Yamaha Virago Starter Gear Repair (GEN II) 1984

Yamaha Virago Starter Gear Repair (GEN II) 1984 - 99

Рет қаралды 7,338

Жыл бұрын

This video shows how I repaired my 1984 Virago 1000 idler gears in the starter system.
NOTE: This video does not cover any problems associated with the first generation (81-83) Viragos that did not have a solenoid. They are completely different systems and have separate issues with those starter systems.
A LOT of people ask about the spring - it is NOT required in this new assembly for several reasons. For the Gen 1 Viragos that did not have a solenoid, the idler gears were part of a Bendix gear. A true Bendix is flawed by virtue of its design: the gear must be engaged by a rotational force. This force causes the idler gear to spin while it's trying to engage a stationary flywheel gear. It was a great idea in the 1920's, but not so great now. Furthermore, because there is no solenoid to disengage the idler gears, a return spring and clutch must be incorporated.
In this new design, an electro-mechanical solenoid is used to engage/disengage the idler gear assembly and therefore a return spring (already present on the solenoid) is not required. The solenoid is designed such that the starter does not begin to turn until AFTER the idler gear has been engaged into the flywheel gear. The shorter cut angle on the idler gear reduces the rotational velocity as well and aids in proper engagement of the system.
Latest revision Yamaha Part Numbers for idler gear assembly is: 3LP-W1551-00-00 and was ordered from Impex Japan (en.impex-jp.com/parts/new/sea....
If you need to order a new starter clutch, they are a little easier to find. I got mine from www.bruceshark.com (Yamaha PN 5A8-15570-00-00) and was also able to find plenty on eBay. Be mindful of the difference between the 1000/1100 starter clutches.
The aftermarket starter solenoid didn't work either - be careful with this if you end up buying aftermarket parts. There are cheaper solenoids out there (Amazon, FortNine, etc) and are inexpensive Chinese "knock-offs" and may or may not work properly. I found that the one I got was not moving (plunging) as far as the OEM solenoid was. I'll have to replace that as soon as I can either find an OEM solenoid or a better aftermarket product that performs as well as the original one did.

Пікірлер: 67

@davidguest6051 Жыл бұрын

Do you have any idea how much time & guess work you have saved me. I am about to tackle this job on my 1985 vx1100. Should be smooth sailing thanks to you. Keep the vids coming. "I'll be back". Cheers. David from Canada, eh!

@KensWorldRestorations Жыл бұрын

Love this comment!! That's exactly why I create these videos. I've never touted my channel as "how-to" since I'm not an expert and I'm not a licensed mechanic. But I do know that when you see something firsthand, it sparks creativity and understanding. Cheers.

@inthesupernovashadow Жыл бұрын

The production quality here forced me to comment. So many videos working on Virago's are low quality, poorly lit, and difficult to see. You put a lot of time and thought into lighting things well, and presenting great angles for the viewer. Awesome work! I had an uncle gift me an '83 XV750 Virago for my first attempt at restoring something. Videos like these are just beyond helpful! Thanks so much.

@KensWorldRestorations Жыл бұрын

Wow! I can't thank you enough for the kind words. I really try to make small improvements with every video and for the bike, I'm still learning along the way too. I'm really happy if the videos help in any way...that's what they're here for. I hope your Virago restoration keeps you motivated too.

@davidmartineau4037 2 ай бұрын

I've had to replace the starter clutch before on my 1985, but now I am having trouble with my starter gear. This video, unlike other vids, gives me a better understanding of how things are supposed to perform and how they are to look. I've been thinking of doing a restoration on the bike, and this year I came across your Yamaha series. I love them.

@KensWorldRestorations 2 ай бұрын

Thanks for the kind words! Yeah, it’s nice to see before you do - just gives you a little bit of extra confidence when doing it yourself.

@randymcm4019 Жыл бұрын

Ken you certainly deserve a lot of credit for sharing and showing all the work you’ve done. Thanks

@KensWorldRestorations Жыл бұрын

Thank you Randy for the really great comments. I really appreciate that.

