Vehicle Segment:
Cruiser Motorcycle
Target Audience:
Owners and independent repair shops seeking detailed factory-level service information.
Competitors:
Harley-Davidson Softail models, Indian Chief, other large-displacement cruiser motorcycles from Japanese manufacturers.
Vehicle Appeal:
Stylish cruiser design, powerful V-twin engine, comfortable riding position, customization potential.
Manual Value Proposition:
Provides dealership-level repair and maintenance knowledge, enabling DIY enthusiasts and professionals to service the motorcycle accurately and efficiently.
Vehicle Scope:
2004 Yamaha Road Star Warrior, 2004 Yamaha Road Star Midnight
Estimated Page Count:
Approximately 400-600 pages (typical for this class of manual)
Type:
Factory Authorized Service Manual / Repair Manual
Format:
Digital (likely PDF), potentially Print
Engine:
Complete engine overhaul, including disassembly, inspection, assembly, piston and cylinder specifications, valve timing, lubrication system, cooling system (air-cooled), fuel system (carburetor tuning/adjustment).
Transmission:
Clutch operation and adjustment, gear shifting mechanism, transmission disassembly and assembly, transmission oil specifications and change procedures.
Electrical System:
Wiring diagrams, ignition system troubleshooting, charging system (stator, regulator/rectifier), lighting system, starting system (starter motor, battery), instrumentation, fuses and relays.
Fuel System:
Carburetor identification and overhaul, fuel tank maintenance, fuel lines, fuel filters.
Braking System:
Front and rear brake caliper inspection, hydraulic system bleeding, brake pad replacement, brake fluid specifications, master cylinder overhaul.
Suspension:
Front fork inspection, seal replacement, oil level and type, rear shock absorber adjustment and inspection, swingarm and linkage maintenance.
Chassis And Frame:
Frame inspection for damage, steering head bearing maintenance, wheel bearing inspection and replacement, tire specifications and pressure.
Bodywork And Trim:
Panel removal and installation, fairing components, seat removal, fender maintenance.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment and lubrication, brake fluid checks, tire pressure checks, general inspection.
Troubleshooting:
Diagnostic charts for common problems, symptom-based troubleshooting guides for engine, electrical, and mechanical issues.
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly, including torque specifications.
Special Tools:
Identification and usage of specialized tools required for specific repair or maintenance tasks.
Depth Of Information:
Comprehensive, from basic adjustments to complete engine and transmission rebuilds, including detailed diagnostic procedures.
Engine Type:
Air-cooled, 4-stroke, V-twin
Displacement:
1600cc (98 cubic inches)
Bore X Stroke:
97.0 mm x 109.6 mm (3.82 in x 4.31 in)
Valve Train:
SOHC, 4 valves per cylinder (pushrod actuated)
Horsepower:
Approximately 80-85 HP (est.)
Torque:
Approximately 100-105 lb-ft (est.)
Fuel Delivery:
Dual Mikuni 39mm constant velocity carburetors
Fuel Type:
Unleaded gasoline, minimum 90 octane
Oil Type:
Yamalube 4 (or equivalent SAE 20W-40 API SG or higher motorcycle oil)
Cooling Method:
Forced air cooling
Overall Length:
Approx. 96.1 inches (2440 mm)
Overall Width:
Approx. 37.4 inches (950 mm)
Overall Height:
Approx. 45.3 inches (1150 mm)
Dry Weight:
Approx. 644 lbs (292 kg)
Wet Weight:
Approx. 692 lbs (314 kg)
Fuel Capacity:
4.0 gallons (15 Liters)
Front Tire Size:
130/70R18M/C 63H
Rear Tire Size:
190/50ZR17M/C 73W
Front Brake:
Dual 298mm hydraulic disc
Rear Brake:
282mm hydraulic disc
Wheelbase:
Approx. 66.3 inches (1685 mm)
Ground Clearance:
Approx. 5.7 inches (145 mm)
Instrumentation:
Analog speedometer, tachometer, digital odometer, trip meters, fuel gauge, clock, warning lights (oil pressure, neutral, turn signals, high beam).
ABS:
Anti-lock Braking System (ABS) was an optional feature on some 2004 Road Star Warrior models, particularly the Midnight edition. The manual would cover its specific diagnostics if equipped.
Lighting System:
Halogen headlight, LED tail light, incandescent turn signals.
First Service:
1000 km (600 miles) or 3 months (whichever comes first): Oil change, filter replacement, chain adjustment, general inspection.
Subsequent Service:
Every 6000 km (4000 miles) or 6 months: Includes first service items plus spark plug inspection/replacement, air filter check, brake and clutch fluid check, valve clearance inspection.
Major Service:
Every 24,000 km (15,000 miles): Includes all routine service items plus transmission oil change, fuel system cleaning/inspection, and more detailed component checks.
Engine Oil Capacity:
3.7 Liters (3.9 US qt) with oil filter change.
Transmission Oil Capacity:
0.5 Liters (0.53 US qt)
Brake Fluid:
DOT 4 (FMVSS No. 116 DOT 4) for both front and rear brake systems.
Common Wear Items:
Clutch plates, brake pads, tires, drive belt, and valve cover gaskets are common wear items subject to regular inspection and replacement.
Potential Issues:
While generally reliable, some owners report occasional issues with carburetor synchronization, charging system components (regulator/rectifier), and potential starter drive gear wear over time. Regular maintenance as per the manual is crucial.
Brand Focus:
Yamaha Motor Company is a Japanese manufacturer known for its diverse product range, including motorcycles, musical instruments, and power sports equipment. In motorcycles, Yamaha is renowned for innovation, performance, and reliability.
Road Star Lineage:
The Road Star line was introduced in the late 1990s as Yamaha's entry into the large-displacement V-twin cruiser market, competing directly with American manufacturers. The Warrior variant, introduced in 2002, offered a sportier, more aggressive take on the classic cruiser formula with performance upgrades.
Production Period:
The Yamaha Road Star Warrior was produced from 2002 to 2009. The Midnight edition was a styling package offered within specific model years.
