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Warrior Maintenance & Repair Documents

21K views 24 replies 1 participant last post by  Modoc 
#1 · (Edited by Moderator)
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. MOCAL Oil Filter Union (Oil Filter Leak Fix)
25.
 
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#3 · (Edited by Moderator)
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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#4 · (Edited by Moderator)
Service Help File: Changing the Motor Oil and Filter, and Checking the Motor Oil Level.

Also See Attachments.

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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&tid=8

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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. If buying online then verify quantity you are buying for the price. Avoid plastic/nylon washers they require lots of torque. Aluminum or copper are used by many, although some say to also avoid copper washers since the motor is aluminum (your call): 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).

[Added} Updated BOSCH 3323 and 3323ST oil filter dimensions (verify bypass valve psi for 3323ST).

[Updated Image Content}
.
252811
 

Attachments

#6 · (Edited by Moderator)
Service Help File: Changing and Adjusting the Drive Belt.

Also: Emergency Drive Belt.

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

See Attachment.
 

Attachments

#7 · (Edited by Moderator)
Service Help File:

Setting-Up the Warrior Before Tuning (and more).

Reading Spark Plugs.


See Attachments.
 

Attachments

#9 · (Edited by Moderator)
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.

253497
 

Attachments

#10 · (Edited by Moderator)
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.
 

Attachments

#14 · (Edited by Moderator)
Photos of Various Uninstalled Component Parts - Group 1.

1. Middle Drive Assembly
2. Transmission Gears
3. Main Drive Gear Set
4. Shift Shaft and Forks
5. Clutch Lever Orientation
6. Barnett SR2 Perfect Fit Fix (old)
7. Barnett SR2 Spring Ratings
8. Roadstar 5th Gear in 02-05 Warrior
9. Right Side Oil Tank Cover Rear View
10. Middle Drive Disassembled.
 

Attachments

#22 · (Edited by Moderator)
About Spark Plugs. About Anti-Seize on Spark Plugs.

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Recommended Spark Plug with Stock Coils:
NGK DPR7EA-9 or Denso X22EPR-U9 or similar. 12mm thread and 18mm hex.
Iridium plugs: NGK DPR7EIX-9 or similar. Also 12mm thread and 18mm hex.

Recommended Spark Plug with Dyna DC2-1 Coils:
NGK DPR7EA-9 or Denso X22EPR-U9 or similar (also buy the terminal nuts). Plugs are 12mm thread and 18mm hex.
Iridium plugs: NGK DPR7EIX-9 or similar (also buy the terminal nuts). Plugs are 12mm thread and 18mm hex.
NOTE: when using spark plugs with terminal nuts the Warrior's spark plug socket in the tool kit may not slip fully
onto the spark plug. I had to carefully increase the diameter of the socket's internal rubber gasket that grabs the
spark plug tip. I used a sharp drill bit a hint larger diameter and used high speed but pushed slowly until the plug fit.
Then I took pains to be sure all debris and any partly-loose rubber shards were out of the socket. When doing a
DC2-1 mod its easier to do this using your new spark plugs as a guide, and before you pull the exisiting plugs.

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Spark Plug Gap with Stock Coils and Stock Plugs:
The servce manual recommends 0.8 ~ 0.9mm gap.

The following gap data is properly stolen from respected posts:

Spark Plug Gap with Dyna DC2-1 Coils and Stock Plugs:
Stock motor w/exhaust and intake mods - .028 gap
HC Pistons w/exhaust and intake mods - .024 gap
108ci 110ci w/exhaust and intake mods - .028 gap
108ci 110ci HC Pistons w/exhaust and intake mods - .024 gap
These gap numbers are reportedly working in the street.

Spark Plug Gap with Dyna DC2-1 Coils and Iridium Plugs:
Some use 0.8 ~ 0.9mm because gap will not widen due to heat.
Some use 0.75 ~ 0.8mm gap successfully.
These plugs are hard to gap, use a tool that does not touch the iridium tip.
These gap numbers are reportedly working in the street.

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Stock Spark Plug Wires exiting the stock coils.
Length from coil body to contact tip inside boot:
(thanks to member Audio77)

Jug 1 RR 27.75-inch
Jug 1 RL 25.25-inch

Jug 2 FL 10.25-inch
Jug 2 FR 08.00-inch

When buying aftermarket spark plug wires for aftermarket coils
remember to adjust length to allow for having a boot at the coil
end and also to allow for the location you want to mount the coils.
When mounting the coils on a relocation plate allow some length to
set the relocation plate aside when servicing the top of the motor.

