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2003 Yamaha Road Star Warrior

Owner reports · Recalls · Investigations

Limited comparison data

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

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Owner complaints by model year

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Counts vary with age, sales and reporting. They are not failure rates.

What owners reported most

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

When problems were reported

Mileage at the reported incident

Limited mileage data: 14 of 26 reports include usable mileage. There isn’t enough coverage to show a useful chart.

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 22 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 3 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 1 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

1 crash reports0 fire reports0 injury reports

Power Train complaints

22 reports
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Mileage unknown · Mar 2, 2004
Power Train

RECEIVED A SAFETY RECALL ON TRANSMISSION OF MY 2003 WARRIOR DATED JANUARY 9, 2004. THE LOCAL DEALERSHIP I BOUGHT MY BIKE FROM, SAYS THEY ARE WAITING ON YAMAHA TO SHIP PARTS TO CORRECT PROBLEM. AS OF TODAY, I HAVE BEEN TO THE DEALERSHIP 3 TIMES AND THEY STILL HAVE NOT RECEIVED PARTS FROM YAMAHA. THE OWNER OF THE DEALERSHIP REFE…

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RECEIVED A SAFETY RECALL ON TRANSMISSION OF MY 2003 WARRIOR DATED JANUARY 9, 2004. THE LOCAL DEALERSHIP I BOUGHT MY BIKE FROM, SAYS THEY ARE WAITING ON YAMAHA TO SHIP PARTS TO CORRECT PROBLEM. AS OF TODAY, I HAVE BEEN TO THE DEALERSHIP 3 TIMES AND THEY STILL HAVE NOT RECEIVED PARTS FROM YAMAHA. THE OWNER OF THE DEALERSHIP REFERRED ME TO YAMAHA CUSTOMER RELATIONS @800-962-7926, IT HAS BEEN TERMINALLY BUSY. I AM STILL WAITING ON A SOLUTION AFTER 2 MONTHS AND SAFETY RECALL SAYS DO NOT RIDE. THIS VECHICLE IS MY DAILY TRANSPORTATION.

NHTSA ODI #10060208

1,500 miles · Feb 27, 2004
Power Train

TWO MONTHS AGO CONSUMER RECEIVED A RECALL LETTER REGARDING TRANSMISSION. DEALERSHIP STILL DID NOT HAVE THE PARTS AVAILABLE TO CONDUCT RECALL FREPAIRS. THE DEALER WAS CONTACTED ,AND INDICATED THAT CONSUMER SHOULD WAIT UNTIL THE MONTH OF MAY. *AK

NHTSA ODI #10060921

5,000 miles · Feb 27, 2004
Power Train

YAMAHA WARRIOR MOTORCYCLE RECALL FOR TRANSMISSION PART. YAMAHA HAS REFUSED TO SHIP PARTS TO REPAIR THIS MANUFACTURING DEFECT. THEY HAVE ADVISED TO NOT RIDE MOTORCYCLE BUT I STILL CONTINUE TO MAKE PAYMENTS FOR THE BIKE AND INSURANCE. THEY HAVE NO ESTIMATED DELIVERY FOR THE REPLACEMENT PARTS. IF IT SITS IN THE SHOP FOR 45 DAYS…

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YAMAHA WARRIOR MOTORCYCLE RECALL FOR TRANSMISSION PART. YAMAHA HAS REFUSED TO SHIP PARTS TO REPAIR THIS MANUFACTURING DEFECT. THEY HAVE ADVISED TO NOT RIDE MOTORCYCLE BUT I STILL CONTINUE TO MAKE PAYMENTS FOR THE BIKE AND INSURANCE. THEY HAVE NO ESTIMATED DELIVERY FOR THE REPLACEMENT PARTS. IF IT SITS IN THE SHOP FOR 45 DAYS DOES IT FALL UNDER THE NEW YORK STATE LEMON LAW? I WOULD RATHER JUST GET IT FIXED BUT YAMAHA WILL NOT ASSIST WITH THAT ENDEAVOR.*AK

NHTSA ODI #10059957

Mileage unknown · Feb 26, 2004
Power Train

I PURCHASED A 2002 YAMAHA ROAD STAR WARRIOR NEW. I LEARNED OF A RECALL WELL OVER A MONTH AGO. THE RECALL SAYS THE BIKE IS UNSAFE, DO NOT RIDE THE UNTIL REPAIRED. THE REPAIR PARTS ARE ON BACK-ORDER AND THE DEALER HAS NO ESTIMATED DATE FOR PARTS DELIVERY. THEY SAID THE SITUATION IS OUT OF THEIR CONTROL AND SUGGESTED I CALL YAMAHA…

