Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
290–25K
225–50K
050–75K
075–100K
0100–150K
0150K+
31 reports with mileage · 53 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
Power Train. Review the 70 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Engine And Engine Cooling. Review the 4 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Electrical System. Review the 2 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
0 crash reports1 fire reports0 injury reports
What owners actually said
84 reports
Mileage unknown · Mar 13, 2004
Power Train
SAFETY RECALL NOTICE FROM YAMAHA, ROAD STAR WARRIOR MOTORCYCLE. I SENT THE FOLLOWING EMAIL SEVERAL TIME REQUESTING ASSISTANCE IN GETTING THE PARTS TO MY DEALER FOR THE REPAIRS. TO DATE I HAVE NOT RECEIVED A RESPONSE NOR HAS MY DEALER RECEIVED THE REQUIRED PARTS. GENTLEMEN, PLEASE HELP A LOYAL YAMAHA CUSTOMER BY EXPEDITING T…
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SAFETY RECALL NOTICE FROM YAMAHA, ROAD STAR WARRIOR MOTORCYCLE. I SENT THE FOLLOWING EMAIL SEVERAL TIME REQUESTING ASSISTANCE IN GETTING THE PARTS TO MY DEALER FOR THE REPAIRS. TO DATE I HAVE NOT RECEIVED A RESPONSE NOR HAS MY DEALER RECEIVED THE REQUIRED PARTS. GENTLEMEN, PLEASE HELP A LOYAL YAMAHA CUSTOMER BY EXPEDITING THE DELIVERY OF PARTS NECESSARY TO SATISFY THE SAFETY RECALL ON MY 2002 YAMAHA ROAD STAR WARRIOR. MY DEALERS NAME AND ADDRESS IS AS FOLLOWS: SUSSEX MOTORSPORTS ADDRESS: 446 HIGHWAY 23 S, SUSSEX, NJ 07461 PHONE: (973) 875-3640 I AM WRITING YOU REGARDING THE RECALL OF ALL 2002 AND 2003 YAMAHA ROADSTAR WARRIOR MOTORCYCLES. I AM VERY UNHAPPY WITH THE WAY YOU ARE HANDLING THE RECALL OF MY 2002 WARRIOR. WHILE I UNDERSTAND THAT RECALLS ARE A SAFETY NECESSITY, AND THE WORK NEEDS TO BE DONE, YAMAHA SHOULD HAVE PLANNED AND ADDRESSED THIS SITUATION MUCH BETTER THAN THEY HAVE. I HAVE BEEN TOLD THAT THE PARTS NECESSARY FOR THE RECALL ARE NOT YET AVAILABLE, AND THAT I SHOULD NOT OPERATE MY VEHICLE UNTIL IT IS REPAIRED. YET, THE COST OF MY OWNERSHIP, E.G., DEPRECIATION, INSURANCE, LOAN PAYMENTS, ETC., CONTINUES ON. I WILL HAVE NO WARRANTY OR ASSURANCE THAT MY MOTORCYCLE WILL OPERATE THE SAME AS BEFORE THE REPAIR WORK. I WOULD FEEL MUCH BETTER ABOUT THE SITUATION YOU HAVE FORCED ME IN IF THE PARTS WERE AVAILABLE, AND THERE WERE SOME GUARANTEE WITH THE ENGINE AFTER IT HAS BEEN REBUILT. NO EXTENDED WARRANTY! HOW IS THAT GOOD BUSINESS? I SINCERELY HOPE YAMAHA RECONSIDERS THEIR POSITION ON THIS RECALL AND MAKE GOOD ON WHAT A COMMON PERSON WOULD CONSIDER GOOD BUSINESS PRACTICES. PLEASE FEEL FREE TO CONTACT ME FOR CLARIFICATION IF REQUIRED. I LOOK FORWARD TO YOUR RESPONSE. SINCERELY, [XXX] [XXX] [XXX] [XXX] [XXX] [XXX] *AK UPDATED 07/26/2012 *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #10062102
Mileage unknown · Mar 13, 2004
Power Train
I RECEIVED A RECALL NOTICE FROM YAMAHA REGARDING MY 2002 WARRIOR THE FIRST PART OF FEBRUARY. THE RECALL WAS BASED ON CERTAIN TRANSMISSION COMPONENTS. I PURCHASED MY MOTORCYCLE 10/31/03 AND BECAUSE OF WINTER RIDING CONDITIONS I WAS NOT ABLE TO RIDE AS MUCH AS I LIKE. HOWEVER, MY MOTORCYCLE HAS 350 MILES ON IT. I TOOK MY MOTOR…