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Its possible to avoid having the steel spark plug threads doing damage to the aluminum motor threads by using new spark plug crush washers every time you remove the spark plugs. These are 12mm spark plug crush washers, like #P-678 (Spark plug, Spark plug wire, spark plug gap, spark plug cross reference and ignition wires at Sparkplugs.com) Example: Sparkplugs.com - Cross Reference Search Results . These washers are currently 12-cents each at this online seller and they mailed them affordably. I use these routinely. The first time you change crush washers, look closely at the crush washers that came on your spark plugs and orient the new washers the same way (usually with the smaller ID toward the spark plug). Its good to use a 3.5-inch (~90mm) length of 3/8" (9.5mm) fuel hose gently pressed over the spark plug tip as a starter-wrench to avoid stripping the aluminum threads on the motor. This length fits close enough under the frame rails and gives your fingers some grip space.

When using new crush washers the spark plugs can be tightened until the moment the crush washer bottoms-out then stop tightening. This advantage allows the use of a small dab of nickle-type anti-seize on spark plug threads. This can be important because new spark plugs (for example NGK) may have (silver/gold/clear) coated threads and that coating is designed to come loose when the spark plug is removed, avoiding galling damage. Others may have no thread coating even when new. When uncoated or partly-uncoated spark plugs are re-installed this thread protection is often damaged or absent, so galling can be a problem. Nickle-type anti-seize takes higher temperatures and prevents galling. I use a small dab and spread it across the threads with my fingers, a small amount goes a long way. Anti-seize will lubricate the plug as it goes into the hole, helping you to avoid cross-threading. But that same lubrication effect will fool your torque wrench so forget it. Just tighten the spark plug until you feel the crush washer land, then tighten to crush the crush washer and when it hits bottom just stop tightening.

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NOTE: over time newer information may become available. To notify of updates please PM ArizonaWarrior.
.
 

Attachments

#23 · (Edited by Moderator)
If You Lost Your Only Warrior Ignition Key.

(This info is dated and has not been re-verified, it's being left here because much of it is still helpful)AW 6/2021

Yamaha USA has no access to the factory records for key codes BUT they have contracted with one company as their official USA locksmith. I verified this information and telephone number today. If you cannot locate an automotive blind key cutter locally, then call Lock World in northern California, ask for Sean, telephone 415-386-3900. For those wanting to be sure of the relationship between Yamaha and this particular Lock World (which seems like a common name for a locksmith but dunno) here's the Yamaha dealer sign-in web page for keys (notice the phone number): [old link broken]

If you choose this procedure then you need to remove the ignition keyswitch (requiring drilling-out the security screws which have a break-off head at torque when installed - see the service manual) and mail it to this particular locksmith. Their current price is $55~$65 USD to cut a blind key to your ignition keyswitch using a Yamaha keyblank. As an option you can have your local Yamaha dealer remove it and they probably send it to the same place. Either way you will also need two Yamaha ignition switch security screws: 2002 thru 2009 Warriors use part #90109-08172-00.

For those wanting to hunt and hope for another solution, here's a code sequence list with key info (Warrior is in group 4th from the bottom): [old link broken] (I found that info difficult to make work for those I was trying to help with no keys).

Here's additional information that will be helpful.
  • If you can find a local expert to cut a blind key to match the ignition switch then it won't necessarily need to be removed. The new key's teeth need to be right-on or over a relatively short time it will wear out the ignition switch tumblers and ruin the keyswitch.
  • Because the seat and fuel locks have fewer tumblers than the ignition switch, a blind key cut to them will not turn the ignition switch so cut the blind key to fit the ignition keyswitch.
  • The one person I know who had a blind key cut in his driveway paid the hourly rate for two hours to get a key. It was about $200 USD including a couple spares. I'm sure that locksmith prices vary by region.
Each time this topic comes up its probably a good idea to remind everyone that buying a spare key or two right now while you are thinking about it can be a literal lifesaver when you least expect it.


NOTE: over time newer information may become available. To notify of updates please PM ArizonaWarrior.

Attached PDF: WARRIOR key blank on page 41 is Ilco part number X248 - YM63. Other references are the ATV Warrior 350, so be careful.
 

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