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2002 Yamaha Road Star Warrior

Owner reports · Recalls · Investigations

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There is not enough comparable history to draw a useful model-year comparison.

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How this year compares

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What owners reported most

All reported categories

Tap a category to read its complaints. One report may name several components.

When problems were reported

Mileage at the reported incident

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 · Feb 20, 2004
Power Train

I OWN A 2002 YAMAHA ROAD STAR WARRIOR THAT IS BEING RECALLED FOR TRANSMISSION PROBLEMS. YAMAHA HAS AGREED TO REPAIR THE BIKE BUT WILL ONLY OFFER A 90 DAY WARRANTY ON THE PARTS, NOTHING ON LABOR. THE REPAIRS ARE NOT AVAILABLE AND WILL NOT ACCORDING TO MY DEALER BE AVAILABLE UNTIL APRIL. MY BIKE WILL BE DOWN FOR AT LEAST 3 MONTHS.…

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I OWN A 2002 YAMAHA ROAD STAR WARRIOR THAT IS BEING RECALLED FOR TRANSMISSION PROBLEMS. YAMAHA HAS AGREED TO REPAIR THE BIKE BUT WILL ONLY OFFER A 90 DAY WARRANTY ON THE PARTS, NOTHING ON LABOR. THE REPAIRS ARE NOT AVAILABLE AND WILL NOT ACCORDING TO MY DEALER BE AVAILABLE UNTIL APRIL. MY BIKE WILL BE DOWN FOR AT LEAST 3 MONTHS. THE RECALL LETTER SAID THAT RIDING THE BIKE BEFORE THE REPAIRS ARE MADE COULD LEAD TO SERIOUS INJURY OR DEATH.*AK

NHTSA ODI #10058617

Mileage unknown · Feb 20, 2004
Power Train

RECALL ON THE YAMAHA ROAD STAR WARRIOR. YAMAHA HAS NOT RESPONDED TO THEIR OWN RECALL OF THE TRANSMISSION ON MY MOTORCYCLE. THE RECALL WAS ISSUED IN AUGUST 2003 AND PARTS ARE STILL NOT AVAILABLE. 6 MONTHS. I HAVE BEEN NOTIFIED BY YAMAHA OF THE RECALL AND HAVE BEEN TOLD NOT TO OPERATE THE MOTORCYCLE. 6 MONTHS. THIS IS UNACCE…

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RECALL ON THE YAMAHA ROAD STAR WARRIOR. YAMAHA HAS NOT RESPONDED TO THEIR OWN RECALL OF THE TRANSMISSION ON MY MOTORCYCLE. THE RECALL WAS ISSUED IN AUGUST 2003 AND PARTS ARE STILL NOT AVAILABLE. 6 MONTHS. I HAVE BEEN NOTIFIED BY YAMAHA OF THE RECALL AND HAVE BEEN TOLD NOT TO OPERATE THE MOTORCYCLE. 6 MONTHS. THIS IS UNACCEPTABLE. I REALIZE THE VEHICLE IS FOR PLEASURE AND IS NOT MY PRIMARY TRANSPORTATION. 6 MONTHS. THE RECALL LETTER WAS DATED JANUARY 9, 2004. THE RECALL WAS ISSUED AUGUST 2003. WHY DID YAMAHA WAIT 5 MONTHS TO SEND A LETTER. IT'S BEEN 6 MONTHS AND THEY STILL DON'T HAVE THE REPLACEMENT PARTS TO THE DEALERS FOR THE REPAIR WORK. *AK

NHTSA ODI #10058609

Mileage unknown · Feb 20, 2004
Power Train

THE MANOR IN WHICH YAMAHA IS ADDRESSING THE ROADSTAR WARRIOR RECALL IS UNFAIR TO THE CUSTOMER. YAMAHA MOTORS IS NOT PROVIDING THE REPAIR IN A TIMELY MANOR, NOR WILL THEY WARRANTY THE LABOR FOR THE REPAIR. THIS LABOR IS NOT ELECTIVE, THE TECHNICIANS THAT YOU ARE PROVIDING ARE NOT QUALIFIED TO PERFORM THE REPAIR. THE REQUEST FROM …

