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ALL MOTORCYCLE DEALERS 1991-1995 XV750/1100 STARTER MODIFICATION

   

OCTOBER1995

 

M95-033

Page 1 of 4

INTRODUCTION

     

PROBLEM

     

Some 1991 ~1995 XV750/1100 motorcycles may experience erratic electric starter engagement. The starter clutch may slip resulting in insufficient torque to rotate the engine. This also causes the starter idler gear#2 not properly engaging into the flywheel and damaging the gear teeth.

REMEDY

     

In the last two model years the factory has made running production changes to the starter system. If required and according to the model and serial number of the unit, the following components may need to be replaced or installed - starter clutch, starter gear set, collar #2, and new starter solenoid lever spring collars. Refer to the table on the following page to see what is required for each particular model.

NOTE: When using the updated starter gear set, you discard the starter compression spring.

   

ACTIONSUMMARY

     

Should your customer encounter this erratic starting engagement problem on their motorcycle, perform this modification.

AFFECTEDUNITS

     

XV750B~G (1991 ~95) XV1100B~G (1991 ~95)

3CN-003101 ~007200 1TF-013101 ~ 021500

   

NOTE: Check the engine serial number pedestal for a punch mark, which would indicate that the modification has already

been completed.

     

Model

Serial Number Range

 

Parts Group

   

XV750B

3CN-003101 ~003201

 

A

B,C,D

   

XV750D

3CN-004101 ~004254

 

A

B,C,D

   

XV750E

3CN-005101 ~005110

 

A

B,C,D

   

XV750E

3CN-005111 ~005260

 

A,

D

   

XV750F

3CN-006101 ~006290

 

A,

D

   

XV750G

3CN-007101 ~007200

 

A,

D

   

XV1100B

1TF-013101~013400

 

A

B,C,D

   

XV1100D

1TF-015101~015700

 

A

B,C,D

   

XV1100E

1TF-016101~016150

 

A,C, D

   

XV1100E

1TF-016151~016700

 

A,

D

   

XV1100F

1TF-018101~018790

 

A,

D

   

XV1100G

1TF-021101~021500

 

A,

D

   

PARTS INFORMATION

           

Part Group

Part Number

Description

 

Quantity

Dealer Net

A

3EG-15451-00-00

Crankcase

   

1

 

$11.78

B

5A8-15542-01-00

Collar#2

Cover Gasket

 

1

 

$2.26

 

90387-0801M-00

Spring Collar

 

2

$

0.45

C

3LP-15570-00-00

Starter Clutch

 

1

$

66.04

D

3LP-W1 551-00-00*

Starter Gear Set

 

1

$

36.80

This includes the new starter idler gear#2 and the starter wheel. They must be changed as a set since they will not interchange with the older parts. The compression spring (p/n 90501-15636) is not to be used with the 3LP-W1551-00 starter gear set.

Order the required parts for the different units based on the above table.

   

OCTOBER 1995

M95-033

Page 2 of 4

SERVICE PROCEDURE

1. Use the procedures that are applicable to the parts that need replacing on the unit you are servicing.

2. Place the motorcycle on a secure surface and on the centrestand.

3. Remove the left-hand footrest bracket and gear shift linkage.

4. Drain the engine oil.

5. Remove the starter shifter cover, pivot pin (1) and stater solenoid lever (2).

6. Remove the screw (3) and collar (4) which attach to the starter drive lever shaft (5).

7. Remove the screws that hold the left-hand crankcase cover and then the cover. (Watch that the shift shaft washer doesn't stick to the crankcase cover and later fall and become lost.)

8. Remove the starter idler gear shaft assembly, discard the compression spring (8), replace the idler gear #2 (7) and the starter wheel (9) with the parts supplied in the kit 3LP-W1551-00.

9. Remove the circlip from the end of the starter motor shaft and pull off

the starter clutch (1 0). 1 0. Install the new starter clutch 3LP-15570-00 (1 0) and the circlip onto the starter motor shaft. 11. Install the starter idler gear shaft assembly with the drive lever shaft (5) engaged to the idler gear # (7) in the left crankcase.

OCTOBER1995

M95-033

Page 3 of 4

12. Install the left-hand crankcase cover with a new gasket.

13. Assemble the new starter shifter collar (4) on the starter drive lever (5). Apply Loctite® to the threads of the shifter collar bolt (3) and torque it to 10 Nm.

14. Fit the starter shift lever (2) with the starter shift lever spring, and the new pivot pin collars 90387-0801M-00 (11) in place for the pivot pin. Apply Loctite® to the threads of the pivot pin (1) and torque the pin to 10 Nn.

15. Install the starter shifter cover.

16. Install the footpeg assembly and shift linkage.

17. Fill the crankcase with oil so that the level is halfway up the oil level check window when the motorcycle is held vertical.

18. Punch a dot in the lower right hand corner of the engine serial number pedestal as per the diagram.

OCTOBER1995

M95-033

Page 4 of 4

WARRANTY PROCEDURES

Submit warranty requests as per normal policy.

List Trouble Code:

Labour Allowance:

M533

1.0 hours per unit

1. Any unit in the affected serial number range may be repaired bythis bulletin regardless of warranty status.

2. Parts from Groups "A" &"D" are common to all units and have been programmed when you enter the warranty request.

3. if the unit you are servicing requires parts from Groups "B" &"C", enter the additional part numbers starting on line 11 of the parts entry screen of the WSBE transaction.

4. Multiple serial numbers (up to 9) for the same model code and colour code may be listed in the comments section of the WSBE transaction of the DEYS system or on single requests.

YAMAHA

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