That's pretty common in the industry. Many many cars trucks and motorcycles have magnets in the oil pan, transmission, and differential. There's no way to completely eliminate metal to metal contact. Dry starts take a moment to get oil pressure, gears mesh, etc. The best you can do is reduce the likelihood of particles entering the oiling system, hence strategically placed magnets.
Sorry for the delayed response. I wish I had replaced the flywheel. It has wear however it does seem to work ok. The shims push the gear on the starter just a fraction out farther, so they engage more positively.
I had an 82 Seca turbo at one time also, different starter setup I believe. Sold it because it was too much of a pain to keep running. My dad had an 81-82? 750 Virago and the starter was a constant pain in the rear!
Sorry for what will be a long comment. But I have owned nearly 2 dozen Viragos over the years and can likely offer some information that may be of help to people. Nearly all if tge viragos I've owned (or worked on) had or developed the dreaded "box of rocks" issue. Many people don't understand there is more than one issue with the starting system in the virago. First if the "tension spring" weakens it can cause slight engagement problems with the flywheel (don't waste your money on the "power clip" it's never worked for me). This can present as spinning the gear but not turning over the engine or grinding the gears either with or without turning the engine. The first mistake most people make is holding the button too long and overhearing the starter. You should NEVER crank any motorcycle starter more than 5 seconds at a time. Sometimes you can flip one of the gears to get a little more life or of it. What has worked the best for me is making sure you have a good battery, a good starter, and using a lathe to turn down the flywheel (it's hardened so it isn't fun but it does work) to freshen up the teeth. I've had VERY little benefit from amy of the gimmick "power clip" or starter shim kits. They are at best a bandaid and more often simply a total waste of time and money. You don't show the results in the video so we don't know how it worked for you. I hope for your sake it fixed your issue. I love the 82 xv920 virago, I like that cycom dash and square headlight. Happy riding.
I had 1982 Virgao 750 for many years. This problem is a design flaw with the bike. I had performed similar repairs as shown in this video many times. It does work for a period of time, but will return. What happens is the gear teeth of the fly wheel wear down. Also the teeth on the start motor gear. However it is the fly wheel teeth wearing down that is the big problem. Eventually the fly wheel teeth wear to a point where shims and replacement springs will not be effective.
Soooo, we only have YOUR word for it that the bike starts okay now. Interesting that you didn't SHOW US. Actually, very good video. Great views of how everything goes together. I knew you were someone to listen to when you made a bolt diagram on the cardboard with holes for each screw. Most guys just throw all the screws in a jar - amateurs.
Don't waste your time with the shims. The outer planetary gear spins inside the starter on the older Viragos. I tack welded the planetary gear to the ring with four tabs that it fits into, this fixes it for good.
The power clip does not help the gears engage - the only thing is does is help the starter motor / gear spin down faster. It makes the starter DISENGAGE faster.
Dr. Virago website, I don't know if it is still working. I think you can also get them from any yamaha dealer or a store like bike bandit. It takes a salesman to look up the correct Yamaha starter repair kit.
PS: It is shame, because this is really a nice bike. I suggest talking to a machine shop to see if possibly they grind and reshape the fly wheel teeth, or perhaps find a salvaged fly wheel from a bike with very low miles on it.
I am trying to do the same fix but I purchased a new 4 brush starter. Installed a new power clip but did not understand your comment about aligning metal rods on reassembly. I did reassembly but something must be jammed because all I get is a clunk, starter will not rotate but did rotate before reassembly. How did you align all the gears before side case install? How did you install side case cover and verify all parts fit correctly? Thanks Rod new biker...
Great video. I have 1983, having big time troubles getting cover off to get to gears. Are there only 14 screws, do the 3 in middle come out also. Front seems to want to come open, but back part fouled. Can you assist please?
I have a '83 Virago 920. If you used the Dr. Virago CD-ROM, did you do everything he did? Including cleaning the starter? I have bought a new #2 Idle, power clip and shims. Will that do the trick?
