Yamaha XV750

[Pat]

Have a 1983 yamaha jap import , imported some 20 years ago that goes well with the exception of starter motor which has given trouble from day 1.If bike doesnt go after two or three shots then you are wasting your time as the battery just goes flat.Electric,s all checked and okay.Have heard this is a common fault .Are there any remedies to this problem.Please help
Pat

[FROSTY]

double post there pat

[Scorpygirl]

Pat, welcome to KB. I hope you are able to get the prob sorted.

I have lots of rellies around Waihi. We had a big do for my Aunty's 80th birthday on 21st Jan at the Waihi Beach RSA. It was a blast!!!! :drinknsin

Hope you enjoy the nuthouse! :niceone:

[Edbear]

Not a mechanic, well not much of one anyway, but heard this is a common problem with Viragos and only fix is overhaul the starter motor. Not sure about costings, but there was a good Yamaha dealer in Morrinsville when we lived there.

[Waylander]

Could check the Idler gears and starter clutch. Had the same problem you describe just before I came to NZ. If the gears are worn then ya need to get all new ones for the whole set as they re-designed them in 98 to not wear out so fast. Also check the starter clutch and make sure it spins only in one diretction. If all else fails, Waihi isn't that far from me (Tauranga) either I could come up one weekend or you could come down and I could take a closer look at it for ya.

[kevie]

What is playing up on your bike? the actual starter or the 'cogs meshing'??

I have restored my XV750.
Starter was crap, if it didnt start first time the cogs would miss and trouble starting.

I checked for new flywheel.... they arent available.

I replaced all the starter cogs (purchased through our local Yammy dealer) and got the flywheel restored by
'Ring gear recovery'
234 Fitzherbert East Rd
Aokautere
Palmerston North
0-6-356 9310
the flywheel repair cost me about $124
(not sure of the total cost of the repair of the starter as it was part of the $4100 I spent on the recondition of the motor)

[Pat]

The starter is noisey and clunky , works well when fully charged, but if battery is low just forget about the bike starting.One nz owner being me , never been dropped , never been abused , over 50k on the clock, great bike just leaves you uncertain when traveling by oneself if the starter is going to be okay.Wasnt a problem 23 years ago when I bought it because I was fit and young enough to push start if necessary , now I am pushing 60 and need some reassurance.I have thought of some how fitting a second battery but that brings all sorts of problems I guess.Anyhow thanks for your comments much appreciated
Pat

[kevie]

The starter is noisey and clunky , works well when fully charged, but if battery is low just forget about the bike starting.One nz owner being me , never been dropped , never been abused , over 50k on the clock, great bike just leaves you uncertain when traveling by oneself if the starter is going to be okay.Wasnt a problem 23 years ago when I bought it because I was fit and young enough to push start if necessary , now I am pushing 60 and need some reassurance.I have thought of some how fitting a second battery but that brings all sorts of problems I guess.Anyhow thanks for your comments much appreciated
Pat


YEP thats the same thing my bike was doing, call your local Yammy dealer to cost the new starter cog set ( I think theres 4 cogs + springs if needed), I forget what I payed for them, and get hold of Ringgear recovery, there's magnets all round the inside of the flywheel and most restoration guys will tell you they have to come off, but Ringgear recovery can rebuild the teeth with the magnets in place, and I thought the job was dam reasonable at $124. My flywheel was done almost 18 months ago I think and im still happy with it..... but point to note ... you MUST replace ALL cogs at same time, I was told the most worn cog will chop the new cogs out quick and you're back to square one in a fairly short time.

If you can locate one ..... purchase the HAYNES manual on the XV750 (1981-1986), ive found it very worth the money spent on it.

The Virago is a dam nice bike to ride, I love mine so much I was crazy enough to pour $5500 into the restoration of it LOL

(wifes expaination of it is >>>>>>> "Boys and their Toys" )

[Waylander]

If you can locate one ..... purchase the HAYNES manual on the XV750 (1981-1986), ive found it very worth the money spent on it.

