BULLETIN TECHNIQUE \ TECHNICAL BULLETIN

ALL MOTORCYCLE DEALERS

1991-1995 XV750/1100 STARTER MODIFICATION
M95-033

OCTOBER 1995

Page 1 of 4

INTRODUCTION
PROBLEM
Some 1 991 ~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.
ACTION SUMMARY
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.

BULLETIN TECHNIQUE \ TECHNICAL BULLETIN

Model
XV750B
XV750D
XV750E
XV750E
XV750F
XV750G
XV1100B
XV1100D
XV1100E
XV1100E
XV1100F
XV1100G

Serial Number Range

3CN-003101 ~003201
3CN-004101 ~004254
3CN-005101 ~005110
3CN-005111 ~005260
3CN-006101 ~006290
3CN-007101 ~007200
1TF-013101~013400
1TF-015101~015700
1TF-016101~016150
1TF-016151~016700
1TF-018101~018790
1TF-021101~021500

Parts Group
A B,C,D
A B,C,D
A B,C,D
A, D
A, D
A, D
A B,C,D
A B,C,D
A,C, D
A, D
A, D
A, D

PARTS INFORMATION
Part Group
A
B
C
D

Part Number
3EG-15451-00-00
5A8-15542-01-00
90387-0801M-00
3LP-15570-00-00
3LP-W1 551-00-00*

Description
Crankcase
Collar#2 Cover Gasket
Spring Collar
Starter Clutch
Starter Gear Set

Quantity
1
1
2
1
1

Dealer Net
$11.78
$2.26
$ 0.45
$ 66.04
$ 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
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
l eve r 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.

M95-033

Page 2 of 4

OCTOBER 1995

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 w i n d o w 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.

M95-033

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OCTOBER 1995

M95-033

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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

MOTOR CANADA LTD.

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