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I PURCHASED A 2002 YAMAHA ROAD STAR WARRIOR NEW. I LEARNED OF A RECALL WELL OVER A MONTH AGO. THE RECALL SAYS THE BIKE IS UNSAFE, DO NOT RIDE THE UNTIL REPAIRED. THE REPAIR PARTS ARE ON BACK-ORDER AND THE DEALER HAS NO ESTIMATED DATE FOR PARTS DELIVERY. THEY SAID THE SITUATION IS OUT OF THEIR CONTROL AND SUGGESTED I CALL YAMAHA CORP. I HAVE BEEN WAITING PATIENTLY. RIDING SEASON IS NOW HERE ! I WANT MY BIKE FIXED ! *AK

NHTSA ODI #10059035

1,500 miles · Feb 24, 2004
Power Train

RE: NHTSA CAMPAIGN ID# 03V309000. I OWN A 2003 YAMAHA ROAD STAR WARRIOR EFFECTED BY THIS RECALL. I CONTACTED 2 DEALERSHIPS AND HAVE BEEN INFORMED BY BOTH THAT YAMAHA IS NOT HANDLING WELL. THEY OFFER NO DATE TO REPAIR MY VEHICLE STATING THAT THE MANUFACTURER IS NOT PROVIDING PARTS. ONE SAID THAT AT THE CURRENT RATE OF PARTS…

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RE: NHTSA CAMPAIGN ID# 03V309000. I OWN A 2003 YAMAHA ROAD STAR WARRIOR EFFECTED BY THIS RECALL. I CONTACTED 2 DEALERSHIPS AND HAVE BEEN INFORMED BY BOTH THAT YAMAHA IS NOT HANDLING WELL. THEY OFFER NO DATE TO REPAIR MY VEHICLE STATING THAT THE MANUFACTURER IS NOT PROVIDING PARTS. ONE SAID THAT AT THE CURRENT RATE OF PARTS RECEIPT IT WOULD BE 6 MONTHS OR MORE BEFORE RESOLUTION. (LEBARD & UNDERWOOD - LAHABRA, CA AND HAHM MOTORSPORTS - ANAHEIM, CA WERE THE DEALERS). I NEXT CONTACTED THE MANUFACTURER DIRECTLY (AS PER THEIR WEBSITE AT 1-800-962-7926) AND WAS INFORMED THEY COULD NOT OFFER ANY DIRECTION OTHER THAN I SHOULD NOT RIDE THE MOTORCYCLE. THEY ADVISED THAT THERE IS NO KNOWN RESOLUTION DATE AND THAT THEY HAD ONLY BEEN NOTIFIED ON JANUARY 9, 2004 OF THE ISSUE DESPITE THE FACT THAT YOUR BULLETIN IS REFERENCED AS AUGUST 22, 2003. AT THIS POINT THE MANUFACTURER'S REPRESENTATIVE BECAME RUDE AND STATED THAT IT WAS NOT HER PROBLEM AND THAT THEY ARE AT THE MERCY OF THE MANUFACTURER WHO IS LOCATED IN JAPAN. CONFUSING AS I CONTACTED YAMAHA MOTORS-USA AND CONCERNING AS EVEN IF ONLY KNOWN ON 1/9, THEY STILL HAD NO PLAN OF ACTION. IT SHOULD ALSO BE NOTED THAT YOUR BULLETIN ADVISES TWO METHODS TO CONTACT YAMAHA UNDER REMEDY. THE PHONE NUMBER ON YOUR NOTICE IN THE CASE OF YAMAHA NOT HANDLING IN A REASONABLE TIME, DOES NOT ANSWER THE QUESTIONS AS NO OPTION IS PROVIDED. ADDITIONALLY THE WEBSITE YAMAHA-MOTOR.COM HAS NO INFORMATION ON THE RECALL AND THEY NO LONGER ACCEPT EMAILS. THIS REPRESENTS AN UN-WILLINGNESS TO REPAIR THE VEHICLES AND A FAILURE TO COMPLY AS DIRECTED BY YOUR AGENCY. THEY ARE PLACING OWNERS IN A SITUATION OF EITHER ACCEPTING POTENTIAL SERIOUS ACCIDENT RISKS BY CONTINUING TO OPERATE THEIR VEHICLES OR TO BE WITHOUT A VEHICLE FOR AN UNDETERMINED PERIOD AND INCUR ASSOCIATED COSTS TO OBTAIN ALTERNATIVE TRANSPORTATION. I AM REQUESTING YOUR ASSISTANCE IN A RESOLUTION.*AK