May have posted this before but I have The Clymer Manual for XV535-11-- from 1981-1999. This one is great aswell.

[Wired1]

Yep they all seem to do that, I have had two XV750's and both start beautifully with a fully charged battery but if not first or second time then the noises begin. I read once that removing the spring on the end of the starter motor fixes it, well it doesn't so forget that. I rebuilt my current starter motor and it improved it shitloads, at a cost of about $15 for the bearing and seals. They are pretty easy to dismantle and predicatably a bit harder to get back together. There is also a guy in ebay selling his design for the cure, but I haven't been game enough to bring one in, if someone has then let us know if it worked.

[Pat]

To Wired , tried to locate the guy on ebay selling the starter solution but could not find .Can you help me locate advert.I have have a donar bike that I picked up several years ago and had the starter motor on that overhauled but it didnt really make any difference.
Kind regards to all those who have replied. Pat

[Wired1]

Sure thing, here are the urls for two of these on ebay right now:
http://cgi.ebay.com/ebaymotors/VIRAGO-XV-STARTER-IDLER-GEAR-CLIP-FIX-700-750-920_W0QQitemZ4640524806QQcategoryZ35594QQssPageNam eZWDVWQQrdZ1QQcmdZViewItem
http://cgi.ebay.com/ebaymotors/VIRAGO-STARTER-REPAIR-SHIM-KIT-2-IDLER-CLIP-FIX_W0QQitemZ4639524240QQcategoryZ35594QQssPageNam eZWDVWQQrdZ1QQcmdZViewItem
The clip works by tigntening the spring clip and thereby stopping the starter from over reving before it can engage with the flywheel. I guess this proves that throwing away the spring clip is a viable fix. I might get one of these and try it on my XV, mine starts nicely 99% of the time unless it has been sitting for a week or two and the mattery is getting down a bit, then its the "box of rocks" sound effects.

[Pat]

Sure thing, here are the urls for two of these on ebay right now:
http://cgi.ebay.com/ebaymotors/VIRAGO-XV-STARTER-IDLER-GEAR-CLIP-FIX-700-750-920_W0QQitemZ4640524806QQcategoryZ35594QQssPageNam eZWDVWQQrdZ1QQcmdZViewItem
http://cgi.ebay.com/ebaymotors/VIRAGO-STARTER-REPAIR-SHIM-KIT-2-IDLER-CLIP-FIX_W0QQitemZ4639524240QQcategoryZ35594QQssPageNam eZWDVWQQrdZ1QQcmdZViewItem
The clip works by tigntening the spring clip and thereby stopping the starter from over reving before it can engage with the flywheel. I guess this proves that throwing away the spring clip is a viable fix. I might get one of these and try it on my XV, mine starts nicely 99% of the time unless it has been sitting for a week or two and the mattery is getting down a bit, then its the "box of rocks" sound effects.

Cheers thanks for have purchased one at a total of $83 nz dollars including postage

[Wired1]

Wow, I didn't do the exchange rate calculation. Hope it works, I guess if it does I'll get one too even at this price.

[Pat]

Thanks Wired , received kit from USA total NZ cost $88 includes postage.Great service received kit seven days after placement of order.Detailed instructions and a full 61 page yamaha xv parts catalogue provided also.It took me 6 hours from time of dismantleing to completion.But you could probably do it a lot quicker , I am a bit of an old lady checking and rechecking.Does it work , it sure does the old xv ratttle clunk clunk has gone , just sounds like any other starter motor.I did a hundred k trip to Thames and return to bed it in , starter works first time everytime.I just hope it lasts.A tip , also have a Haines manual on hand it helps.Kind regards to all who responded Pat

[Wired1]

Thanks for the update Pat, I have just bought two so I'll be fitting them in a couple of weeks I guess. I just bought another XV750 this week so the second one will be going straight onto the new bike as I'm sure it will have the same problem. Thanks mate, Simon.

