Author Topic: Need Virago 700 Help - Know of any forums that specialize in Viragos? (Read 4329 times)

RRRToolSolutions · « **on:** March 27, 2011, 07:03:31 PM »

Guys, I've done some Google searching for forums on the Virago, but have not found a dedicated board. Help/input for any you know of would be appreciated.

Thanks, Gordon

Grnrngr · « **Reply #1 on:** March 27, 2011, 08:00:13 PM »

http://viragotechforum.com/

Not quite as "active" as this one, mostly older guys but lotsa knowledge...

I've got a couple Viragos too...

arblebang · « **Reply #2 on:** March 28, 2011, 08:15:59 AM »

I had a 95 Virago 750 until about a month ago, and I currently have an 82 Virago 920, what problem are you experiencing with yours?

seaweb11 · « **Reply #3 on:** March 28, 2011, 09:52:36 AM »

Here is a thread on a 750 Virago I cleaned up and got running for a friend.

http://forums.sohc4.net/index.php?topic=74835.0

Might help you out with a few problems

RRRToolSolutions · « **Reply #4 on:** March 28, 2011, 07:43:31 PM »

Guys, the issue is with the starter. The starting motor spins nicely, but refuses to stay engaged to the flywheel more than a second. I can pull the plugs and it does fine - it's only when the compression is there the bendix/starter clutch refuses to stay long enough to actually start the engine.

What I've done is to pull the left cover and remove the idle gears and shaft. I've order a new, factory idler #2 gear and clip (the one that engages the flywheel on the crankshaft. This is the only part on this 2,000 mile bike that has/shows any wear.

This design is so bad that Yamaha actually engineered a case to hold a magnet immediately below the gear to catch the teeth and sheared metal. They had a big design flaw, knew it, and spent money to "patch it" from the factory - poor use of design resources in my opinion.

This is not my bike, but one a friend/neighbor picked-up on Craig's List for cheap. It's on my table for repairs and has been for over a month now. I want to see it go. While I'm providing the labor and tools free of charge, I have projects of my own I want to use that table for. Inputs appreciated.

This video was very helpful - Gordon

seaweb11 · « **Reply #5 on:** March 28, 2011, 07:54:49 PM »

Over on the Virago Forum someone sells a cheap kit that shims the starter somehow to alleviate the problem which seems to have been one of the bikes down sides.

lordmoonpie · « **Reply #6 on:** March 30, 2011, 01:08:57 AM »

The problem is the spring on the idler gear - it's too weak to hold the gears together for long hence lots of gear crashing and chewing and ove time you have to buy a new idler gear #2. Mine is on order at the moment for my XV750 restoration :-)

The fix is a little P style clip on the spring to give it more tension coupled with bushing the starter motor f you have an original motor. The best kits are from Chopperbob on ebay (search for his name in advanced search) but he's very pricey with postage - may be better in the USA itself. The magic bit really is the clip, the shims and rubber o-ring to shim out the starter is not rocket science but then I guess you're paying for his research and development.

I think he sells the clips on their own as well if you don't want a full kit.

Installed in 10 minutes - no starter woes afterwards.

RRRToolSolutions · « **Reply #7 on:** March 30, 2011, 06:45:58 PM »

Chopperbob is not coming up in my search. I'd buy it.

lordmoonpie · « **Reply #8 on:** March 31, 2011, 03:55:28 AM »

He should come up if you do advanced search and then "by seller". I'll look him up tonight though and paste his email address here so you can contact directly...

lordmoonpie · « **Reply #9 on:** March 31, 2011, 03:57:10 AM »

He's here...

http://members.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewUserPage&userid=*chopperbobs*cycleworks*

RRRToolSolutions · « **Reply #10 on:** March 31, 2011, 11:23:40 AM »

Found, bought, and waiting receipt of the kit! Thanks for the inputs -

Gordon

lordmoonpie · « **Reply #11 on:** April 01, 2011, 03:18:30 AM »

You'll have to report on the fix efficacy Gordon - It'll be a long while before I can test mine out so am interested in how well it works...