@daxifigueroa9854 Жыл бұрын

Ei Ken, started watching you videos since last year. Very very helpful videos, thank you very much. I have the same motorcycle a 85 Xv1000 which i bought last year and might be starting to restore it anytime soon.

@daxifigueroa9854 Жыл бұрын

What repair manual do you suggest i get, a hanes manual or a clymer’s manual? Thanks

@KensWorldRestorations Жыл бұрын

Thanks so much for the kind words!!! All the best with your restoration.

@KensWorldRestorations Жыл бұрын

@@daxifigueroa9854 I prefer the Haynes manuals - if you can find one in print, it's nice to be able to write notes in it. The electronic copies are convenient too because you can keep them handy on an iPad or phone.

@billm5758 11 ай бұрын

Fantastic set of videos

@AC-vz9cz Жыл бұрын

Yes :-) Yes :-) I'm very happy for you it's so nice !! The bike looks so good, I'm praying for you to have safe rides every trip you take ken '', And many great memory's Cheers Ken from a friend from West Coast BC

@KensWorldRestorations Жыл бұрын

Hey Ralph!! Hope all is well!! Looks like we're going to have some really nice weather this weekend - I'll take the GoPro out and get some nice video! Thanks so much for all the support and wonderful comments.

@yarekk Жыл бұрын

The view of a smile on your face brought a smile to mine 😊

@KensWorldRestorations Жыл бұрын

Thanks buddy...that's what I like to hear!!!!

@owencaton2433 5 ай бұрын

Man how the hell is your bike so clean I’ve been trying so hard to get my bike this clean

@KensWorldRestorations 5 ай бұрын

Year-long frame off restoration. Thanks so much. It’s not a garage queen and I do drive it but it’ll be fair weather only from here on in.

@johnny8418 Жыл бұрын

HI　ken　回答ありがとう、再度質問ですが新しいギヤーに交換した時にスターターソレノイドはそのままの物を使用しても大丈夫ですか？

@KensWorldRestorations Жыл бұрын

はい、ただしソレノイドが正常に動作していることを確認してください。ソレノイドが古くなると、ソレノイドが必要なだけ深く沈み込まなくなり、アイドラギアが十分に深く噛み合わなくなることがあります。

@kdsowen2882 11 ай бұрын

Your bike looks to be a superb-example .It's the early Bendix -one ,750 that is a 'box-of-rocks' (Steve's DIY shows some great permanent-fixes for it ) Your-one suffers from a 2-pole-starter, later they became 4-pole, 87-onwards plus mikuni-carbs that you can still buy parts for . Weak-batteries, compromised-wiring in the starter-circuit and poor 'earths' are some problems with yours (along with the gear-design that you've replaced ) plus people re-start before the gears have stopped-moving from the first-attempt . I added a separate-earth from the battery directly to the starter , which helped a lot . New spark-plug-caps make for faster-starts , as-does an ignitech-ignition if you want to get serious . Yours seems to start fine now though. Those 'couple-of-bucks' gaskets are 65NZD where I live ! (about 30-US ) I ride an 82 TR1 XV1000 Roadster which has the same-starter as-yours and the later Virago-1100's . Your smile was priceless when the bike fired-up , we all know that feeling . Ride-Safe , Dave NZ

@seanhall4098 2 ай бұрын

Where did you hook up the ground to the starter ?

@kdsowen2882 29 күн бұрын

@@seanhall4098 I ran a wire from the starter (where it bolts on) under the motor and up to the battery negative (earth) plus another smaller earth-wire from that same earth-terminal, up under the tank and followed the loom to the handle-bar starter-button . I soldered it Directly to the small brass earth-bar that 'earths' to the handle-bar . This made a big-difference as the starter-circuit is permanently-live , relying on the flimsy earth button (Starter-button ) to complete the-circuit . if any of your earth-wires are compromised , you get an extremely-poor earth through that starter-button , because the handle-bars are insulated by rubber -mounts at the top fork-yoke . You can test all this out by using decent wire and strong crocodile-clips/clamps before running the wires . A friend only ran the one from starter to battery but carries a wire with two clips rolled-up in his bag for every-start (to the handle-bar ) . You can also fit a later 4-pole-starter from 87/8--onwards bikes which are far-superior . I'm just about to renew my clutch as it's slipping under throttle, Good luck with yours , Dave nz