[Rashika]

Congrats on getting it sorted out Pat!
Its amazing what we can actually achieve when we put our mind to it. Good service from the USA place. :yes:

[Wired1]

Just fitted my first one of these clips and all went smoothly. I also replaced the seal around the gear shift as I had a slight seep there, cost me $5 for the seal from the bearing shop, money well spent I reckon. I took the bike for a burst up the road and all sounds good, tried restarting it half a dozen times and every time was smooth as. I recommend this fix to anyone with an XV.

[patch111]

HI Guys.
I have the typical XV750 starter problem. Mine is fairly straightforward as I pulled the starter off today and the little planetary gears and the large gear around it are chewed up. I rang Yamahe and they want $395.00 AUD for the reduction gear assembly (they call it clutch assembly) so thats out. I am ordering a new 4 brush starter from the US for $129.00USD +freight so it looks to be the way to go.

Just a dumb newbie question.

I just pulled the starter out gently and have not moved anything. Should I be able to put the new starter in without pulling off the left side cover. I seem to see differing opinions on the various forums on the net.
cheers

patch111

[Pat]

Patch , you should not have been able to pull the starter out if everything was intact as it should have been.The cog/gearing on the end of the starter motor has a circlip/friction clip on the inside of the housing , this is designed to slow it down but also prevents you from removing the starter motor without removing the outer case.It would appear to have either been removed or has broken off on the inside .Whatever has happened my advice is to do the job correctly and remove the cover and check the starter clutch out.First thing to do is to make sure the starter you have ordered is a four brush starter , these use significantly less charge and have a modified planetry system.Get yourself a loan of a Haynes manual for the xv , try the library if not let me know and I maybe able to post you the relevent pages.When you remove the housing take your time , make a cardboard template or similiar so you know where all the relevent bolts go when you reassemble.When I did mine I purchased a sarter clutch kit from Chopper Bobs which included a tension clip that fits over the circlip/friction on number 2 Idler gear , this reduced the noise from that area significantly.Wired has also had lots of experience in this area.All I can say is that after years poor starting now that I have installed the 4 brush starter and tensioned the idler clip the bike starts everytime with little or no noise which is a relief.
Pat

[patch111]

Hi Pat,
That's weird. I just took out the 2 bolts and disconnected the cable and it slide straight out. There is a 19tooth gear with a circlip still holding it on to the starter shaft. I looked in the hole and there does not seem to be anything hangong loose.

I had a mechanic "fix" this about 6 weeks ago (to his credit he said there was a tooth off one of the planetary gears and it would not last so I was expecting it to go to god.

I think I'll ring him and tell him I've ordered a new 4 brush starter fom the US. Thanks for the advice about Chopper Bob's mod. I ordered a clip today as well. I did not order the shims as I am guessing that seeing as though I am buying a new starter with the gear rduction nose piece already attached I dont nee the shims.

Cheers
patch

[patch111]

Well.....
There is no friction clip. Looks like some dumb ass has left it out at some previous time. Does anyone have one just in case I cant get one here.
cheers
patch

[Pat]

I will have a look thru my box of bits and pieces but I dont think I have the one that fits the starter gear will let you know later..Best of luck.
Pat

[patch111]

Thanks Pat,

The local Yamaha shop actually had the clip in stock (amazing). Just went and got it as its such a high selling item that somone else might have snapped it up (NOT).

All I need is a set of clutch plates now. The clutch was slpping fairly badly so I may as well change them while I am at it.

Now just have to wait for the bits to get here from the US. Chopper Bob has already dispatched but the starter guy has not given me a tracking number yet. They are DB Electrical, Tennesee, is that the people you dealt with for yours?

cheers

patch

[Pat]

No I have the name of firm out in the garage , they specialised in starters for bikes cars tractors etc, I paid by paypal on a Sunday evening and had the starter the following Friday to install on Saturday, so the service was good.The price was the same $129 US.Keep me informed , its all good stuff.Did Chopper Bob email the parts catalogue.
Pat

[patch111]

Yep.... He sent the email just about the same time as he received the payment...good service so far.

[patch111]

The latest news from starter hell.

