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2002-2003 Yamaha Road Star Maintenance Schedule and Service Intervals

2002-2003 Yamaha Road Star- Stock Image

This is the maintenance schedule and associated service intervals for the 2002-2003 Yamaha Road Star

2002-2003 Yamaha Road Star Maintenance Schedule

Below is the maintenance schedule for the 2002-2003 Yamaha Road Star

The maintenance for the 2002-2003 Yamaha Road Star is broken into two sections: periodic maintenance for emission control systems, and general maintenance and lubrication.

Periodic Maintenance Emission Control System

No.ItemRemarks 600 mi (1,000 km) or 1 month4,000 mi (7,000 km) or 6 months8,000 mi (13,000 km) or 12 months12,000 mi (19,000 km) or 18 months16000 mi (25,000 km) or 24 months20000 mi (31,000 km) or 30 months
1*Valve clearance• Check valve clearance when engine is cold.
• Adjust if necessary.
Every 16,000 mi (25,000 km)
2Spark plug• Check condition.
• Adjust gap and clean.
• Replace at 8,000 mi (13,000 km) or 12 months and thereafter every 8,000 mi (13,000 km) or 12 months.
ReplaceReplace
3*Crankcase ventilation system• Check ventilation hose for cracks or damage.
• Replace if necessary.
4*Fuel line• Check fuel hoses for cracks or damage.
• Replace if necessary.
5*Fuel filter• Replace initial 20,000 mi (31,000 km) or 30 months and thereafter every 20,000 mi (31,000 km) or 30 months.Replace
6*Exhaust system• Check for leakage.
• Retighten if necessary.
• Replace gasket(s) if necessary.
7*Idle speed• Check and adjust engine idle speed.
• Adjust cable free play.
8*Evaporative emission control system (For California only)• Check control system for damage.
• Replace if necessary.

* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.

General Maintenance and Lubrication Chart

No.ItemRemarksType 600 mi (1,000 km) or 1 month4,000 mi (7,000 km) or 6 months8,000 mi (13,000 km) or 12 months12,000 mi (19,000 km) or 18 months16000 mi (25,000 km) or 24 months20000 mi (31,000 km) or 30 months
1Engine oil• ReplaceSee page 8-1.
2*Oil filter• Replace.
3*Air filter (See NOTE on page 6-6.)• Clean with compressed air.
• Replace if necessary.
4*Front brake•Check operation and fluid leakage. (See NOTE on page 6-6.)
• Correct if necessary.
Replace brake fluid
5*Rear brake•Check operation anf fluid leakage. (See NOTE on page 6-6.)
• Correct if necessary.
Replace brake fluid
6*Clutch• Check operation and free play.
• Correct if necessary.
7*Transfer case oil• Check vehicle for leakage.
• Replace every 16,000 mi (25,000 km) or 24 months.
SAE 80 API “GL-4”
hypoid gear oil
ReplaceCheckReplace
8*Control cable• Apply chain lube thoroughly.Yamaha chain and cable lube or SAE 10W30 motor oil
9*Rear arm pivot bearing• Check bearing assembly for looseness.
• Moderately repack every 16,000 mi (25,000 km) or 24 months.
Medium weight wheel bearing grease.Repack
10Brake/Clutch lever pivot shaft• Apply chain lube lightly.Yamaha chain and cable lube or SAE 10W30 motor oil
11Brake pedal and shift pedal shaft• Lubricate
• Apply chain lube lightly.
Yamaha chain and cable lube or SAE 10W30 motor oil
12*Sidestand pivot• Check operation and lubricate.
• Apply chain lube lightly.
Yamaha chain and cable lube or SAE 10W30 motor oil
13*Sidestand switch• Check and clean or replace if necessary.
14*Front fork•Check operation and leakage.
15*Steering bearings• Check bearing assembly for looseness.
• Moderately repack every 16,000 mi (25,000 km) or 24 months.
Lithium soap base greaseRepack
16*Wheel bearings• Check bearings for smooth rotation.
17*Rear suspension link pivots• Apply grease lightly.Molybdenum disulfide grease
18*Drive belt• Check for belt tension
• Adjust if necessary.
Every 2,500 mi (4,000 km)

* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.

Note:
● From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.

Note:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake system
– When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid level
regularly and fill as required.
– Replace the oil seals on the inner parts of the master cylinder and caliper every two years.
– Replace the brake hoses every four years, or if cracked or damaged.

About the 2002-2003 Yamaha Road Star

The 2002 Road Star is a purist cruiser, powered by a mighty 1602cc v-twin, with an push rod architecture and air-cooled, mated to a belt-driven 5-speed wide ration transmission for a broad power deployment in various scenarios. There are plenty of classic elements about the 2002 Road Star, from the leather saddlebags to the rich chrome accents, the comfy riding position and the bevy of optional parts and accessories to customize your ride the way you want.

Manual for the 2002-2003 Yamaha Road Star

2002-2003 Yamaha Road Star Maintenance schedule screenshot from manual.

The above information was gleaned from the owner’s manual for the 2002-2003 Yamaha Road Star.

You can download it from Yamaha’s website here.

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