@MrClics 10 ай бұрын

Hello Ken! Thank you so much for the detailed video description! Great explanation and great quality! I am going to change the starter clutch on my Virago VX1100 (1999) but I am not sure if it is the actual problem.. Do you think I can reuse the carefully drained oil (which is fresh) for testing ? and if everything works fine - drain it again and use new oil and filter?

@KensWorldRestorations 10 ай бұрын

Thanks for the wonder comment!! Short answer is yes, you can reuse previously drained “fresh” engine oil. Be cautious of the container in which you capture it - make sure it’s free of other fluids & contaminates. I also use a automotive paint filter (very cheap item) to strain just before putting it back in the engine. Good luck with your repair - that’s the last year for the Virago and with a bit of luck, you fixed your problem.

@MrClics 10 ай бұрын

@KensWorldRestorations thank you so much for your reply, Ken. Judging from the part list- 1999 Virago should have the idler gears without the spring already. So we will see) Hopefully it is only the starter clutch that needs to be changed🙏

@KensWorldRestorations 10 ай бұрын

@@MrClics Yes, from 1995 (ish) the spring was removed and the latest idler gear assembly is what I installed in mine. You should have the latest revision already. If you're having starter problems make sure your solenoid is healthy too - double check all connections as a frayed connection could cause grief. Take the small cover off and watch the solenoid action while you crank it - it should stay engaged the whole time you're cranking.

@MrClics 10 ай бұрын

@KensWorldRestorations Dear Ken! We did everything exactly as per your perfect manual! Thank you again. It looks like the problem is in starter clutch, because it is rotating in both sides. We got same generic one from China as you did but it is not fitting on starter axel easily as per old original. You put it in place with a hammer... is it normal procedure? Shall we do same?

@KensWorldRestorations 10 ай бұрын

@@MrClics I had to put some grease on the shaft of the starter motor and tap the starter clutch gently with a rubber mallet around the outside of the starter clutch. GENTLY. While I was tapping, I was also pushing slightly on the clutch in different places just to get it to seat properly. It is a clearance fit so there's not a lot of wiggle room. It is a very tight fit when new.

@joef6858 Жыл бұрын

Hey Ken, you look very pleased with your starter upgrade. I thought the flywheel gear was unavailable. Hope you find one. As for the side cover gasket where do you source yours? I have an 81 xv750 and a year ago I replaced that gasket for $42ca from Partzilla. Thought that was expensive. As always a great video presentation.

@KensWorldRestorations Жыл бұрын

Hey Joe...yeah, I'm pretty sure it is unavailable but you never know...if I come across an old engine somewhere I could always have a peak at parts. I get the gaskets from China (eBay) but if I was in the US I'd go with Caltric. They're cheap enough but the shipping to Canada from the US is just F%#$KING stupid. I can buy stuff in China (or Japan, Thailand, etc) and have it shipped to Canada faster and cheaper than from the US. Something just not right there...

@leroylightfoot7358 10 ай бұрын

what was the starter acting like before you changed the parts,mines an 85 and its got starter problems

@KensWorldRestorations 10 ай бұрын

The starter gears were jumping off the flywheel when I hit the starter button. It would initially engage but then jump out which makes an awful grinding noise. I couldn’t figure out what it was at first but it turned out to be the aftermarket solenoid not plunging far enough in order to pull the gears in. I eventually found an OEM solenoid but it was too late - the damage was done to the idler gears. The metal on the flywheel gear is harder and that was done intentionally by the engineers at Yamaha - better to wear down gears you can easily replace than to have to deal with the flywheel gear.