You make a slight mistake when you take the cover off there is a shim on the shifter shaft that needs to be reinstalled. Most times when the cover is removed the shim falls off. or sticks to the cover. This makes it a lot harder to install the stator cover
I don't think the cover will go all the way on if the metal rods I was referring to was not properly aligned. Maybe you have a wrong order on the gears (probably not) or they are torqued sideways preventing them from functioning. Sounds like a take apart job again. Sorry I couldn't be more helpful.
also the factory changed the design in production year 1983 and that is why you have no power clip and is trouble free. A hot battery is a must as this system is sensitive to low voltage. Voltage is power and the starter requires much. amps is the rate of speed.
so this motorcycle mechanic is working on this heart surgeon's cycle.. He asks the surgeon, "Say, we both diagnose complex problems, open up the subject, fix the problem, and close it all back up. How come you make so much more $ than me?" The surgeon leans over and whispers, "OK, so try replacing a piston while its running."
i used the power clip and my 83 virgao and it starts up great now. strange how making the clip more powerful helps it. any explanations as to how that works?
I stupidly knocked off the friction clip attached to the starter assembly so now I have to go through this entire process to get it back on. So since I'm at it, any know the cost of the power clip? Or has anyone tried or seen the hose clamp on the clip trick?
Wtf. Why can’t anyone ever have their video show the new starter firing up. I have no idea if this worked or you just wasted 6 hours and a lot of money
if you trash the flywheel gear, your chances of finging another one ore slim to non. the modification must be done. It is easy and intermediate gear is still available. the factory is obseleting some of these parts.
hello.my names is viorel .I have a virago xv 750 se 81-83 ,I want to know if there is any change in or how can fix ,the starte clucth mechanism and how it can solved .thanks.
hi steve, i know this is an older video and your resources might not be up to date anymore; however where did you get that rebuilt starter and fix kit? I'm working on a 81 xv920 and i'm having starter woes. thanks
how is the fix still working? I am about at my whits end with trying to get my starter to hit everytime. What is the average amount of trys does it take to start the bike?
Hey guys. could any of u help me out here please. I got a 1999 virago 125cc. The starter wont start the bikeIt wont even make a noise nothing. I have to hit second gear and run with the bike to get it to turn on. After its turns on everything works geart and when it gets hot the starter will work just fine... I changed the battery spark plugs cleaned out the carburetor and i even took a part the starter from the handel bars apart and cleaned it. Nothing is working and i reallly dont know what else to do here. Any ideas would be greatly appreciated
where do I get the chims and the power clip I have the 1982 virago 920 and I have the problem I which I watch your video before and save me a lots of problems
if you have 82 or older, you must fix it. anytime gears are grinding, you are shaving metal off the sides of the teeth. A huge no-no! and of course these fine metal particles get circulated through the engine. another no-no.
I have a1993 virago 750. Maybe someone here can point me in the right direction. This all started after riding her through some rain (which I do often, its my only mode of transportation). So there was a delay when I turned the ignition to when the lights came on, then when I hit the starter everything just shut down. Took the seat off, fuses seem ok--battery is brand new. Tried to push start, got a little grumble and light flickering but ultimately nothing. My baby is sitting alone in the parking lot at work now.
factory has superseeded the original gear with a gear that is much harder steel. ir you take a pair of channel locs and compress clip, is is workable. i modified my clip with steel ring. bitch to get on though.
I love how Yamaha designed it from the start with a magnet to catch the broken metal pieces
That's pretty common in the industry. Many many cars trucks and motorcycles have magnets in the oil pan, transmission, and differential. There's no way to completely eliminate metal to metal contact. Dry starts take a moment to get oil pressure, gears mesh, etc. The best you can do is reduce the likelihood of particles entering the oiling system, hence strategically placed magnets.
Steve's DIY is the most comprehensive and Permanent starter-fix on gen-1 virago's , that I have ever-seen and i've seen most of them . Dave nz
I just purchased the kit from Dr. Virago's web site. He still has them and it worked great on my bike!
Dr.Virago
Yes, I did everything. And it did the trick, greatly improved, not perfect, however like 90% better which I am happy with.
Hey mandosteve......looks like someone before you tried a "band-aid" fix on the starter issue, LOL. Thanks for posting!
Sorry for the delayed response. I wish I had replaced the flywheel. It has wear however it does seem to work ok. The shims push the gear on the starter just a fraction out farther, so they engage more positively.