NHTSA ODI #10058837

Mileage unknown · Feb 22, 2004
Power Train

I HAVE BOUGHT MY YAMAHA ROAD STAR WARRIOR ON MAY 15 2003 AND I FOUND OUT THAT YAMAHA HAD A RECALL ON TRANSMISSION PARTS THAT ARE BACK ORDERED, I HAVE MY BRAND NEW BIKE PARKED BECAUSE IT IS UNSAFE TO DRIVE FOR OVER 40 DAYS. 20 CALLS WERE MADE TO YAMAHA CUSTOMER SERVICE THEY ARE VERY RUDE AND SAY WE WILL CALL YOU DEALER TO FIND O…

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I HAVE BOUGHT MY YAMAHA ROAD STAR WARRIOR ON MAY 15 2003 AND I FOUND OUT THAT YAMAHA HAD A RECALL ON TRANSMISSION PARTS THAT ARE BACK ORDERED, I HAVE MY BRAND NEW BIKE PARKED BECAUSE IT IS UNSAFE TO DRIVE FOR OVER 40 DAYS. 20 CALLS WERE MADE TO YAMAHA CUSTOMER SERVICE THEY ARE VERY RUDE AND SAY WE WILL CALL YOU DEALER TO FIND OUT WHEN THE PARTS WILL ARRIVE AND THEY DO NOT CALL. MY BRAND BIKE IS USELSS AND YAMAHA HAS NO SUPPORT AND THEY DO NOT CARE ABOUT FIXING THIS PROBLEM AND IF THEY DO THE ARE GIVING US 90 DAYS WARRANTY SO IF ANY THINGS GO BAD AFTERWARDS THEY ARE NOT LIABLE. I'M VERY DISAPPOINTED WITH THEIR CUSTOMER SERVICE AND I HAVE FILED A LAWSUIT WITH A LOCAL LAW FIRM. UNDER CALIFORNIA LEMON LAW I'M ENTITLED TO HAVE YAMAHA PURCHASE BACK MY BIKE. I DO NOT WANTED IT .IS SITTING HERE AND I'M JUST PAYING FOR GARAGE, INSURANCE ...ETC AND I CAN NOT EVEN RIDE IT TO WORK, I HAVE TO TAKE A CAB OR RIDE THE BUS, THIS STUPID AND VERY INCONVENIENT. WHAT MAKES THE MATTER WORSE THAT THE RECALL BEEN OUT FOR MONTHS AND YAMAHA DID NOT TAKE ANY ACTION TO NOTIFY US FOR OUR SAFETY. THEY DID NOT EVEN SHARE IT WITH DEALERS SO THEY CAN PUSH MORE SALES AND MORE PROFITABILITY VERSUS SAFETY. I HAVE YAMAHA AND I HAVE BEEN CHEATED AND I WILL NOT LET THEM TAKE MY MONEY LIKE THAT. THIS IS AN ABSOLUTE RIP OFF. PLEASE ADVISE. *JB

NHTSA ODI #10058713

Mileage unknown · Feb 22, 2004
Power Train

RE: 2003 YAMAHA WARRIOR MOTORCYCLE RECALL YAMAHA CORP. ISSUED A RECALL DUE TO A DEFECT IN THE TRANSMISSION WHICH MAY CAUSE THE REAR WHEEL TO LOCK UP AND CAUSE DEATH. YAMAHA DEALERS ARE SAYING THAT CORP. IS "...DRAGGING THEIR FEET, NOT ALLOWING US TO STOCK THE PART, CASE BY CASE ONLY, WEEKS IF NOT MONTHS UNTIL REPAIR POSSIBLE..…

