Warrior Maintenance & Repair Documents - Road Star Warrior Forum : Yamaha Star Warrior Forums

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Old 06-19-2012, 03:33 PM   #1 (permalink)
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Default Warrior Maintenance & Repair Documents

This area is a storehouse for General Warrior 'Maintenance & Repair' Help Files.

1. This Table of Contents.
2. Stock Turn Signal Bulbs by Model Year, plus UK notes. Replacing the Flasher.
3. Stock Warrior Tool Kits, 2002, 2003-2005, and 2006+, Plus Other Tools.
4. Changing the Motor Oil and Oil Filter, and Checking Motor Oil Level.
5. Changing the Transfer Case (Middle Drive) Fluid.
6. Changing and Adjusting the Drive Belt. Emergency Drive Belt.
7. Setting-Up the Warrior Before Tuning; Reading Spark Plugs.
8. About the ECU, Where it Lives, What it Does, Error Messages.
9. Disassembled Views of Some of the Parts that Differ by Model Year.
10. About the Fuel Tanks, Pump, Filters, Injectors, Dry Breaks, Low Fuel Sensor, Gas & Octane.
11. About the 'Exhaust Header' Gaskets and Options.
12. About the Wiring Under the Rear Fender.
13. About the Wiring in the Headlight Bucket and Replacing Bulb.
14. Photos of Various Uninstalled Component Parts - Group 1.
15. Photos of Various Uninstalled Component Parts - Group 2.
16. About the Wiring Under the Rider Seat and Fuel Tank.
17. About the Battery and the Circuit Fuses.
18. Adjusting the Warm Idle. Understanding LCV Issues.
19. Adjusting the Clutch Cable.
20. Yamaha Fastener Part Number Tips and Tricks.
21. Bedding and Re-Bedding Disc Brake Pads to Rotors.
22. About Spark Plugs. About Anti-Seize on Spark Plugs.
23. If You Lost Your Only Warrior Ignition Key.
24.
25.

Last edited by arizonawarrior; 09-25-2012 at 02:42 PM.
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Old 06-19-2012, 03:34 PM   #2 (permalink)
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Service Help File: Turn Signal Bulbs.

See Attachment.
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Attached Files
File Type: pdf Replacing the Denso Flasher May 2007.pdf (455.7 KB, 141 views)

Last edited by arizonawarrior; 06-29-2012 at 12:38 PM.
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Old 06-19-2012, 03:36 PM   #3 (permalink)
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Service Help File: Stock Warrior Tool Kits.

1. Warrior OEM Tool Kits by Model Year.
2. Spark Plug Thread Back-Tap.
3. Craftsman Aluminum Motorcycle Jack.
4. Warrior OEM 2003+ Shock Adjustment Tool Dimensions.
5.
6.
7.
8.
9.
10.
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Name:	Craftsman Aluminum Motorcycle Jack.jpg
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Attached Files
File Type: pdf Warrior 2003 Shock Spanner Wrench and Newer.pdf (73.0 KB, 111 views)

Last edited by arizonawarrior; 07-27-2012 at 09:08 PM.
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Old 06-19-2012, 03:39 PM   #4 (permalink)
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Service Help File: Changing the Motor Oil and Filter, and Checking the Motor Oil Level.

Also See Attachments.

-----

Checking the motor oil's level in your Road Star Warrior is different than you probably expect and not realizing this can be a little embarrassing in the forums. Please take a few minutes to view this Yamaha video at least twice because the procedure is important, and its different enough its worth a second look. If you own a Warrior then you want to know about this.

Please Click Here: https://www.starmotorcycles.com/star/service/viewservicetip.aspx?ls=star&yr=2003&lid=2&mid=61&t id=8

-----

If you need replacement oil plugs, get them from Yamaha dealer locally or remove both of yours during an oil change and match at the local auto parts store for length. Oil plugs are 12mm with 1.5 pitch and 17mm hex head. Length could be standard or special, don't know.

Its possible to avoid the need to over-torque the steel oil plug into the aluminum motor by using new oil plug gaskets (washers) every oil change, or every second oil change if you want to keep track. They are 14mm aluminum oil pan plug gaskets, try Dorman #65292 (www.DormanProducts.com). The Dorman washers are available online and in local auto parts stores. Here's the Dorman website to see what vehicles interchange the same washer http://www.dormanproducts.com/gsearch.aspx?type=keyword&q=65292 . If buying online then verify quantity you are buying for the price. IMO avoid the plastic/nylon washers. Also avoid copper washers since the motor is aluminum: http://www.berridge.com/Preventing%20Electrolysis.pdf

[Added} this is an updated link for the attached PDF for the JASO-MA 'wet-clutch' information and links to additional reading: JASO MA and JASO MB classifications - oilspecifications.org