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THE MANOR IN WHICH YAMAHA IS ADDRESSING THE ROADSTAR WARRIOR RECALL IS UNFAIR TO THE CUSTOMER. YAMAHA MOTORS IS NOT PROVIDING THE REPAIR IN A TIMELY MANOR, NOR WILL THEY WARRANTY THE LABOR FOR THE REPAIR. THIS LABOR IS NOT ELECTIVE, THE TECHNICIANS THAT YOU ARE PROVIDING ARE NOT QUALIFIED TO PERFORM THE REPAIR. THE REQUEST FROM YAMAHA THAT THE VEHICLE IS TO BE TAKEN OUT OF SERVICE UNTIL THE REPAIR IS MADE IS NOT REASONABLE WHEN THEY ARE NOT YET PROVIDING THE REPAIR PARTS. MY PURCHASE WAS MADE IN GOOD FAITH WITH A COMPANY THAT I HAD PREVIOUSLY RESPECTED. THIS RESPECT HAS BEEN SADLY FORGONE WITH THIS ISSUE. I AM, I MUST SAY SORRY THAT I HAVE ELECTED TO PURCHASE THIS PRODUCT FROM YOUR COMPANY AND WILL NOT MAKE THE SAME MISTAKE TWICE.*AK

NHTSA ODI #10058560

6,000 miles · Feb 20, 2004
Power Train

YAMAHA ROADSTAR WARRIOR TRANSMISSION FAILURE OF YAMAHA TO PROVIDE TIMELY REPAIRS TO A NOW UNUSABLE VEHICLE. FAILURE OF YAMAHA TO PROVIDE SUFICCIENT WARRANTY FOR SUCH AN INVASIVE REPAIR.*AK

NHTSA ODI #10058554

1,100 miles · Feb 19, 2004
Power Train

THE OWNER RECEIVED A RECALL NOTICE (NHTSA RECALL# 03V 309 000/REAR WHEEL LOCKUP ) FROM THE MANUFACTURER ON FEBRUARY 17, 2004. HE LATER CONTACTED THE DEALER AND MADE NUMEROUS CALLS TO YAMAHA MFR. BUT COULD NOT GET ANY STRAIGHT ANSWERS AS TO WHEN THE PARTS WOULD BE AVAILABLE FOR REPAIR. *NM

NHTSA ODI #10059375

Mileage unknown · Feb 19, 2004
Power Train

I HAVE A 2002 YAMAHA ROAS STAR WARRIOR THAT HAS BEEN WAITING ON THE TRANSMISSION RECALL PARTS. THE DEALER HAS BEEN GIVEN NO DATE TO GET THE PARTS. YAMAHA CUSTOMER RELATIONS SAYS THE THE PARTS MY BE IN THE US THIS MONTH AND TO THE DEALER MID TO LATE MARCH. MY DEALER HAS 30+ BIKES TO DO AND EACH TAKE A DAY OR MORE. YAMAHA HAS SENT…

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I HAVE A 2002 YAMAHA ROAS STAR WARRIOR THAT HAS BEEN WAITING ON THE TRANSMISSION RECALL PARTS. THE DEALER HAS BEEN GIVEN NO DATE TO GET THE PARTS. YAMAHA CUSTOMER RELATIONS SAYS THE THE PARTS MY BE IN THE US THIS MONTH AND TO THE DEALER MID TO LATE MARCH. MY DEALER HAS 30+ BIKES TO DO AND EACH TAKE A DAY OR MORE. YAMAHA HAS SENT A RECALL SAYING NOT TO RIDE THE BIKE AND WHEN I ASK CUSTOMER RELATIONS THAY SAY PARK IT FOR A FEW MONTHS. YAMAHA IS GIVING A 90 DAY WARRANTY FOR PARTS ONLY. YAMAHA DOES NOT WANT ME TO RIDE BUT THEY ARE IN NO HURRY TO FIX THE PROBLEM. I HAVE BEEN ON THE WAITING LIST FOR OVER A MONTH NOW.

