Notes from my Service Manual (all sources are trusted): [* denotes corrected or clarified]
Page 1-30 Instrument Panel: Make a note that the Odometer's memory is inside the Speedo Head.
Page 2-2 Fuel - Fuel Tank Capacity: Make a note 3.965 US Gallons (4.0 US Gallons including fuel in the lines).
Page 2-18 Bulbs (voltage/wattage): Make a note the Narva-brand H4 100/90 #P43T-38 works well in the Warrior headlight. Many of us have run it for years, wifey and I run this bulb in all three bikes with zero wiring issues. Its brighter, but its not HID.
Page 2-23 Drive Sprocket: fix error: not 72foot/lbs so make it read 110 foot/lbs. tightening torque (verified by Churchkey).
Page 2-24 Handlebar holder (lower): make a note * Yami TT-bar bolt size is M12x70mm zinc. Need * bushings and washers under risers.
Page 2-25 Rear wheel axle nut M18: fix error: not 110 Ft/Lbs so make it read 72 Ft/Lbs tightening torque (verified with Churchkey - he discovered this was confused at printer w/drive sprocket torque).
Page 2-25 Rear wheel sprocket and rear wheel drive hub: the 68ft/lbs shown is correct (verifed with Churchkey).
Page 2-26: add helpful info about the rear fender stay oem bolts from published topics:
* fender bolts = M8x1.25 25 mm long.
* frame bolts = M10x1.25 60 mm long.
Page 2-30 Oil Filters: note member 'best' choices are K&N and Purolator PureOne.
Page 3-5 Headlight and Meter Assemblies: Item 4 Tach Assy - side-mount bolts 5.8 ft/lbs torque, bolts are M6x25 1.00 pitch. Can use hardware store stainless with standard button head if you have (for example) a Boulevard Windshield mounted, and possibly even if its just stock with no (for example) windshield. The nice looking OEM bolts are special with a larger diameter button head.
These bolts seem to vibrate out, use Loctite Blue 243.
Page 3-9: The stock undertank airbox uses a K&N #YA1602-U. Same filter fits the Speedstar right side scoop, but not the stock right side airbox.
Page 3-27: use a good 6-point 17mm stubby wrench for the engine oil drain bolt. Same, or 17mm socket, for oil tank drain bolt.
Page 4-1 Front wheel and brake discs: Make a note item #7 front wheel axle is 22mm (make same note on Page 4-4 Checking the front wheel). Also note to remove front axle use 19mm allen, or the back-end of a spark plug socket is often 19mm.
Page 4-1 also note that beginning 2006 model year bike has radial brakes and some parts are not individually interchangable although the entire front ends with front brake systems can be swapped.
Page 4-11 Item #3 Rear fender bracket (left and right) bolt is button head Yami #92014-08025-00 (4 each) sorta special.
Page 4-89 Drive belt and drive sprocket: change torque for nut #6 to 110 ft/lbs. Make a note for Item #5 oem belt is 130-tooth
1-1/8" wide with 14mm pitch. Its built with same capacity for torque as standard 1.5" belts (which are thinner) according to Yami (who knows).
Page 4-91: change: Tighten: Drive sprocket nut (from 72 ft/lbs to 110 ft/lbs).
Page 7-55 Injectors: Make a note that member Sam Vallas (Vall345) once posted that he successfully used injectors for a 2000 Mitsubishi Starion 4cyl as hot rod replacements for his race Warrior (which has 9-second official runs). He's still around sometimes for questions.
These are the notes I have made in my service manual. See also the Model Year Differences topic in the General forum, and this Popular Mods topic and the rest of the Technical forum, for handy info. I hope this helps you, too. If there's an error in this I haven't seen or heard of it - ever - and everything I used myself I found was correct. * Plus we've beat it to death to wring out the last weeping possibly inaccuracies so from here on out you are on your own my friends! Be well.
Mike
Click Here: http://rswarrior.com/forums/p/115929/1007589.aspx#1007589 to JUMP past the next several posts that are already added into this post and marked with (*) above.
As of Feb 4th 2009 all items in this post, above, have been worked over, beat-up, and punched into shape and then clarified or corrected - so with luck (salt over shoulder) you can skip the several interim clarifying posts below - unless you simply need to grin at us guys working this out! Use the JUMP above. The real Topic data starts again with posts dated after Feb 4 2009 - well - unless of course someone notices something we all missed and gets their clock spring all wound up again. But it won't be me!
