RoadVitals

2003 Yamaha Road Star Warrior Recalls

Safety recall campaigns filed with NHTSA that cover this model year

Data refreshed

Recalls apply to specific vehicles, not to every vehicle of a model year. Check your VIN with NHTSA or your manufacturer's dealer to confirm whether a recall affects your vehicle.

Check a VIN on NHTSA.gov
Recall campaignsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
1
Newest Aug 26, 2003
Carrying an NHTSA advisoryCampaigns where NHTSA told owners not to drive the vehicle, or to park it outside, until the repair is done.
0
Open investigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
0
1 investigation on file

Recall campaigns

1 campaign cover this model year — what the defect is, what it could cause, and what the remedy is

03V309000

POWER TRAIN:MANUAL TRANSMISSION

Aug 26, 2003
29,139 units potentially affected
The defect: 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.
The risk: 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.
The 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.
YAMAHA MOTOR CORPORATION, USAManufacturer number M2004-001View on NHTSA.gov

What a recall is

Safety recall
A safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
Safety investigation
NHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
Manufacturer communication
Manufacturers file copies of the bulletins they send to dealers with NHTSA. These often describe diagnostic or repair procedures for a known condition. They are not recalls: repairs described in a bulletin are usually only free if the vehicle is still under warranty or the manufacturer has extended coverage.

Safety investigations

NHTSA inquiries naming this vehicle. An investigation is not a finding of a defect, and it is not a recall.

PE03038ClosedPreliminary Evaluation

UNINTENDED REAR WHEEL LOCKUP

Opened Aug 11, 2003
Closed Nov 6, 2003

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

POWER TRAIN:MANUAL TRANSMISSIONLed to recall 03V309000

Elsewhere on this vehicle

Data sources

Data on this page last refreshed .