NHTSA ODI #10058530

11,919 miles · Feb 19, 2004
Power Train

YAMAHA HAS NOT NOTIFIED ME ABOUT A DANGEROUS TRANSMISSION PROBLEM. I HAVE BEEN TO MY DEALER 4 TIMES IN LAST MONTH FOR PARTS, AND THEY ALSO MADE NO MENTION OF IT. I WOULD NOT KNOW ABOUT THE TRANSMISSION IF NOT FOR A FRIEND AT BIKE NIGHT. I SINCE HAVE PARKED THE BIKE, BUT YAMAHA HAS NO IDEA WHEN THE PARTS ARE COMING, AND WILLL …

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YAMAHA HAS NOT NOTIFIED ME ABOUT A DANGEROUS TRANSMISSION PROBLEM. I HAVE BEEN TO MY DEALER 4 TIMES IN LAST MONTH FOR PARTS, AND THEY ALSO MADE NO MENTION OF IT. I WOULD NOT KNOW ABOUT THE TRANSMISSION IF NOT FOR A FRIEND AT BIKE NIGHT. I SINCE HAVE PARKED THE BIKE, BUT YAMAHA HAS NO IDEA WHEN THE PARTS ARE COMING, AND WILLL ONLY PROVIDE A 90 DAY WARRANTY ON THE ONE PART THEY ARE REPLACING, BUT NOT THE ENTIRE ENGINE AND TRANSMISSION WHICH WILL BE TAKEN COMPLETLY APART TO FIX THE TRANSMISSION.

NHTSA ODI #10058516

Mileage unknown · Feb 19, 2004
Power Train

NHTSA CAMPAIGN ID#:03V309000, CONTACTED YAMAHA AND THEY ARE NOT GIVING ANY INFORMATION ON WHEN PARTS WILL BE AVAILABLE. MEANWHILE THEY HAVE INSTRUCTED ME NOT TO OPERATE THE VEHICLE IN QUESTION. THIS IS NOT ACCEPTABLE FOR THEM TO DOWN MY VEHICLE WITH NOT INFORMATION ON WHEN REPAIRABLE PARTS WILL BE AVAILABLE. LASTLY YAMAHA W…

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NHTSA CAMPAIGN ID#:03V309000, CONTACTED YAMAHA AND THEY ARE NOT GIVING ANY INFORMATION ON WHEN PARTS WILL BE AVAILABLE. MEANWHILE THEY HAVE INSTRUCTED ME NOT TO OPERATE THE VEHICLE IN QUESTION. THIS IS NOT ACCEPTABLE FOR THEM TO DOWN MY VEHICLE WITH NOT INFORMATION ON WHEN REPAIRABLE PARTS WILL BE AVAILABLE. LASTLY YAMAHA WILL NOT WARRANTY THE WORK PERFORMED BY THEIR SERVICE CENTERS. THEREFORE WE HAVE NO RECOURSE IF THE SERVICE CENTER PERFORMS SUB STANDARD WORK AND THE VEHICLE FAILS SHORTLY AFTER THE REPAIR. IN THE MEANTIME I HAVE TO CANCEL ALL PRE-ARRANGED PLANS THAT INCLUDED USE OF MY VEHICLE AT MY OWN COST. ALSO THE COST OF OWNERSHIP OF SAID VEHICLE CONTINUES WHILE IT IS NOT OPERABLE AGAIN WITHOUT ANY DATE AS TO WHEN IT WILL BE OPERABLE AGAIN.

NHTSA ODI #10058498

1 miles · Feb 19, 2004
Engine And Engine Cooling

2002 YAMAHA ROADSTAR WARRIOR TRANSMISSION RECALL (2,995 MI.). MY COMPLAINTS: COMPLAINT 1: THE PARTS TO AFFECT THE REPAIRS ARE NOT AVAILABLE TO THE DEALERS. NO FIRM TIMEFRAME HAS BEEN GIVEN TO THE DEALERS, BUT EXPECTATIONS ARE THAT PARTS WILL BEGIN TO ARRIVE BY MARCH, 2004. DEALERS EXPECT FROM 1 TO 3 DAYS OF WORK FOR EAC…

