Preliminary data on woodruff key failures
Posted November 25, 2003 - 10:34 AM
Yamaha Motor Corporation USA
Customer Relations Department
P.O. Box 6555
Cypress, California 90630
On (date) I purchased in good faith a 2003, WR450F from your dealer xxxx, located in yyyyyy. Since that purchase dozens of Yamaha 2003, WR450F’s have reported failures due to a design flaw in the woodruff key starter system. The failure rate of these bikes has been calculated at over thirty percent (30%) within nine months from date of purchase.
Yamaha Engineering has recognized the engineering design flaw as evidenced by their complete redesign of the woodruff key starter system for the 2004 model. A retrofit to the 2004 design from the 2003 model is estimated to cost including labor around $700 list price.
Yamaha issued a “Technical Bulletin” number M2003-007, informing dealers to put the loctite 648 glue on the failed 2003 models crankshaft. Many who have had this fix have had repeat failures. This is unacceptable.
Please inform me when I should bring my WR450F to my dealer for them to do the woodruff key starter system upgrade to the 2004 model at Yamaha’s expense. I expect this will be handled in an expedited manner.
Thank you for your help. I will be awaiting your response.
cc: My dealer – his address
Posted January 09, 2004 - 10:52 PM
Jim Owen's number is 1-800-962-7926 but you MUST WRITE a letter.
Posted January 11, 2004 - 08:40 PM
Posted January 13, 2004 - 10:43 AM
Posted January 15, 2004 - 05:31 PM
Posted January 16, 2004 - 05:02 PM
Posted January 21, 2004 - 08:33 PM
Posted February 02, 2004 - 03:34 AM
FWIW my 03 has around 8 races on it and well over 2000 miles with no problems.
I was in the same frame of mind as you. 2600 miles and no problems. One year to the day I bought it and WHAMMO! Sheared the key. I have been looking long and hard at the 04 upgrade parts and now I'm most likely going to do that.
Posted February 02, 2004 - 03:45 AM
I would love to help you out by hosting the correspondance on my site or by providing a direct link to your site with the information.
Posted February 11, 2004 - 06:55 PM
<ul type="square"> Law_boy and wjc2003 [/list]
Posted March 18, 2004 - 05:42 PM
Posted March 29, 2004 - 02:27 AM
i would like to do the same for rocker arm failure in husabergs 2002 onwards.
Posted June 25, 2004 - 02:54 PM