The good news is that all the mods and the new 4 brush starter arrived and it sounds like any other bike out there. Starts first pop and I am a very happy pirate (one eye, wear an eyepatch).

Getting there was the problem. There are a few things I should mention that might help others along the way.

1. The 81 XV750 has a friction clip on the starter gear with a tail on it about 27mm long. This was only on the 81. My bike is a Jan 82 and its clip has a tail about half that length. Given that its hard to buy these bits I recomend that you look at this first as the mechanic I had looking at my bike said he feels that about half of the Xv's that he's looked at over the years dont have the friction clip at all. I finally got the right clip this morning from Yamaha and it works great.

2. I purchased the Chopperbob (ebay) mod as Pat reccomended. It seems to work great so I am happy. Just a bit pissed off that the freight was way more expensive than the clip.

3. The 4 brush starter is the bomb. It has permanent magnets so it draws less battery power than the original and the bike starts in a flash. From order time (from Tennessee) to being at my door here on the Gold Coast it took 5 days, very cool service and cheaper than having my old one "reconditioned" here.

So now I am in Starter heaven........................

Cheers

Patch

PS. I now have an original starter that hyas just been reconditioned but the planetary gear part is screwed. If anybody has a need for a starter and your old planetary gears are ok I will sell it CHEAP.

[Pat]

Very pleased that you have solved the starter problem and all is going well.The four brush starter certainly seems to be the ticket to reliable starting.Pat

[patch111]

Hey Pat,
Yep it's great. I dont have to hide or wait until everybody else has gone before starting my bike. We went out on it today (Indy is on this weekend and the bike is THE only way to get through the traffic) and it was such a blast to stop and start with confidence and even pride hahahahaha.
cheers
patch

[degrom]

Very pleased that you have solved the starter problem and all is going well.The four brush starter certainly seems to be the ticket to reliable starting.Pat

Hi Pat, how is the bike going? Still running fine with the fix you made to the starter?

[degrom]

Is this the kit you installed that fixed the problem?

http://cgi.ebay.com/ebaymotors/VIRAGO-STARTER-REPAIR-SHIM-KIT-2-IDLER-CLIP-FIX_W0QQitemZ260164224365QQihZ016QQcategoryZ35594Q QssPageNameZWDVWQQrdZ1QQcmdZViewItem

[patch111]

Nope...

That is the complete kit. Because I was also fitting a brand new starter I just purchased the little "C" clip that you see in this kit.

I highly recommend that you buy a new 4 brush starter from DB Electrical, Tennessee.

I have not had on scrap of trouble since changing to the 4 brush start and adding chopper bobs clip to the origional friction clip.

By the way...I also puoght a new friction clip from Yamaya as mine was missing so I guess that helped as well.

People cant believe that mine starts like it does. Every other one I'v seen sounds like a bucket of bolts in a concrete mixer.

Cheers

Patch111

[degrom]

Nope...

That is the complete kit. Because I was also fitting a brand new starter I just purchased the little "C" clip that you see in this kit.

I highly recommend that you buy a new 4 brush starter from DB Electrical, Tennessee.

I have not had on scrap of trouble since changing to the 4 brush start and adding chopper bobs clip to the origional friction clip.

By the way...I also puoght a new friction clip from Yamaya as mine was missing so I guess that helped as well.

People cant believe that mine starts like it does. Every other one I'v seen sounds like a bucket of bolts in a concrete mixer.

Cheers

Patch111

Thanks for that Pat. I will see if I can organize all the needed parts.
Will be great if I can get it running properly... :)

[Cliffy1]

My xv 750 Yam,s starter runs on a fraction after starting maybe a thing with this model. thanx

[Cliffy1]

Great to read of all the support out there it gives me confidence for future repairs and maintenance. Thanx ALL.

[Waylander]

Great to read of all the support out there it gives me confidence for future repairs and maintenance. Thanx ALL.
A good start would be spelling the name properly lol.

As for your Question, My 1100 did it as well. Just winding down or you're holding the button down a fraction to long lol.