Preliminary data on woodruff key failures

234 replies to this topic
  • Poway Rider

Posted March 30, 2003 - 07:25 PM

Bought SN 2240 on Thursday (3/27), had mod done on Friday at San Diego area dealer and rode 40 miles today in Socal desert. Great bike and no problems so far.

  • glenm

Posted March 31, 2003 - 08:11 AM

I called my dealer in regards to the bulletin you posted and asked him about it. I referred to the numbers you posted also. He said he looked and the only thing he has on his computer (via internet) is about the new torque value. Got anything I can tell him to get him going in the right direction? He sells a lot of bikes and has quite a few wrenches working in there so I think we must just be looking in the wrong place.

  • APhantomduck

Posted March 31, 2003 - 08:30 AM


I too didn't find the Service Bulletin on the Yamaha web site for the dealers. That is why I had to correct my previous post, as I received it in the mail on Saturday. Ask the dealer you are working with to call their RTA and have them fax a copy to them.

  • glenm

Posted March 31, 2003 - 08:49 AM

Dealer called me back about 10 minutes after I posted. Said he just got it in the mail. Will do fix as soon as I drop bike off. Thanks for the ACURATE information!

  • yamaha.dude

Posted March 31, 2003 - 10:43 AM

I just shooting the breeze with my dealer here in Australia... as a point of interest, I asked and he said they have a service bulletin for the flywheel nut... didn't go into details, but the word is out there now, so no dealer should be ignorant of this matter...

Phantom Duck, if you can e-mail me the PDF, I will host and post it here...



  • xr600r

Posted March 31, 2003 - 12:13 PM

the service manager at my dealer just got the tsb as we were talking on the phone goes in tomorrow.
hopefully this whole problem will soon be history. :)

  • Rokatt88

Posted March 31, 2003 - 01:44 PM

Hey Poway Rider! How was riding with ThumpDaddy650? I'm so glad to hear that your dealer was savy to the problem and already did the mod for you. Me and ThumpDaddy (& Rich too) will be keeping an eye out for you Brother! Thump On and welcome to the Family! :) It doesn't matter what color your bike is, just as long as you gas it! We are gonna have FUN! :D

  • Poway Rider

Posted April 01, 2003 - 07:59 AM

Hey Rokatt88, sorry to break ranks and go with a blue bike! As Rich will tell you, I was really torn between one of the Hondas (450 or 650), a KTM 525 or the WR450. I found out about the potential Woodruff key issue before I made my purchase and was willing to take the risk. I called Yamaha directly, talked to four San Diego area dealers and decided to buy it anyhow. I was pleased with the ride and felt like it rode and handled somewhere in between the Honda CRF450 and the XR650. ThumpDaddy650 did have to rescue me on one very steep climb. He's a great guy. I hope to see you and the Posse out there some time soon! Regards, Poway Rider

  • Rokatt88

Posted April 01, 2003 - 11:08 AM

Hey PR, Don't be sorry for breaking ranks! We need variety in our hood, Dawg! :) When it's time to replace Der Pig, I'm gonna get the best bike for me that I can. I've been following the WR450 forum to keep up with the latest steed. The XR is a great bike for what T-Diddy & I do. Rich loves his CRF450. A year from now the choices are gonna be sweet! :D Is this a great country or what? :D

  • mntmayfly

Posted April 10, 2003 - 03:59 AM

boy o boy did this thread die out or what? i guess yamaha is taking care of business? my bike is at the dealer, but no parts to fix! its been there a week. :)

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  • Poway Rider

Posted April 13, 2003 - 04:51 PM

190 miles and no failure... :)

  • Jonesy920

Posted April 14, 2003 - 05:01 PM

I ordered the parts 3 weeks ago when we got wind it was coming. :)..The gasket is in but no Key....Hope mine is in good condition, if so I'll have an extra.


Posted April 16, 2003 - 05:22 PM

Excelnt job describing this to everyone. Everyone should remember this has acctually more POWER than the YZF but it has a heaver flywheel. Second thing is when are 99% of these breaking? It is happening on starting. Before you kicked your ass of to hopefully get enough power in your foor to turn that big trash can piston over, when she kicked back at you it tries to eject you from the sadle. Now you push a button spinning it allot faster than your kick, so when it barks back at you something MUST give. If this tapper is off .1 degree you will get problems. :)
Engineering 101 Every action has an equal and opposite reaction.
Pick up my 03 WR450F tomarrow. :D :D :D

  • CraigW

Posted May 25, 2003 - 08:48 PM

I'm about to pick my 450 up this week.
A friend collected his on Friday, and true enough his key sheared on Sunday.

Our engine numbers are in the 9000's, I would have thought that by now the problem has been solved at factory level, prior to despatch.

Is the lapping of the flywheel the solution?
What worries me is a number of people continue to experience the problem after the mod.

I ride a fair amount of time by myself. I could be up to 30miles from home at any point. If i have a major failure I'm in big trouble. Do I buy this bike or not????? :)

  • CraigW

Posted May 26, 2003 - 01:08 AM

Point of correction.

My friends motor that failed is number 516, apparantly his was from an earlier shipment.

Mine is number 9015.
Are the later manufactured motors fault free?

  • yimmyhauler

Posted May 26, 2003 - 03:12 PM

Well It finally happened to me today ... woodruf sheared. I don't think it was my problem but the nut backed off. (maby it was mine) I didnt check it ... it has been running fine till now ser#1295 :)

  • Machster

Posted May 27, 2003 - 05:20 AM

As far as I have heard, there really hasn't been any more trouble since the first fiasco. If there was, you would have seen it in here..Guaranteed!. The bike is get down there and pick it up!

  • Aussie_Bigman

Posted May 27, 2003 - 08:18 PM

Hey David,

Did you happen to ever get that Service Bulletin? I wouldn't mind a copy if available, I'm ordering my WR this weekend and want them to do the checks before I take delivery, if possible.


  • CraigW

Posted May 27, 2003 - 08:27 PM

Thanks for the re-assurance Machster.

I :snore:'ll sleep easier tonight

  • yimmyhauler

Posted May 27, 2003 - 08:39 PM

Well I went to the dealer to find out how long it would take to repair the key problem and he said 2 weeks ... key not in stock. Not liking the idea of this I proceded to PEP boys (remembering that they sold woodruf keys) and picked up a sae version that was the same length and shape. I was a little thicker though. After a bit of time on a piece of emery cloth it fit quite well (15 min max). The lapping, locktite (red), assembly and oil went as planned. I started right up and ran great for 3 minutes and died. The battery was dead after another 20 minutes of trying to get it to start (good spark ect.). Then I finally realised what that selector on the bottom of the gas tank did. What a day! :)


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