I had an 82 Seca turbo at one time also, different starter setup I believe. Sold it because it was too much of a pain to keep running. My dad had an 81-82? 750 Virago and the starter was a constant pain in the rear!
Sorry for what will be a long comment. But I have owned nearly 2 dozen Viragos over the years and can likely offer some information that may be of help to people. Nearly all if tge viragos I've owned (or worked on) had or developed the dreaded "box of rocks" issue. Many people don't understand there is more than one issue with the starting system in the virago. First if the "tension spring" weakens it can cause slight engagement problems with the flywheel (don't waste your money on the "power clip" it's never worked for me). This can present as spinning the gear but not turning over the engine or grinding the gears either with or without turning the engine. The first mistake most people make is holding the button too long and overhearing the starter. You should NEVER crank any motorcycle starter more than 5 seconds at a time. Sometimes you can flip one of the gears to get a little more life or of it. What has worked the best for me is making sure you have a good battery, a good starter, and using a lathe to turn down the flywheel (it's hardened so it isn't fun but it does work) to freshen up the teeth. I've had VERY little benefit from amy of the gimmick "power clip" or starter shim kits. They are at best a bandaid and more often simply a total waste of time and money. You don't show the results in the video so we don't know how it worked for you. I hope for your sake it fixed your issue. I love the 82 xv920 virago, I like that cycom dash and square headlight. Happy riding.
Paul Waltenberg . What's the best way to fix this problem? Gotten new starter and good battery..whats next step
I had 1982 Virgao 750 for many years. This problem is a design flaw with the bike. I had performed similar repairs as shown in this video many times.
It does work for a period of time, but will return. What happens is the gear teeth of the fly wheel wear down. Also the teeth on the start motor gear. However it is the fly wheel teeth wearing down that is the big problem. Eventually the fly wheel teeth wear to a point where shims and replacement springs will not be effective.
I think the powerclip makes a big improvement. I don't think you can get by without it.
Good job thank you.
Soooo, we only have YOUR word for it that the bike starts okay now. Interesting that you didn't SHOW US. Actually, very good video. Great views of how everything goes together. I knew you were someone to listen to when you made a bolt diagram on the cardboard with holes for each screw. Most guys just throw all the screws in a jar - amateurs.
I think the powerclip makes a big improvement. I would not put an original clip back into the starter system.
Don't waste your time with the shims. The outer planetary gear spins inside the starter on the older Viragos. I tack welded the planetary gear to the ring with four tabs that it fits into, this fixes it for good.
David Algie is this inside the starter?
The power clip does not help the gears engage - the only thing is does is help the starter motor / gear spin down faster. It makes the starter DISENGAGE faster.
The bike had the light changed out and the seat before I got it. They also rewired the entire bike, that had to be a huge chore.
Dr. Virago website, I don't know if it is still working. I think you can also get them from any yamaha dealer or a store like bike bandit. It takes a salesman to look up the correct Yamaha starter repair kit.
WHERE DID YOU GET THE SHIMS FROM?
I hAve a new starter in And it came with a free wheel flywheel conversion but don't know what I have to change in order to fit it
PS:
It is shame, because this is really a nice bike. I suggest talking to a machine shop to see if possibly they grind and reshape the fly wheel teeth, or perhaps find a salvaged fly wheel from a bike with very low miles on it.
Can someone please send me a link to the parts I need to repair this.
I am trying to do the same fix but I purchased a new 4 brush starter. Installed a new power clip but did not understand your comment about aligning metal rods on reassembly. I did reassembly but something must be jammed because all I get is a clunk, starter will not rotate but did rotate before reassembly. How did you align all the gears before side case install? How did you install side case cover and verify all parts fit correctly?
Thanks Rod new biker...
Great video. I have 1983, having big time troubles getting cover off to get to gears. Are there only 14 screws, do the 3 in middle come out also. Front seems to want to come open, but back part fouled. Can you assist please?
Can you please tell me where you bought the shims and power clip Thanks
I wonder if it actually started without changing the worn gears?
czcams.com/video/vqLHwX_z6kI/video.html
What about teething problems (destroyed) in the six-big-rivets starting flywheel? Usually every big Virago's died exclusively for it.
I have a '83 Virago 920. If you used the Dr. Virago CD-ROM, did you do everything he did? Including cleaning the starter? I have bought a new #2 Idle, power clip and shims. Will that do the trick?