RRRToolSolutions · « **Reply #12 on:** April 01, 2011, 09:08:44 PM »

Will definitely do -

seaweb11 · « **Reply #13 on:** April 01, 2011, 10:09:54 PM »

Someone came by my place today and asked if I would sort out his Virago starter issues and a few other gremlins.

No not the same guy as the last one

jakecb420 · « **Reply #14 on:** April 02, 2011, 05:20:06 AM »

ha, im messing with a virago 1100 right now. it also has starter issues. this one, the starter was locked up solid. i had it rebuilt, bought a new gasket, new spring, new oring for the starter, only to put it all back together and forget the triangle thing with balls in it for the clutch.(the clutch wouldnt adjust) off comes the alternator cover again. i find the piece for the clutch in my oil drain bucket. put it all back together, trying to repair my new ripped gasket with indian head shellack. that may have worked but when i hit the starter button again, the starter just spins and spins.

so, does that mean the starter clutch is bad? when i took that back off again, the gear freely spun both ways, however after playing with it a little while, now it only spins one way. i didnt do anything other than spin it with my hands.

i dont want to hijack the thread or anything, just throwing my problems into the mix.
also, i couldnt get that link to work for the starter shims.

lordmoonpie · « **Reply #15 on:** April 04, 2011, 10:59:20 AM »

I think you need to get your starter clutch gears off to check for damage from that clutch ramp going walkabout.

Gordon - got my #2 idler gear today so I can start rebuilding. Gave up on reconditioning my starter though - it's seen some bad times and with DB Electrical of Tennessee offering new 4 brush replacements for $100 it's too good to pass up - one on the way to me as we speak :-)

I should fit the chopper bob fix soon though on the idler #2 spring clip. Anyone wants to mail chopperbob for a fix - he can be reached at chopperbob@computermail.net

RRRToolSolutions · « **Reply #16 on:** April 06, 2011, 04:41:18 AM »

Ok, the results are in - the repairs to the starter were 100% successful. There is no drag, no grinding, or meshing issues. The bike starts after 2 seconds and the bendix pulls the starter out of the way immediately upon firing.

Here is what I did -
1) replaced the #2 idler gear that meshes with the flywheel with a new factory part
2) replaced the clips/drag springs on both the starter motor and the new #2 idler gear
3) installed ChopperBob's starter repair kit.

Now, specific to the starter repair kit - the small clip that goes on the #2 idler gear clip is tough to install and really pulls down on the gear - I think it will hold that spring tension for a long time and solve the problem of the gear/flywheel sticking together - a good thing.

The kit adds a large, heavy-duty O-ring to go between the driven gear from the starter and the #2 idler gear. It's purpose is to limit that idler gear's movement away from the flywheel. It just makes the job of engagement easier and faster - great idea and there is still plenty of clearance between the two when the engine is running.

The diagrams need to be more specific. The large shim he provides goes under the planetary gear set and the drawing does not show that detail. I pulled the starter apart like shown and found 2 other shims on top of the planetary gears and thought the shim was simply another to be added - no it won't allow the starter to be re-assembled. It must go "under" the planetary gears. It's whole purpose is to push the starter gear further into the engine. I didn't know it had a problem there, but installed it while apart and my hands were dirty.

One last point before the verdict - he states something in his instructions that I was quiet pleased to read - that #2 idler gear that is quite expesive $60 ? It can be turned over and used backwards - the clip/spring to the back and the like-new, undamaged side of the gear used to mesh with the flywheel. The slot in the case that holds the clip is in fact long enough that the starter doesn't care where that clip/spring goes - great tip.

The kit is confirmed. I like it and the install was less than 20 minutes extra. If I had know up-front to put the shim under the planetary set, maybe 10 minutes. As for holding up and lasting, I can only repeat what a friend told me when he saw the "up" arrow cast into the case just above the magnet made to catch the pieces from the self destructing starter....That's where you direct your prayers while making starter repairs that you think will last......