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I RECEIVED A RECALL NOTICE FROM YAMAHA REGARDING MY 2002 WARRIOR THE FIRST PART OF FEBRUARY. THE RECALL WAS BASED ON CERTAIN TRANSMISSION COMPONENTS. I PURCHASED MY MOTORCYCLE 10/31/03 AND BECAUSE OF WINTER RIDING CONDITIONS I WAS NOT ABLE TO RIDE AS MUCH AS I LIKE. HOWEVER, MY MOTORCYCLE HAS 350 MILES ON IT. I TOOK MY MOTORCYCLE TO THE COMPANY I PURCHASED FROM, SAN LUIS MOTOR SPORTS, SAN LUIS OPISBO, CA. THIS OCCURED JANUARY 24 AS THE TRANSMISSION WAS MAKING AN ODD NOISE. I HAULED THE MOTORCYCLE IN THE BACK OF A TRUCK 150 MILES ONE WAY, LEFT THE MOTORCYLE AT THE DEALERSHIP. DROVE HOME FOR ANOTHER 150 MILES. DROVE BACK TO THE DEALERSHIP ON JANUARY 31 TO GET THE MOTORCYCLE AS THE DEALERSHIP COULD NOT FIND ANYTHING WRONG. AT THIS POINT I HAVE DRIVEN 300 MILES. ON FEBRUARY 7, 2004 I AGAING HAULED MY BIKE TO SAN LUIS MOTOR SPORTS. THE SERVICE DEPARTMENT DID NOT KNOW HOW LONG IT WOULD TAKE TO REPAIR MY MOTORCYCLE AS THEY DID NOT HAVE ANY PARTS TO REPLACE WITH. THEY TOLD ME THEY WOULD CALL ONCE A WEEK TO GIVE ME AN UPDATE. MEANWHILE, WHEN THE FIRST REPLACEMENT PART ARRIVED THE SERVICE DEPARTMENT PUT THAT PART ON A NEW FLOOR MODEL MOTORCYCLE. I HAVE CALLED THE SERVICE DEPARTMENT SEVERAL TIMES AND WAS TOLD SOMEONE WOULD GET BACK TO ME. I HAVE CALLED THE YAHAMA CORPORATION AND WAS TOLD MY MOTORCYCLE WOULD BE THE FIRST TO BE REPAIRED. IT IS NOW MARCH 14, 2004 I AM PAYING FOR "A DEAD HORSE" PAYING INSURANCE FOR SAID "DEAD HORSE" AND HAVE NOT RECEIVED ANY COMPENSATION FOR THE 600 MILES I HAVE DRIVEN TO GET MY MOTORCYCLE REPAIRED. HOW LONG MUST I WAIT BEFORE GETTING THE QUALITY RESULTS THAT I AM ENTITLED TO? I FEEL I SHOULD BE COMPENSATED FOR MY LACK OF MOTORCYCLE, PAYING FOR SOMETHING I DO NOT HAVE, AND A MOTORCYCLE THAT I TRADED IN. THANK YOU FOR YOUR HELP. WILLIAM WILDEMAN. *AK
NHTSA ODI #10062096
3,950 miles · Mar 12, 2004
Power Train
CONSUMER RECEIVED NHTSA RECALL 03V309000 ON FEB. 14 2003. 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. THE DEALERSHIP STILL DOES NOT HAVE THE PARTS AVAILABLE TO CONDUCT RECALL REPAIRS. *AK …
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CONSUMER RECEIVED NHTSA RECALL 03V309000 ON FEB. 14 2003. 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. THE DEALERSHIP STILL DOES NOT HAVE THE PARTS AVAILABLE TO CONDUCT RECALL REPAIRS. *AK
NHTSA ODI #10063098
Mileage unknown · Mar 10, 2004
Power Train
YAMAHA ANNOUNCED A RECALL ON MY 2002 ROADSTAR WARRIOR'S TRANSMISSION AND, IT SEEMS AS THOUGH THEY ARE MAKING LITTLE EFFORT TO DISTRIBUTE THE KITS TO FIX THEM. MY DEALER RECENTLY RECEIVED ONE KIT AND THAT'S IT. I ALSO FOUND OUT THAT THEY HAVE DISTRIBUTED NUMEROUS KITS TO CANADA WHERE PEOPLE CAN'T EVEN BEGIN RIDING FOR OVER ANOT…
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YAMAHA ANNOUNCED A RECALL ON MY 2002 ROADSTAR WARRIOR'S TRANSMISSION AND, IT SEEMS AS THOUGH THEY ARE MAKING LITTLE EFFORT TO DISTRIBUTE THE KITS TO FIX THEM. MY DEALER RECENTLY RECEIVED ONE KIT AND THAT'S IT. I ALSO FOUND OUT THAT THEY HAVE DISTRIBUTED NUMEROUS KITS TO CANADA WHERE PEOPLE CAN'T EVEN BEGIN RIDING FOR OVER ANOTHER MONTH! MY MOTORCYCLE IS MY PRIMARY VEHICLE AND, THE RECALL STATES I SHOULD NOT RIDE IT UNTIL THE RECALL IS DONE. SO, WHAT AM I SUPPOSED TO DO WHILE YAMAHA TAKES MONTHS TO GET THE KITS OUT???? THIS IS RIDICULOUS!!!*AK
NHTSA ODI #10061880
1,200 miles · Mar 10, 2004
