Got the recalls done. I messed with my map an added values to the 0% throttle in the 750-1250 RPM ranges. So far, so good. My plugs seem to be a good color too. I'll try getting the battery this week.

 

ok - add me to the list of CPS failures, only I didn't get stranded, just noticed the symptoms. will know for sure once I take it apart and inspect it.
check out this thread for details. It's scary how the symptoms are so alike among all the members....
http://rswarrior.com/forums/topic.asp?TOPIC_ID=57917
Stupid question, in order to replace the cps, will I need to drain the oil before I take off the clutch cover? This is my first time going into that part of the bike....

 

I just bought a 2007 Midnight Warrior last Saturday. Should I be worried?

I put 200+ miles between Saturday and Sunday. Everything was fine. It only stalled one time before warming up. It was cold.

Should I take her to the dealership for the Pick-up Coil Recall?

Maybe on the 600 miles maint. schedule should be a good time to do it.

 

Looks like my 2005 needs the recall CPS and TPS.. its acting like one cylinder isnt firing and has significantly less power..

Can i drive slowly to the dealer? 30 minutes away?

Alan

 

My 2005 has 30k miles on it, and the CPS failed for the 4th time this weekend!


My dad is a welderby trade, and runs an HVAC company in AZ. He seems to think that it is due to a design flaw. He says that since thewires are soldered on and emersed in hot oil, the solder gets too warm and the wires basically drift away from the posts due to constantvibration. His theory makes sense to me because every time it has failed, i have been on a long trip- where i have been riding 700-1000 miles in one day. always happens at the end of a long day of hard riding, or the morning after.


anyone know what the oil temputure is after riding for 12 hours straight? versus the melting point of standard solder? i think most solder melts at around 500 degrees. if the oil temp gets up to even 400 degrees, i think that would make the solder soft enough to allow the wires to move.


seems to me that if you could mechanically attach the wires, using a small bolt or crimp or something, that would be better than solder.


Anyone else modified the sensor posts to connect another way besides using solder and RTV? btw, i've used the RTV idea after failure #2, and it held for about 10k miles before failure #3.

 

My 2005 has 30k miles on it, and the CPS failed for the 4th time this weekend!


My dad is a welderby trade, and runs an HVAC company in AZ. He seems to think that it is due to a design flaw. He says that since thewires are soldered on and emersed in hot oil, the solder gets too warm and the wires basically drift away from the posts due to constantvibration. His theory makes sense to me because every time it has failed, i have been on a long trip- where i have been riding 700-1000 miles in one day. always happens at the end of a long day of hard riding, or the morning after.


anyone know what the oil temputure is after riding for 12 hours straight? versus the melting point of standard solder? i think most solder melts at around 500 degrees. if the oil temp gets up to even 400 degrees, i think that would make the solder soft enough to allow the wires to move.


seems to me that if you could mechanically attach the wires, using a small bolt or crimp or something, that would be better than solder.


Anyone else modified the sensor posts to connect another way besides using solder and RTV? btw, i've used the RTV idea after failure #2, and it held for about 10k miles before failure #3.

The sensor bracket will also fail.


Yamaha has admitted the design failure and redesigned the pickup coil. Stop wasting your time and take the bike in for the recall. the new part has been good. I lost five of them before getting the new design and have had no trouble since.


RVT before it fails works great. I doubt it would be of much good once the wires have been broken.

 

Re: Crank position sensor / Pickup sensor / CPS

Solder generally melts at about 190C (374F). http://www.irational.org/sic/radio/solder.html


Oil standards allow oil to lose grade viscocity after 212F so any hotter than 212F and your oil looses a full grade of lubrication. In most cases this would mean that your CPS would be the least of your problems. You can find this info on most oil company websites. Here's some data:


Oil - Viscocity: (W=Winter) 10W40 at 32-degrees F flows as 10 weight; at 212-degrees F flows like 40 wt.
Oil - Viscocity: 20W-50 = 20 weight oil that will not thin more than a 50 weight would when 212-degrees F.
Oil - Viscocity: http://www.valvoline.com/carcare/articleviewer.asp?pg=ccr20040601ov


Copper wire melts at 1083C (1981F)so its not a heat problem with the wire or the solder.