Regards, Gordon

crazypj · « **Reply #17 on:** April 06, 2011, 12:10:17 PM »

First one we sold we took apart because it sounded so bad (brand new bike, uncrate , PDI, take apart and fix

)
Yamaha told us it was 'normal' then started sending service bulletins and updates.
It's a very well known issue with the XV's
Take numbers to a Yam dealer (VIN, engine) and have them check if all the updates were done, you may get some 'free' parts
Yamaha are actually the best company for warranty work, you may get a discount even if you don't get repair parts (I've done warranty on 3~4 yr old bikes, very unexpected)
If it was a recall part it will be one no matter what age it is

lordmoonpie · « **Reply #18 on:** April 07, 2011, 12:47:24 AM »

Quote from: Ilbikes on April 06, 2011, 04:41:18 AM

Ok, the results are in - the repairs to the starter were 100% successful. There is no drag, no grinding, or meshing issues. The bike starts after 2 seconds and the bendix pulls the starter out of the way immediately upon firing.

Here is what I did -
1) replaced the #2 idler gear that meshes with the flywheel with a new factory part
2) replaced the clips/drag springs on both the starter motor and the new #2 idler gear
3) installed ChopperBob's starter repair kit.

Now, specific to the starter repair kit - the small clip that goes on the #2 idler gear clip is tough to install and really pulls down on the gear - I think it will hold that spring tension for a long time and solve the problem of the gear/flywheel sticking together - a good thing.

The kit adds a large, heavy-duty O-ring to go between the driven gear from the starter and the #2 idler gear. It's purpose is to limit that idler gear's movement away from the flywheel. It just makes the job of engagement easier and faster - great idea and there is still plenty of clearance between the two when the engine is running.

The diagrams need to be more specific. The large shim he provides goes under the planetary gear set and the drawing does not show that detail. I pulled the starter apart like shown and found 2 other shims on top of the planetary gears and thought the shim was simply another to be added - no it won't allow the starter to be re-assembled. It must go "under" the planetary gears. It's whole purpose is to push the starter gear further into the engine. I didn't know it had a problem there, but installed it while apart and my hands were dirty.

One last point before the verdict - he states something in his instructions that I was quiet pleased to read - that #2 idler gear that is quite expesive $60 ? It can be turned over and used backwards - the clip/spring to the back and the like-new, undamaged side of the gear used to mesh with the flywheel. The slot in the case that holds the clip is in fact long enough that the starter doesn't care where that clip/spring goes - great tip.

The kit is confirmed. I like it and the install was less than 20 minutes extra. If I had know up-front to put the shim under the planetary set, maybe 10 minutes. As for holding up and lasting, I can only repeat what a friend told me when he saw the "up" arrow cast into the case just above the magnet made to catch the pieces from the self destructing starter....That's where you direct your prayers while making starter repairs that you think will last......

Regards, Gordon

Great feedback Gordon, I started looking at mine last night and have the benefit of the great new DB Electrical starter so no motor shim required, just the idler gear clip and o-ring shim. It all looks good. The trick on switching over the starter gear is fantastic. I'm lucky to be able to afford to buy a new gear #2 but I'll certainly keep the old one for spares. Appreciate your posting the results Gordon...

seaweb11 · « **Reply #19 on:** May 19, 2011, 09:57:04 AM »

Just a heads up on the starter shim kit from Chopperbob
I read what was here and what was on the instructions and was at odds as to the correct way to instal so I emailed him.

Reply:
" if you seperate the nose cone from the starter motor the shim should slip in the cone against the ring gear not under it. If there are shims already in there then remove and measure them. the one i supplied should be thicker so install that one without the ones you removed"

He read this thread and then came back with....
"Yea I was reading that. However after study, just because I have never installed it that way I believe it will still function in the same fashion without harm. I just never had a reason to look beyond first application discovery. There are a lot of smart people that get creative by necessity."

I'm off to the shop to finish this project. I'm still waiting on a new clutch cover gasket but will give my results when finished.

News:

Author Topic: Need Virago 700 Help - Know of any forums that specialize in Viragos? (Read 4329 times)