABOVE.3.YAMAHA JAPAN IDENTIFIED THE PROBLEM WAS RELATED TO THE ENGAGEMENT DOG ON THE 2ND/3RD PINION GEAR.4. YAMAHA JAPAN RECORDS INDICATED THAT THE JIG USED TO PRODUCE THE 2ND/3RD PINION GEAR WAS RE-CALIBRATED ON JANUARY 13, 2001.5.PARTS PRODUCED BEFORE NOVEMBER 30,2000 AND AFTER JANUARY 13, 2001 WERE SAMPLED AND FOUND TO BE WITHIN SPECIFICATION (THE RECALL WAS EXTENDED BEYOND JANUARY 13 BUILD AS A PRECAUTION).WITH YAMAHA?S RECALL, WE ARE CLOSING THIS INVESTIGATION BUT WILL CONTINUE TO MONITOR THE FIELD PERFORMANCE OF ALL ROAD STAR MODEL MOTORCYCLES TO ASSESS THE PERFORMANCE OF THOSE BIKES NOT COVERED BY THE RECALL.SHOULD THE FACTS WARRANT ADDITIONAL INVESTIGATION, WE WILL PROCEED ACCORDINGLY.
Additional source detail variants (2)
Power Train:manual Transmission
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
Power Train:manual Transmission
SUMMARY: ON AUGUST 22, 2003 YAMAHA NOTIFIED THE AGENCY THAT IT WAS RECALLING CERTAIN MODEL YEAR2001 XV1600 ?ROAD STAR? MODEL MOTORCYCLES TO ADDRESS TRANSMISSION FAILURE IN THOSE VEHICLES.ACCORDING TO THE COMPANY, THE TRANSMISSION WOULD FAIL DUE TO EXCESSIVE BUSHING WEAR ON THE 4TH PINION GEAR.BASED ON ITS ANALYSIS OF FAILED TRANSMISSIONS FROM THE FIELD, THE COMPANY FOUND ?UNEVEN CONTACT BETWEEN THE ENGAGEMENT DOGS ON THE 2ND/3RD PINION GEAR.WHEN IN 4TH GEAR, THESE UNEVEN SURFACES CAUSED UNEVEN BUSHING WEAR IN THE 4TH GEAR BUSHING.THIS WEAR WOULD EVENTUALLY CAUSE THE 4TH GEAR RETAINING CIRCLIP TO FAIL, LEADING TO TRANSMISSION FAILURE.?THIS COULD RESULT IN BOTH TRANSMISSION AND REAR WHEEL LOCKUP AND YAMAHA CONCLUDED A SAFETY RECALL SHOULD BE CONDUCTED TO ADDRESS THE PROBLEM.YAMAHA IS LIMITING THE RECALL?S SCOPE TO THOSE MOTORCYCLES BUILT BETWEEN NOVEMBER 30, 2000 AND JANUARY 24, 2001 BASED UPON THE FOLLOWING:1. YAMAHA U.S. REPORTED FIELD FAILURES (INVOLVING BIKES BUILT IN DECEMBER, 2000) TO YAMAHA JAPAN.2.YAMAHA JAPAN INVESTIGATED AND VALIDATED THE CAUSE DESCRIBED ABOVE.3.YAMAHA JAPAN IDENTIFIED THE PROBLEM WAS RELATED TO THE ENGAGEMENT DOG ON THE 2ND/3RD PINION GEAR.4. YAMAHA JAPAN RECORDS INDICATED THAT THE JIG USED TO PRODUCE THE 2ND/3RD PINION GEAR WAS RE-CALIBRATED ON JANUARY 13, 2001.5.PARTS PRODUCED BEFORE NOVEMBER 30,2000 AND AFTER JANUARY 13, 2001 WERE SAMPLED AND FOUND TO BE WITHIN SPECIFICATION (THE RECALL WAS EXTENDED BEYOND JANUARY 13 BUILD AS A PRECAUTION).WITH YAMAHA?S RECALL, WE ARE CLOSING THIS INVESTIGATION BUT WILL CONTINUE TO MONITOR THE FIELD PERFORMANCE OF ALL ROAD STAR MODEL MOTORCYCLES TO ASSESS THE PERFORMANCE OF THOSE BIKES NOT COVERED BY THE RECALL.SHOULD THE FACTS WARRANT ADDITIONAL INVESTIGATION, WE WILL PROCEED ACCORDINGLY.
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