But from the standpoint of vibration yes it could fail. This is from the Yamaha website CPS recall post:The reason for this recall: In affected motorcycles, the pick-up coil mounting bracket is not sturdy enough to prevent vibration caused by magnetic force as the pick-up rotor passes the pick-up coil, if there is too small of a clearance between them. This vibration can eventually weaken the lead wires and cause them to break. If the pick-up coil breaks while the engine is running, the engine will stall and will not restart. [/b]


I'm not plugged-in to the number of problems with the new design CPS members might be having.


You might read the entire recall document at: http://rswarrior.com/files/folders/recalls/entry877452.aspx(under DOWNLOADS on this site). It requires that the entire length of the CPS wiring harness be replaced. If the dealer cut and spliced the harness to reduce labor time, that may be the cause of your problems.

 

Re: Crank position sensor / Pickup sensor / CPS

That is a little misleading. They do not replace the entire wiring harness. Just the two wire harness that is routed to the main harness under the seat. I know that is what you meant but it might confuse someone who has never done it.


The vibration will not only weaken the wires it will eventually cause the mount to fail at the bend and the entire pickup coil will fall off.

 

Re: Crank position sensor / Pickup sensor / CPS

Thanks for the POV. Fixed.

That is a little misleading. They do not replace the entire wiring harness. Just the two wire harness that is routed to the main harness under the seat. I know that is what you meant but it might confuse someone who has never done it.

Yes, the vibration had that affect on the original part design. The new design is supposed to be resistant to engine vibration like the old part was, but also resistant to the effects of the magnetic force imparting vibration on the bracket and copper wires.

The vibration will not only weaken the wires it will eventually cause the mount to fail at the bend and the entire pickup coil will fall off.

 

I don't know what is wrong with your bike, but it doesn't matter if its a CPS or TPS or some other trouble like a bad coil making it run on one jug, only you can decide if you can ride it to the shop!

Looks like my 2005 needs the recall CPS and TPS.. its acting like one cylinder isnt firing and has significantly less power. Can i drive slowly to the dealer? 30 minutes away? Alan

 

Re: Crank position sensor / Pickup sensor / CPS

This is the typical CPS failure shown here. Cracked Black conductor and nothing at allto do with oil temperature and solder break down

Mine failed exactly as shown in the 1st photo.


The failure is due to extreme vibration from the CPS which is a reluctance device. The magnetic core of the CPS vibrates at various frequencies as the notched crankshaft sensor plate rotates past the device.


Yamaha engineering Fix was to encapsulate the 2-soldered connections as well as a new redesigned formed/dimpled gusseted bracket.


FAILED OEM PART: TPS Failure Suspected....RESOLVED....at last!http://rswarrior.com/forums/p/23814/355348.aspx#355348

NOTCHED SENSOR PLATE ON CRANKSHAFT THAT PASSES ACROSS THECPS PICKUP COIL MAGNETIC FACE

MY PERSONALFIX PRIOR TO FACTORY RECALL PART: Silicone bridge to engine caseused to prevent vibration of the pick-up coil bracket andwires encapsulated with Permatex® Ultra Gray® RTV Silicone Gasket Maker. This never failed

NEW YAMAHARECALL PART I REPLACED DURING BARNETT INSTALL: The encapsulated wires are visible and the bracket is significantly wider at the 2-mounting holes. Not discernible is the dimpled portion of the bracket.

 

I WAS WRONG. i admit it. once i got the new re-designed sensor from my local Yami dealer i realized vibration was the problem. Upon further inspection of my old sensor, the solder was fine, the wire had snapped off at the base of the solder.


anyway, once i got the new one in, everything's honky-dory.

 

Not to beat a dead horse but, did or has anybody thought of drilling a hole in front of the case? in the first post, back in 2006 or so, the wire runs inside for about ten to twenty feet, meaning a long run,

 

I WAS WRONG. i admit it. once i got the new re-designed sensor from my local Yami dealer i realized vibration was the problem. Upon further inspection of my old sensor, the solder was fine, the wire had snapped off at the base of the solder.


anyway, once i got the new one in, everything's honky-dory.

How did you get the dealer to just give you the recall parts? Every dealer ive been to wont give me the parts so that I can install them myself.


Ive got an 02 with about 30,000 on it and neither CPS or TPS has been done beause I dont want some monkey jackin with my bike, yet they wont give me the parts so i can do it myself.


There is one dealer within 30 miles of me that I hasn't screwed me over, butive never had any work done there either. I may end up having to give them a chance.

