LOL Doc. I have been having those days everyday lately. Hope you have been well and as always, thanks for being the key player here!

Am I missing something here...???
Abnormal wear causes the circlip to break
certain transmission components may not meet Yamaha

quality-control standards, which could allow abnormal wear that eventually

results in a broken retaining circlip. If the circlip breaks, the transmission

I am assuming they are replacing a gear,collar, and washer any of which could show signs of abnormal wear and it is good practice to replace circlips once they have been sprung

And DOC you said
you certainly do not use automobile or motorcyle engine oil in your transmission.
Which was my first instinct and ...since they do...that is why why this whole discussion started in the first place

The right oil will slow wear of transmission gears and components and allow smoother shifting as well

and in light of the fact... stated by Yamaha ...abnormal wear could lead to circlip breakage .. transmission lock up ..it is an area worth our attention<br><br>Post edited by: Pop Rivet, at: 2006/10/17 00:28

Pop Rivet,

The original trans recal goes back to early 2004. If you're interested then go on the R* Riders Forum site. There is a Recal folder on the Forum which contains hunderds of posts related to this recall. Have fun

There are various theories regarding transmission failure but I don't remember them being related to gear wear. The best theory was related to a circlip on the main axle.

There is a circlip and adjacent washer on the main axle which keeps the pinion gears in place. It was suggested that either the circlip breaks on it's own or the washer and circlip were put on in reverse order resulting in circlip wearing out and breaking.

In both situations this results in gear movement and damage to the gears. In a worse case the gears break up and voila ...

Doc

I found this on the www.nhtsa.dot.gov site




Make / Models : Model/Build Years:
YAHAMA / XV1600ASNC 2001

YAMAHA / MIDNIGHT STAR 2001-2003

YAMAHA / ROAD STAR 2001-2003

YAMAHA / ROAD STAR LIMITED EDITION 2002-2003

YAMAHA / ROAD STAR SILVERADO 2001-2003

YAMAHA / ROAD STAR WARRIOR 2002-2003

YAMAHA / XV16 2001-2003

YAMAHA / XV1600AN 2001

YAMAHA / XV1600ANC 2001

YAMAHA / XV1600ASN 2001

YAMAHA / XV17PCP 2002-2003

YAMAHA / XV17PCPC 2002-2003

YAMAHA / XV17PCR 2002-2003

YAMAHA / XV17PCRC 2002-2003

Recall Number: 03V309000
Summary:
IN THE TRANSMISSION ON CERTAIN MOTORCYCLES, THE SECOND/THIRD PINION GEAR MAY BE INCORRECTLY MACHINED WHICH COULD CAUSE ABNORMAL WEAR THAT EVENTUALLY RESULTS IN A BROKEN RETAINER CIRCLIP.
Consequence:
IF THE CIRCLIP BREAKS, THE TRANSMISSION COULD LOCK UP, WHICH WOULD ALSO CAUSE THE REAR WHEEL TO LOCK UP. THIS COULD RESULT IN LOSS OF CONTROL AND A CRASH, POSSIBLY RESULTING IN SERIOUS INJURY OR DEATH.
Remedy:
YAMAHA WILL REPLACE THE TRANSMISSION GEARS AND SHAFTS WITH NEW ONES. OWNER NOTIFICATION BEGAN ON SEPTEMBER 9, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT YAMAHA AT 1-800-88-YAMAHA OR VISIT THEIR WEBSITE AT WWW.YAMAHA-MOTOR.COM.
Notes:
ALSO, CUSTOMERS CAN CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION&amp;#146;S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

Thanks Cougar.

Doc