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RE: 2003 YAMAHA WARRIOR MOTORCYCLE RECALL YAMAHA CORP. ISSUED A RECALL DUE TO A DEFECT IN THE TRANSMISSION WHICH MAY CAUSE THE REAR WHEEL TO LOCK UP AND CAUSE DEATH. YAMAHA DEALERS ARE SAYING THAT CORP. IS "...DRAGGING THEIR FEET, NOT ALLOWING US TO STOCK THE PART, CASE BY CASE ONLY, WEEKS IF NOT MONTHS UNTIL REPAIR POSSIBLE..." MEANWHILE, CORP. IS SAYING "...DO NOT USE, DEATH MAY RESULT." IF NHTSA COULD PRESSURE YAMAHA CORP. TO ALLOW THE DEALERS TO STOCK THE PART NECESSARY TO REMEDY THE RECALL, IT WOULD CREATE A SAFER SITUATION. THANK YOU. *JB

NHTSA ODI #10058683

1,600 miles · Feb 21, 2004
Power Train

YAMAHA ROAD STAR WARRIOR RECALL, THE MOTORCYCLE WILL NOT BE FIXED FOR MORE THAN 30 DAYS AND STILL COUNTING BOUGHT NEW IN JULY 2003 AT WILLY WORLD IN JOLIET ILL. FROM WHAT I HAVE GATHERED CAN I HAVE YAMAHA FORCED TO BUY MY BIKE BACK, ACCORDING TO LEMON LAWS, YAMAHA DID NOT LET ME KNOW THIS, AND I CANT RIDE THE BIKE BECAUSE IT S…

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YAMAHA ROAD STAR WARRIOR RECALL, THE MOTORCYCLE WILL NOT BE FIXED FOR MORE THAN 30 DAYS AND STILL COUNTING BOUGHT NEW IN JULY 2003 AT WILLY WORLD IN JOLIET ILL. FROM WHAT I HAVE GATHERED CAN I HAVE YAMAHA FORCED TO BUY MY BIKE BACK, ACCORDING TO LEMON LAWS, YAMAHA DID NOT LET ME KNOW THIS, AND I CANT RIDE THE BIKE BECAUSE IT STATES IN THE RECALL LETTER I MUST NOT , ITS UNSAFE, NO INFO FROM DEALERSHIP WHEN IT CAN BE FIXED , THEY SAY THEY ARE WAITING ON YAMAHA TO GET OUT PARTS AND WHO KNOWS WHEN THAT WILL BE. *JB

NHTSA ODI #10058634

Mileage unknown · Feb 12, 2004
Power Train

CONSUMER RECEIVED RECALL 03V309000 CONCERNING TRANSMISSION FAILURE. CONSUMER RECEIVED THE RECALL NOTICE AND CONTACTED THE DEALER, WHO INFORMED THE CONSUMER THAT PARTS WERE NOT AVAILABLE BECAUSE YAMAHA HAD NOT SENT THEM. *AK

NHTSA ODI #10058012

Mileage unknown · Feb 6, 2004
Power Train

I RECEIVED A SAFETY RECALL NOTICE FROM YAMAHA CORP. U.S.A. CONCERNING A PROBLEM WITH MY 2002 YAMAHA ROADSTAR WARRIOR MOTORCYCLE. THE PROBLEM WAS WITH THE TRANSMISSION AND SERIOUS INJURY OR DEATH COULD RESULT IF THE BIKE IS OPERATED ACCORDING TO YAMAHA. I CALLED THREE LOCAL YAMAHA DEALERS AND ALL OF THEM INFORMED ME THAT YAMAHA…

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I RECEIVED A SAFETY RECALL NOTICE FROM YAMAHA CORP. U.S.A. CONCERNING A PROBLEM WITH MY 2002 YAMAHA ROADSTAR WARRIOR MOTORCYCLE. THE PROBLEM WAS WITH THE TRANSMISSION AND SERIOUS INJURY OR DEATH COULD RESULT IF THE BIKE IS OPERATED ACCORDING TO YAMAHA. I CALLED THREE LOCAL YAMAHA DEALERS AND ALL OF THEM INFORMED ME THAT YAMAHA CORPORATION U.S.A. HAD NOT PROVIDED THEM WITH THE PARTS TO FIX THE PROBLEM. ONE DEALER SAID EXPECT TO WAIT UNTIL ABOUT JUNE OR JULY BECAUSE ONCE THEY GOT THE PARTS THEY COULD FIX ONLY ABOUT TWO OR THREE MOTORCYCLES A WEEK. I FEEL YAMAHA SHOULD BUY THE BIKE BACK OR ISSUE A REFUND. SINCE THEY CANNOT COMPLY AND FIX THE PROBLEM IN A TIMELY MANNER.*AK

NHTSA ODI #10056656

Official recalls

1

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.

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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