 

Thanks again to AlanH. In looking at his pics and comparing to mine when I did my motor & clutch upgrades last winter I have determined that my CPS has been replaced when I thought it hadn't. The dealer in Connecticut that did the work put several parts (rear motor mounts ,spacers and bolts on backwards..or wrong placement) and I thought they had left the old cps but that is not the case... so my apologies for that part of my rant in other posts. (I will try to find and edit those)

 

i pulled the old sensor out, brought it up to the dealer and laid it on the parts guy's desk. i said "this bike obviously isn't moving and it's 30 minutes away. you could tow it or just give me the parts." and he didn't even blink, he just said "sure, just leave me the broken one."

 

Welcome to the "I changed the **** thing on the side of the road" club. It sucks

 

I want to inspect mine and seal it. Is there motor oil in there? or is it dry?

Thanks.

 

There is oil in there... but as when doing clutch conversion, you can lean the bike to the right so that it is on an angle and remove this cover without changing (or draining) the oil. I'm not sure what you mean by seal it ... there is actually a replacement part that is stronger and sealed better... that's what you should have . Also , you will need a new gasket.

 

I meant to use high temperature RTV sealant to prevent wire from shearing off. Okay I understand now that there is a better part than the stock. Do you by any chance know the kit part number?I Thanks for the info.

 

I bought my bike used. I called Yamaha and my bike has the new and improved part "Recall" was done on 2007.
Thanks for all the information.

 

according to this Yamaha 5PX-81670-01-00 Pick-Up Assy; ATV Motorcycle Snow Mobile Scooter Parts - Georgia Watersports Boat Jet Ski Parts Repair Rentals Sylvan Pontoon Yamaha Lake Oconee Sinclair Eatonton Atlanta Milledgeville Greensboro Macon there is a new part number for the cps- my question is : i have had the recall done - it was done in 2002 - i am now having problems with the bike cutting out after hard acceleration ( its not the over rev limiter- lol) at approx 3000rpm let off throttle and bike returns to normal - is it the cps and should i have it replaced by the new part number? i also have an old pc3 with the old serial port could it be that? no codes are present when it happens - thank you in advance for the help.

 

I received your message and will reply here as requested.

Its doubtful you had the CPS recall work done in 2002 since it was discovered to be a problem in February 2007, after some or all of the 2007 model year bikes had shipped.

IMO your best bet is to look at the VIN plate on the right-side of the neck on your Road Star Warrior motorcycle, and call a local Yamaha / Star dealer and ask what recalls have been done, and what recalls have not been done.

To your question for the Pick-Up Assembly (CPS):
CPS Recall Date: February 2007
CPS Recall Covers: 2002 - 2007 model years

If you use the Yamaha / Star parts fiche:
Part# 5PX-81670-00-00 shown for 2002 - 2007
Part# 5PX-81670-01-00 shown for 2008 - 2009

However, yes, if a CPS is ordered for any model year Warrior, it'll arrive as the new part# however I would always follow-up with the dealer to assure this.

 

thanks for the help after further reading - i am going to replace the LAS (aka) Yamaha 5PS-82576-01-00 EMERGENCY STOP SWITCH wich i found for $42.00 i have ordered one today and ill let you guys know if that has ended the problem.

 

CPS classic failure here

thanks for the help after further reading - i am going to replace the LAS (aka) Yamaha 5PS-82576-01-00 EMERGENCY STOP SWITCH wich i found for $42.00 i have ordered one today and ill let you guys know if that has ended the problem.

Read this early thread in its entirety before wasting your money. The CPS recall kit is approx $10.75 + shipping from MSSS.com

• TPS Failure Suspected....RESOLVED....at last!

Jpegs here

• CPS Recall & Barnett SR-2 Pressure Plate

The National Recall Kit for the CPS is:

• Pick Up Kit Part No. 90891-30047-00

 

So today i was going down an entrance ramp on the highway and i was in 3rd gear, got on it...and it went no where. engine just died.

check engine light, error code 12. and according to this thread its the CPS.

it does everything that everyone has said on here. wont turn over or anything.

so what do i do? advice?
what are my options on getting this fixed?

my bike has 11k miles on it...so its out of warranty, im the second owner so i dont know what recall work has been done to it. im not sure is the CPS code 12 issue is a recall item.

thanks in advance for the help, i need to get the warrior back on the road ASAP, the weather is getting nice here.