Power Train
RECEIVED RECALL NOTIFICATION FROM YAMAHA, RECALL 03V-309, ON 2/12/04. YAMAHA UNABLE TO MAKE REPAIRS BEFORE 8/3/04. VEHICLE CAN NOT BE DRIVEN UNTIL REPAIRS ARE MADE.*AK
NHTSA ODI #10060907
16,000 miles · Mar 9, 2004
Power Train
CONSUMER WAS WAITING FOR PARTS FOR RECALL 03V309000. CONSUMER FELT YAMAHA WAS NOT BEING RESPONSIBLE. PARTS WERE NOT AVAILABLE SINCE JANUARY 12, 2004.*AK
NHTSA ODI #10061677
Mileage unknown · Mar 9, 2004
Power Train
YAMAHA RECALL NOTICE 990022
NHTSA ODI #10060871
1,100 miles · Mar 9, 2004
Power Train
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 …
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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. THEN I HAVE TO BREAK THE BIKE IN FOR 600 MILES AGAIN AND HAVE THE FIRST SERVICE DONE AGAIN AT MY COST (APPROX $300). I BOUGHT THIS BIKE LAST SUMMER AND ONLY HAVE 1100 MILES ON IT. NOW THE REMAINING PORTION OF MY WARRANTY IS RUNNING OUT WHILE MY BIKE SITS IN MY GARAGE BECAUSE IT IS UNSAFE TO DRIVE. SEEING HOW THEY ARE REBUILDING THE MOTOR I THINK THE NORMAL 1 YEAR WARRANTY SOULD BE GIVIN WITH THE REPAIR. ALSO I SHOULD NOT HAVE TO PAY FOR THE FIRST SERVICE AFTER THEY FIXED IT I PAID THAT ONCE ALREADY THEN LAST THE COMMUNICATION IS HORRIBLE IF DIDN'T HAVE FRIEND WITH THE SAME BIKE MY FAMILY MAY HAVE FOUND OUT ABOUT THE RECALL AFTER MY REAR TIRE LOCKED UP ON THE HIGHWAY DOING 75 MPH CAUSING ME TO LOSE CONTROL CROSS THE MEDIAN AND GET HIT MY A SEMI- TRUCK HEAD ON AND DIE!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
NHTSA ODI #10060780
Mileage unknown · Mar 5, 2004
Power Train
YAMAHA MOTOR CORP. HAS PERFORMED A RECALL ON ALL 02-04 ROADSTAR WARRIOR MOTORCYCLES. THEY HAVE ADVISED THEIR CUSTOMERS NOT TO RIDE THEM, AS THE TRANSMISSION COULD SEIZE, RESULTING IN POSSIBLE DEATH. HOWEVER, THEY ARE OFFERING ONLY A LIMITED 90 DAY WARRANTY ON PARTS AND SERVICE AND ARE MAKING ALL OF THEIR FAITHFUL CUSTOMERS WAI…
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YAMAHA MOTOR CORP. HAS PERFORMED A RECALL ON ALL 02-04 ROADSTAR WARRIOR MOTORCYCLES. THEY HAVE ADVISED THEIR CUSTOMERS NOT TO RIDE THEM, AS THE TRANSMISSION COULD SEIZE, RESULTING IN POSSIBLE DEATH. HOWEVER, THEY ARE OFFERING ONLY A LIMITED 90 DAY WARRANTY ON PARTS AND SERVICE AND ARE MAKING ALL OF THEIR FAITHFUL CUSTOMERS WAIT UPWARDS OF SIX MONTHS TO PERFORM THE RECALL. MEANWHILE, US CUSTOMERS ARE STILL MAKING OUR PAYMENTS, PAYING OUR INSURANCE, AND WILL ALSO HAVE TO HAVE ANOTHER INITIAL 600 MILE SERVICE PERFORMED AFTER THE RECALL WORK IS DONE ($250) AS THE RESULT IS, IN ESSENCE, A REBUILT TRANSMISSION. THIS IS HORRIBLY WRONG THE WAY THAT YAMAHA IS HANDLING THIS. WHAT CAN BE DONE ABOUT IT? *JB
NHTSA ODI #10060471
Mileage unknown · Mar 4, 2004
Power Train
YAMAHA MOTORS RECALLED MY 2002 ROAD STAR WARRIOR. THEY HAVE NOT ISSUED THE PART AND HAVE NO RELEASE DATE. ALL THEY ARE SAYING IS DO NOT RIDE. I DO NOT FEEL THEY HAVE HANDLED THIS RECALL IN A TIMELY MANNER. *AK
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
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
Additional source detail variants (2)
Power Train:manual Transmission
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
Power Train:manual Transmission
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