[Added} two additional PDF files: JASO (use for wet clutch proof) and API (use for service grade proof).
.
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Attached Files
File Type: pdf Service Help File Motor Oil Change PicThread by Darkside.pdf (957.9 KB, 196 views)
File Type: pdf Service Help File Motor Oil Drain Plugs.pdf (145.2 KB, 150 views)
File Type: pdf Motor Oil Change Variables Tips and Tricks.pdf (11.6 KB, 160 views)
File Type: pdf Oil Filters by Mike Guillory.pdf (279.5 KB, 128 views)
File Type: pdf Motorcycle Motor Oil Wet Clutch JASO-MA.pdf (414.4 KB, 127 views)
File Type: pdf API Engine Oil Guide March2010.pdf (972.3 KB, 122 views)

Last edited by modoc; 08-22-2013 at 11:47 AM.
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Old 06-19-2012, 03:41 PM   #5 (permalink)
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Service Help File: Changing the Transfer Case (Middle Drive) Fluid.

See Attachment.
Attached Files
File Type: pdf Service Help File Transfer Case Oil Change.pdf (103.3 KB, 253 views)
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Old 06-19-2012, 03:44 PM   #6 (permalink)
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Service Help File: Changing and Adjusting the Drive Belt.

Also: Emergency Drive Belt.

(thanks to siradude for reducing some documents in filesize!)

See Attachment.
Attached Files
File Type: pdf Service Help File Drive Belt Change Tips.pdf (20.5 KB, 314 views)
File Type: pdf Service Help File Drive Belt Set Up Rev4.pdf (605.9 KB, 358 views)
File Type: pdf Emergency Drive Belt 40171-97.pdf (61.5 KB, 191 views)

Last edited by arizonawarrior; 09-20-2012 at 01:04 PM.
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Old 06-19-2012, 03:45 PM   #7 (permalink)
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Service Help File: Setting-Up the Warrior Before Tuning; Reading Spark Plugs.

See Attachments.

Last edited by arizonawarrior; 07-07-2012 at 04:58 AM.
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Old 06-19-2012, 03:48 PM   #8 (permalink)
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Service Help File: About the ECU, Where it Lives, What it Does, Error Messages.

See Attachments.
Attached Thumbnails
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Attached Files
File Type: pdf Service Help File ECU Pinout by Stowawarrior.pdf (70.8 KB, 135 views)
File Type: pdf Service Help File ECU Voltage by Pin.pdf (18.6 KB, 121 views)

Last edited by modoc; 06-20-2012 at 05:47 PM.
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Old 06-19-2012, 03:51 PM   #9 (permalink)
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Service Help File: Some of the parts that differ by Model Year.

1. Seats.
2. Front Brakes.
3. Front and Rear Fenders.
4. Middle Drive and Front Pulley.
5. Shock Absorber.
6. Fuel Injection System Relay.
7. Turn Signal Bulbs and Lenses.
8. Rider Peg-and-Control Mounts.
9. Handlebars.
10. The Model Year Differences Thread.
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Name:	Warrior Seat Differences.jpg
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Name:	Warrior Front Brakes.jpg
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Name:	Warrior Fender Differences.jpg
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Name:	Warrior Middle Drive and Front Pulley Differences.jpg
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Attached Files
File Type: pdf Scaweins Model Year Differences OP.pdf (93.3 KB, 193 views)

Last edited by arizonawarrior; 06-24-2012 at 04:08 AM.
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Old 06-19-2012, 03:59 PM   #10 (permalink)
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Service Help Files: About the Fuel Tanks, Pump, Filters, and Low Fuel Sensor.

1. Fuel Pump Assembly and Low Fuel Sensor.
2. Main Fuel Tank Exit Feed, Screen, Seal.
3. Fuel Injector Sketch with Dimensions.
4. Fuel System Dry Break.
5. Brass Nipple Fuel Pump Nipple Repair.
6. Fuel Pump Info and Sketch.
7. Badly Repaired Fuel Tank Warning.
8. Aftermarket Fuel Pump Motor.
9. Fuel Injector Spray Pattern & Cleaning.
10. Octane Explanation and the Different Calculation World Wide.
Attached Thumbnails
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Name:	Service Help File Fuel Pump and Sensor.jpg
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Name:	Warrior Fuel Tank Exit Feed Screen.jpg
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Name:	Warrior Fuel Injector Dimensions Sketch.jpg
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Name:	Warrior Fuel Pump Sketch.jpg
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Name:	Warrior Tank Repaired with Putty.jpg
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Attached Files
File Type: pdf Service Help File Fuel Pump Dry Breaks William3rd.pdf (333.4 KB, 191 views)
File Type: pdf Service Help File Fuel Pump Brass Nipple Repair.pdf (1.34 MB, 157 views)
File Type: pdf Service Help File Fuel Pump Aftermarket Install.pdf (478.5 KB, 156 views)
File Type: pdf Fuel Injectors SamVallas Thread.pdf (1,004.9 KB, 136 views)
File Type: pdf Wiki Octane Rating Explanation.pdf (122.7 KB, 122 views)

Last edited by arizonawarrior; 02-11-2013 at 03:55 PM.
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