@kdsowen2882 11 ай бұрын

Just a thought, I have seen the flywheel-gear removed, turned , placing the chewed-up side away from the 'working-mesh-side' . It appeared to function properly . Dave NZ

@KensWorldRestorations 10 ай бұрын

I've heard of that too but never done it personally. I'd say if it was all you had as an option, then there's the answer.

@johnny8418 Жыл бұрын

質問ですがアイドラーギヤーのスプリング有と無しはギヤーの形状が違いますね、スターティングはどちらの方が良いのでしょうか？

@KensWorldRestorations Жыл бұрын

The new one is better for starting. The old “bendix” spins the idler gear too fast and that causes the theeth to grind too. The new version design allows the teeth of the idler gear and flywheel gear to mesh smoothly. The new gear doesn’t need a return spring because the solenoid does have a return spring. I hope this helps.

@leroybrodian 9 ай бұрын

First off I'd like to say is I bought a new gear and tried that 2 times 2 ways. With and without the spring. I know you can't answer my question because it's difficult when both gears got ate up by the flywheel within a few hours. I changed the flywheel before the install and 10 years later my bike is still sitting in the garage with absolutely no success. Why is it eating the gears up within a few hours? Why am I only getting a few good cranks and then back to the same old grind? I'LL WAIT FOR YOUR REPLY...

@KensWorldRestorations 9 ай бұрын

Have a look at your solenoid. If you have a 1984 to 1999 then the solenoid will sometimes break down over time. What ends up happening is the solenoid doesn’t completely close and that causes the gears to only partially engage. You’ll end up replacing gears because of the solenoid. If you have a gen one Virago (81 to 83) then there’s a more serious problem with the bendix design itself.

@DaveYadaraf Жыл бұрын

PTSD. I first replaced the quasi-bendix, but still had a starting prob. I then had to tear it all down again to replace the clutch, which upon closer inspection by hand was obviously bad. Different topic: Concerning the two crash bars, they are held together at the top by a single, long bolt, which (to me) seemed to be the correct size until the bars were added, after which there were only a few threads to grab (maybe three turns?). Did you use the original bolt?

@KensWorldRestorations Жыл бұрын

Looks like deja vu for you...I've got pretty much exactly the same thing going on here. Because the old "quasi-bendix" and solenoid have caused enough tooth decay on my flywheel, I'll always have problems. Also, the aftermarket solenoid didn't fully engage the idler gears after the fact. I'm sure I'll be at it again replacing the flywheel gear someday. Good eyes - I had to replace the OEM bolt because of just that - it was about 1cm too short. I ended up getting a custom bolt made (machined threaded rod) from the machine shop and bought 2 stainless steel cap nuts, one held firm with locktite.

@DaveYadaraf Жыл бұрын

@@KensWorldRestorations Yep. Need to fix that bolt and I think threaded rod should suffice. Still on the fence about forward controls, because the ones I've looked at are fairly ugly.

@KensWorldRestorations Жыл бұрын

@@DaveYadaraf I'm in the same boat - not a fan of the forward controls but I am ok with the right size/look highway pegs. I figured a good quality threaded rod would be ok so I went that route. Good luck with it all...cheers.

@yarekk Жыл бұрын

I don’t have forward controls on mine, but I got a feel for breaking with my right heel while I keep my feet on the highway pegs. Since I bought my virago nearly 4 years ago, I’ve been rising up the pegs a little bit every year. I find it really relaxing on long rides to recline and put my feet up… I don’t think I will ever add forward controls. The bike has enough torque to pull in 5th gear even at relatively low speeds, so no need to shift with my feet up. And between rear breaking with my heel, and using the front break, I’m good on that front as well

@KensWorldRestorations Жыл бұрын

@@yarekk That's exactly what I was doing when I first got the bike - it had the OEM Yamaha highway pegs (poorly installed). I didn't think I was going to like it, but it was super comfy. And I did the same thing!! Just brought my foot down and braked with my heel if needed. I'm actually going to start looking for a nice set of aftermarket highway pegs and a sissy bar bag now that she's running and summer is here.

