The Yamaha Road Star Warrior Forum

Here you go Tom and Mike. I changed the angle of the clutch splined lever so I could get more adjustment up at the bars.

I'm afraid Tom, it's a wrist breakage for you with the strength of mine too.............

Gav:

Here you go Tom and Mike. I changed the angle of the clutch splined lever

i've got only one question to ask about those pics....are those 'real' scottish pebbles ya parked on!!?...or di you airbrush them in!!!...gawf

i'm not getting this clutch lever thing...you see.. if it's real easy to pull back when ya want to change gear...or just because it's just so easy to pull back!!...why wouldn't ya choose my clutch lever set up!?...why would ya want a wrist breaker for a clutch lever!? ...lol...surley [italian hand gesture!!]..mine is the way to go!!?..or are you 2 beefing up for some arm wrestling comp i don't jnow about!!....over....

tomba:

i've got only one question to ask about those pics....are those 'real' scottish pebbles ya parked on!!?...or di you airbrush them in!!!...gawf

the pebbles are called 22mm gravel, from a quarry 20 miles along the road. Yep Tom......Scottish stone..I got 15 ton dumped a few years ago.

Probably the reason for the tough clutch is......we're just masochists. [:'(] ....tennis elbow, frozen shoulder...all that kinda stuff. "no pain, no gain".

Just foolin'.....

 I don't know why Tom, it's just what i'm used to.

OK guys, here's what I've found on the clutch case lever's torsion spring from the Star website.  The spring is Part# 90508-16007-00 for all model years 2002-2009 indicating no intended change in the part.  So Yamaha probably had a vendor change and some bikes got a larger-diameter spring wire but there doesn't seem to be a way to document that by model year.

Item #6 in this disassembled view:

Jarv, thanks for the info.  That made this a lot easier!

From the pic Tom posted (copy below) it appears your clutch push lever at the case (Item #5 in the disassembled view above) is adjusted at a different angle than stock.  Of course this could have been changed over the years to accomodate the 31.3mm distance specified on Page 5-69 of the service manual (needed to maximze cabble travel).   

Gav posted above that he changed the lever's angle a bit to get more cable travel dustance for better adjustment at the handlebar levers.  I've seen a number of guys change that lever angle for various reasons and it seems to me to make the clutch lever feel heavier due to increased angle, but that isn't documented.

All this being said, Jarv it seems yours came from the factory that way and it works just fine so leaving it where it is would be my choice if it were my bike!

I can't figure a way to add the angle of this lever to the chart maybe for now lets leave the data here in these posts and see what develops in the future, then we can add it to the chart when the big picture comes clear.

This is great info to have!  Thanks guys!

Some UK bikes have the LED tail/brake light assembly but have been dealer-modified to UK laws by removing the front running light bulbs by installing single-filament front bulbs and unplugging the blue wire connecting the then-absent second filament for the running lights.  These bikes have the stock rear license plate filament bulb which also connects to the same circuit.  Its possible these bikes may develop the click-of-death if the license plate filament bulb is removed (or changed to LED) since this licence plate filament bulb may be the only power-drain for the ECU on shut-down.  This is undocumented because the UK dealers are tasked with doing the modifications required by UK laws in cases where an international bike is imported. 

On a separate semi-related topic, since this is the only spot handy for this information to be included, the international Denso turn signal flasher remains the same in the UK bikes including the 'Grey Imports'.

I've seen some guys install a straight clutch cable when they install drag bars but all the stock clutch cables 2002-2009 appear to have the 45-degree bend showing on the Yami/Star website.  I wonder if this referenced '03 bike with a straight clutch cable is an anomoly?

Gav:

Spied Jarvs clutch today. The inside of his cable is definitely thicker than an 03, his is an 06. His cable has a 45 degree bend at the bars, 03 is straight. Both 03 & 06 springs for the spindle lever down at the clutch casing are the same thickness Tom.

 I'd say (have to be very careful how I word this) the strength of pull on both levers are about the same. Phew....

OOOps Mike, my mistake. I remember now. When I fitted the 40" wide drag bars early last year, I straightened the bend at the top with a little heat. It's an age thing ????  All the year cables will have the bend. .......Jarv's cable core is thicker though.

LED tail light ?.... With 03's for UK and possibly most of Europe having the double filament single bulb, does this mean the click of death won't happen if we do away with the separate number plate light ??

It appears its just the UK bikes that get an incandescent tail/brake light mod.  It seems like some get it, and some don't, so its like the "Grey Imports" are mixed.  Anyway, in the UK, models that happen to retain the LED rear tail/brake light would probably get COD if the license plate light were removed because the license plate light would be the only incandescent on the circuit, being that the front running lights don't exist on the UK Grey Import bikes.   I agree with you, if the bike has the UK incandescent tail/brake lights then the tail light - which is on the running light circuit - would prevent COD.

Thanks for the heads-up on the cable - its one less item to keep an eye out for over future months!

Gav:

OOOps Mike, my mistake. I remember now. When I fitted the 40" wide drag bars early last year, I straightened the bend at the top with a little heat. It's an age thing ????  All the year cables will have the bend. .......Jarv's cable core is thicker though.

LED tail light ?.... With 03's for UK and possibly most of Europe having the double filament single bulb, does this mean the click of death won't happen if we do away with the separate number plate light ??  [I think yes you are correct]

The September 1st 2009 Update has been posted.

Its a couple days early - hope nobody minds too much.

JUMP to Page 1: http://rswarrior.com/forums/t/16547.aspx

The 2010 Warrior and 2010 Midnight Warrior have been added.  Lucky Canadians! 

A new tidbit has come to light.  It would be helpful if several members in the USA/CAN, in the EU, and in AUS would take a minute to remove one front and one rear stock turn signal bulb and report what bulb is provided stock.  Let us know if you have clear lenses and amber bulbs, or amber lenses and clear bulbs.  Also, what model year you have.

It looks like a change took place during the 2004 model year but it may not have included all Warrior's worldwide, so some 2004's could be 1156/1157 and others could be the newer bulbs.  The 2004 model year could have been a change-over year.

Mine is a USA 2003 model, I have 1156/1157 bulbs.  Mine were stock amber lenses with clear bulbs, but I modernized mine with clear lenses and amber bulbs.  (yes I tried the chrome/amber and they were not bright enough for me)

Here's the info as it might look in Model Year Differences, once we figure things out:

Light Bulbs - Signals - 02-04: Front 1157 (clear)   Rear 1156 (clear).  (verify your '04)
Light Bulbs - Signals - 05-10: Front BAZ15D-3 (amber)  Rear PY21W (amber). (verify your '04)

Here's what the bulbs look like (tell us if you have something else okay?):

BAZ15D-3 (front):

PY21W (rear):

1156 Bulb (single filament):

1157 Bulb (dual filament):

Arizona Warrior:

It would be helpful if several members in the USA/CAN, in the EU, and in AUS would take a minute to remove one

For 2003 UK.

Single filament, clear glass, 21w bulb for both front and rear Mike.

Same as your 1156 bulb.

Gav.

nice one gav!!......never did undersatnd the 12v 23/8w for the front and the 12v 23w for the rear in the handbook!!?...thought i was going crazy

just told mike... the orange bulbs are marked PY 21w 12v and the clear bulbs are marked P 21w 12v for the uk market