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2002 YAMAHA ROADSTAR WARRIOR TRANSMISSION RECALL (2,995 MI.). MY COMPLAINTS: COMPLAINT 1: THE PARTS TO AFFECT THE REPAIRS ARE NOT AVAILABLE TO THE DEALERS. NO FIRM TIMEFRAME HAS BEEN GIVEN TO THE DEALERS, BUT EXPECTATIONS ARE THAT PARTS WILL BEGIN TO ARRIVE BY MARCH, 2004. DEALERS EXPECT FROM 1 TO 3 DAYS OF WORK FOR EACH MOTORCYCLE TO BE REPAIRED. THE WAITING LIST IS GOING TO BE LARGE AND THE WAIT FOR REPAIRS CONSIDERABLE. I CANNOT USE MY MOTORCYCLE UNTIL THE REPAIR IS MADE. I HAVE LOST THE ENJOYMENT OF THIS PRODUCT, I AM PAYING FOR A PRODUCT THAT I CANNOT USE, AND I AM FORCED TO INSURE A PRODUCT THAT I CANNOT USE. COMPLAINT 2: THE REPAIRS ARE BEING DONE BY MECHANICS OF VARYING DEGREES OF SKILL AND EXPERIENCE AT LOCAL DEALERSHIPS, HENCE -THERE IS NO GUARANTEE OF A QUALITY JOB (NO QUALITY ASSURANCE CHECK), -THERE IS NO WARRANTY ON LABOR, -THE ENGINE IS "REBUILT" VERSUS "FACTORY BUILT." THUS, IF MY MOTORCYCLE IS RETURNED TO ME AFTER THE REPAIR AND THE ENGINE MALFUNCTIONS, I WILL BE FORCED TO PAY FOR ALL THE REPAIRS. 3. MY MOTORCYCLE HAS ALREADY SUFFERED LOSS IN VALUE AS A RESULT OF THIS RECALL. I UNDERSTAND I CANNOT SELL THIS MOTORCYCLE UNTIL THE REPAIRS ARE MADE. MY MOTORCYCLE WILL, IN ALL LIKELIHOOD, SUFFER FURTHER DEVALUE AND DEPRECIATION FAR GREATER THAN ITS USE AND AGE WOULD OTHERWISE DICTATE, SIMPLY BECAUSE IT WILL HAVE A REBUILT MOTOR. YAMAHA HAS NOT OFFERED ANY OFFSETTING COMPENSATIONS FOR MY LOSS OF USE, FOR THE POTENTIAL FOR SUFFERING WITH AN INFERIOR ENGINE (AFTER REBUILD), FOR THE DEVALUATION OF MY MOTORCYCLE, OR FOR THE PURE AGGRAVATION ASSOCIATED WITH THIS RECALL. 1. I WANT YAMAHA TO OFFER A SIGNIFICANT MILEAGE WARRANTY, NOT TIED TO A DATE, ON THIS MOTORCYCLE AFTER THE REPAIR. 2. I WANT TO RECEIVE COMPENSATION FROM YAMAHA COMMENSURATE WITH MY LOSS OF USE, MY MOTORCYCLE'S DEVALUATION, AND THE INCONVENIENCE OF HAVING THE REPAIRS DONE IN THE MANNER AND TIMEFRAME THEY HAVE PRESCRIBED.

NHTSA ODI #10058473

4,000 miles · Feb 18, 2004
Power Train

CONSUMER RECEIVED NHTSA RECALL LETTER 03V309000 ON DECEMBER 2003 REGARDING TRANSMISSION FAILURE. DEALERSHIP DID NOT HAVE THE PARTS AVAILABLE TO CONDUCT RECALL REPAIRS. DEALER WAS CONTACTED, AND INDICATED THAT CONSUMER SHOULD WAIT AN ADDITIONAL TWO MONTHS. ALSO, CONSUMER SHOULD NOT TO USE THE MOTORCYCLE. *AK

NHTSA ODI #10059233

Official recalls

2

03V309000 · Power Train:manual Transmission

Aug 26, 2003

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.

02V181000 · Fuel System, Gasoline:storage:tank Assembly:mounting

Jul 23, 2002

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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