@_MotoMikey_ Ай бұрын

Hi. What did You use to get that cover piece in beautiful gold? Looks immaculate!

@KensWorldRestorations Ай бұрын

Thanks!! I have another video called making gold chrome. I basically figured out what Yamaha did and tried to replicate that. So the gold is actually brass plated with a tinted translucent yellow clear coat. Makes the brass bits look gold and gives it a UV hard clear at the same time.

@DenalisGarage Жыл бұрын

hahahaha that intro... thats literally every time I take a part out of a box and inspect it

@KensWorldRestorations Жыл бұрын

There is a slight chance that I actually dropped it more than once...

@DenalisGarage Жыл бұрын

@@KensWorldRestorations hahaha thats JUST like me then

@KensWorldRestorations Жыл бұрын

@@DenalisGarage My other brother from another mother. Hahaha!

@frantisekkmotrik5063 9 ай бұрын

Díky za tvá videa.Zaujal mě zvuk zařazení prvního převodového stupně je to tak Ok? Dříve jsem jezdil na Jawa 250/559(1967) a tam to bylo normální,ale u takto mladého stroje mě to překvapilo 😊 díky za info.Franta

@KensWorldRestorations 9 ай бұрын

Hi Franta - you have a keen eye for detail. That jump into first gear was not normal. The clutch pack and springs are all new and it was sticking. It seems to be fine now so there must have been some sort of break-in with the clutch discs. After riding it for about 500kms, everything is running like new, including the clutch.

@davidguest6051 9 күн бұрын

These starter gears are not OEM. I have 2 Viragos and replaced these a total of 3 times. They last about 8 months then give up. Not sure what country is making these, but not from home.

@KensWorldRestorations 9 күн бұрын

I bought the idler gears from IMPEX Japan and they are OEM Yamaha. The starter clutch was aftermarket and so far, I haven't had any troubles. I think the problem with the starter clutch is that it's generic - Yamaha didn't design it so you'll find a lot of poor quality imitations out there. Most likely the product of China. So far every aftermarket (China) starter solenoid I've tried was garbage.

@johnny8418 Жыл бұрын

スプリング有、無しどちらが良いのですか

@KensWorldRestorations Жыл бұрын

新しいシステムは、スプリングなしで動作するように設計されています。実際、リップの直径が小さすぎるため、古いスプリングを追加することはできません。ソルデノイドにはリターンスプリングが組み込まれており、スターターから電源が遮断されるとギアのカット角度によってアイドラギアが戻ります。

@Consigliori Ай бұрын

Hi! How tall are you?

@KensWorldRestorations Ай бұрын

183cm. 6 feet tall

@Consigliori Ай бұрын

@@KensWorldRestorations Thanks for the answer! Good luck on the roads!

@tetriseffect711 7 ай бұрын

So a single carb conversion for fun

@leroybrodian 9 ай бұрын

This video shows you working on a very nice bike and you stated that you should've changed that gear when you did the rebuild or something like that, i just know by the looks of that bike, you shouldn't have issues with that gear. Sorry i dont believe you on this video.

@KensWorldRestorations 9 ай бұрын

Have a look at all my other videos. What you’re looking at in this video is 6 months of servicing and repairs followed by a year long restoration where I took the bike completely apart and restored it to new. I found the bike in a sea can and it was pretty neglected and it wasn’t running. When I did the restoration, I took it down to the bare frame, removed the engine and did all the repairs that needed to be done before the restoration was started. The carbs were removed and completely disassembled as was the starter and clutch. When I rebuilt the clutch and starter, both side covers came off (those were sand blasted to remove the pitted chrome plating) and were polished. I replaced the starter, the starter solenoid and the clutch. At the time, I didn’t think I needed to replace or repair the starter clutch or the gears but after I put everything back together, I noticed the starter started skipping out and grinding. It was caused by the aftermarket solenoid. Now everything is back to 100% with an OEM solenoid, new idler gears, starter and starter clutch.