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Documentation error by Yamaha Motors and carried on here!

[upated February 24th 2009 by ArizonaWarrior with help from Desertwndrr for 2006 Supplement data]
[updated July 19th 2010 by ArizonaWarrior to repair broken link and add 2009 parts manual info]
[updated January 4th 2011 by ArizonaWarrior to re-foprmate for the new forum parameters, and update]

To be sure you are covered, look for these Service Manuals for each Model Year:
From the Star website: http://www.yamahapubs.com

2002 XV1700PCP* service manual is LIT-11616-15-37

2003 XV1700PCR* service manual is LIT-11616-RS-WO
2003 XV1700PCR* supplement is LIT-11616-16-36

2004 XV17PCS* service manual is LIT-11616-RS-WO

2005 XV17PCT*service manual isLIT-11616-RS-WO

2006 XV17PCV* service manual is LIT-11616-RS-W1
2006 XV17PCV* supplement is LIT-11616-19-46
2006 XV17PCV* parts manual is P15-1217006-06

2007 XV17PCW* service manual is LIT-11616-RS-W1
2007 XV17PCW* parts manual is P15-1217006-07

2008 XV17PCX* service manual is LIT-11616-RS-W1

2009 XV17PCY* service manual is LIT-11616-RS-W1
2009 XV17PCY* parts manual is P15-12170000-09

2010 XV17PCZ* service manual (likely same as 2009)
There exists a major documentation error by Yamaha Motors for the proper Warrior wiring diagram for USA BUILD years '2004-2005' and the info currently posted above should not be considered Boiler Plate until corrected by the OP!

The Technicolor folded wiring diagram in LIT-11616-RS-WO located in the back of the factory manual is for build years '2002-2003' which has an earlier Main Wiring Harness (MWH) and Relay Unit (RU) that has been superceded to later P/N's for both the MWH & RU for all USA build years '2004-2009'

The 2006 supplement LIT-11616-19-46 is available in hard copy from MSSS.com for approx $15.00 and should have the later 2-pg wiring diagram in Black & White with the accompanying color code descriptors to support the wiring for all builds 2004 & up.
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Not to hijack the essence of the OP, the earlier (02-03) MWH & RU have a moulded connector with the capability of 16-Pins of which only 11-Pins are active.
There exists a handlful of passive electrical components in this early RU that serve no useful purpose for the Warrior imo.

The later (04-09) MWH & RU have a moulded connector with 11-Pins eliminating the passive components.

THE WIRE COLOR CODING REMAINS THE SAME FOR '2002-2009' AND THE ONLY DIFFERENCE IS THE ARRANGEMENT OF THE PINS IN THE MH CONNECTOR
  • The earlier diagram will support the bikes except for the connector configuration
Forward or backward compatability is not possible unless the user extracts the crimped pins from the connector or fabs electrical jumpers.
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FWIIW, this info was inspired by my recent contributions to RS JOKER's Wierd starting prob here: http://www.rswarrior.com/forums/13-technical-discussion/171704-wierd-starting-prob.html#post2197059 and his feed-back regarding the RU's of early & late builds ('02' & '05') being different.
This writer has been cognizant of the MWH part number differences for many years that exists with the handlebar Hitachi connector colors but not the new RU with the different pin configurations.
 

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To help you determine model year, these numbers appear on a (white?) sticker on
top of the frame brace under your rider seat. Please help complete this list for
missing years by adding your bike's model year and model number by Quick Reply:

XV17PCR (2003) covering:
5PX4 for U49
5PX5 for California
5PX6 for Canada and South Africa

XV17PCS (2004) (could be same as 2003 above)
Here's some pay-back for your tiny jpeg image of the B&W wiring diagram i requested :rolleyes: to kick-start Warrior builds 2004; my ride mfg'd Jan 04 ...... what goes around comes around ;)

http://www.rswarrior.com/forums/_Upload/alanh/200562719510_DSCN1018.jpg

http://www.rswarrior.com/forums/_Upload/alanh/2005627194950_DSCN1014.jpg

http://farm3.static.flickr.com/2306/1687013222_5f59df5e47_o.jpg
 

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Discussion Starter #23
I've re-organized the original post (above) and expanded the known service manual identification numbers. I've also clarified those containing the manual and the supplement(s) (whose numbers end in "WO" and W1"). I've heard rumors of a "W2" volume containing the service manual and the 2003, 2006 supplements, plus a 2008 supplement covering the 2008+ model year bikes, but if it exists I cannot locate it. I'm not aware of any significant changes that would warrant a complete supplement. But the bottom line is I don't know if it exists or what it might contain.

I've also corrected an unfortunate prior cut-and-paste error that left a 'dangling' incorrect referral regarding the 'paint color' identification sticker under the rider seat. As you likely know already, the 'paint color' numbers are used when ordering a new fender or main fuel tank to match your original colors, and can also be handy for Midnight bikes in certain other cases. For example, there seem to be at least two shades of black used for Midnight tins and possibly two for the wheels too.

I've also updated the original post with every scrap of info I have on-hand, so its as complete as it needs to be to serve our mutual needs into the future. I hope!

Jump to Original Post: http://www.rswarrior.com/forums/13-technical-discussion/147350-service-manuals-model-year.html#post1952343
 

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Has anyone got an electronic version of the 2004 service manual? Not that I am a cheapskate but I would spend $10 for one.
 

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Discussion Starter #30 (Edited)
The initial rush of downloads seems to have subsided and load times have improved, so I've added your link to the original post above (thanks!):

Manuals - 2002 Service, 2003 and 2006 Supplements: http://www.robriguez.com/motorcycle/Service/WarriorServiceManual-WO3646.pdf

Its been in the Popular Mods post under 'Manuals' for awhile, of course.

Again, great find and thank you Rob!
 

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Discussion Starter #31
You are right. The UK bikes are either 'Imports' or 'Grey Imports' (a term coined by Jarv) so some are UK-modified to meet local laws, and others are not modified so were shipped and sold in same condition as USA bikes (some are USA49 and some are USA-California bikes). It makes it challenging sometimes to lend a hand. But since the UK boys identified those issues its become a lot easier.

Of course Tom's 2004 model UK bike is actually a 2003 model USA bike so it looks like maybethere were a few shipped as UK domestic in 2004. Or the dealers sold them as 2004 who knows. But one way or another the 2003 model bikewas sold as a 2004 in the UK. They even have the 2003 model number on them, which Tom mentions earlier above.

 

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Discussion Starter #32
With Robrigez's introduction of the single-pdf file containing the 2002 service manual and the 2003 and 2006 supplements ( http://www.robriguez.com/motorcycle/Service/WarriorServiceManual-WO3646.pdf ), all model years are covered by a single manual-set!

It turns out the 2003 and 2006 Supplements both contain some details not published in the 2002 service manual, so regardless of what model year your Warrior is . . . get both supplements too. Just remember: if you have an earlier model year bike, SOME of the supplement information will NOT apply to your Warrior so pay attention!

As always, when buying or downloading a service manual, notice its 'part number' then use the information in the Original Post (#1 above) to determine what that manual covers.

There's additional helpful information integrated into the #1 post.

I don't see any reason to further maintain this topic, it seems complete.
 
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