You make a slight mistake when you take the cover off there is a shim on the shifter shaft that
needs to be reinstalled. Most times when the cover is removed the shim falls off. or sticks to the cover. This makes it a lot harder to install the stator cover
once you had all the allan bolts out of the crank cover and removed the cover, what was the configuration of the starter clutch gears please?
I don't think the cover will go all the way on if the metal rods I was referring to was not properly aligned. Maybe you have a wrong order on the gears (probably not) or they are torqued sideways preventing them from functioning. Sounds like a take apart job again. Sorry I couldn't be more helpful.
good vid
forget the shims. just weld the gear tot he ring. this solves box of rocks problem.
Dean Manfrin do u have pictures
also the factory changed the design in production year 1983 and that is why you have no power clip and is trouble free. A hot battery is a must as this system is sensitive to low voltage. Voltage is power and the starter requires much. amps is the rate of speed.
so this motorcycle mechanic is working on this heart surgeon's cycle.. He asks the surgeon, "Say, we both diagnose complex problems, open up the subject, fix the problem, and close it all back up. How come you make so much more $ than me?"
The surgeon leans over and whispers, "OK, so try replacing a piston while its running."
it might hurt your fingers a little. but at least its still running. who needs the piston anyway.
Thanks for the cool vid, i was wandering whre you ot your cool sea and aso how muc of an ordealwas it to change that headlight?
-chuck
hey where did u get the shims and the clip?
Good job! Can you explain how this new powerclip works?
Yea that's most of I want to see
I don't know. I would be surprised if the starters were identical.
i used the power clip and my 83 virgao and it starts up great now. strange how making the clip more powerful helps it. any explanations as to how that works?
I stupidly knocked off the friction clip attached to the starter assembly so now I have to go through this entire process to get it back on. So since I'm at it, any know the cost of the power clip? Or has anyone tried or seen the hose clamp on the clip trick?
Wtf. Why can’t anyone ever have their video show the new starter firing up. I have no idea if this worked or you just wasted 6 hours and a lot of money
czcams.com/video/vqLHwX_z6kI/video.html
if you trash the flywheel gear, your chances of finging another one ore slim to non. the modification must be done. It is easy and intermediate gear is still available. the factory is obseleting some of these parts.
hello.my names is viorel .I have a virago xv 750 se 81-83 ,I want to know if there is any change in or how can fix ,the starte clucth mechanism and how it can solved .thanks.
hi steve, i know this is an older video and your resources might not be up to date anymore; however where did you get that rebuilt starter and fix kit? I'm working on a 81 xv920 and i'm having starter woes. thanks
I have an 83 and same issues . Wonder if I can make my own shims. Not sure what they do exactly for the issue
how is the fix still working? I am about at my whits end with trying to get my starter to hit everytime. What is the average amount of trys does it take to start the bike?
Hey guys. could any of u help me out here please. I got a 1999 virago 125cc. The starter wont start the bikeIt wont even make a noise nothing. I have to hit second gear and run with the bike to get it to turn on. After its turns on everything works geart and when it gets hot the starter will work just fine... I changed the battery spark plugs cleaned out the carburetor and i even took a part the starter from the handel bars apart and cleaned it. Nothing is working and i reallly dont know what else to do here. Any ideas would be greatly appreciated
The early "80"s yamahas had bad starters, not a problem on the xs because it still had a kick-start,- these only had electric start only!!!!
hi friends ,, i have a problem with my Virago motorcycle ,, where can I get a starter Virago 535 ?? I am from Indonesia
where do I get the chims and the power clip I have the 1982 virago 920 and I have the problem I which I watch your video before and save me a lots of problems
Hello. What is the game between valve and rocker arm for xv750se 81- 83
парни масло нужно сливать перед снятием этой крышки двигателя?
if you have 82 or older, you must fix it. anytime gears are grinding, you are shaving metal off the sides of the teeth. A huge no-no! and of course these fine metal particles get circulated through the engine. another no-no.
I have a1993 virago 750. Maybe someone here can point me in the right direction. This all started after riding her through some rain (which I do often, its my only mode of transportation). So there was a delay when I turned the ignition to when the lights came on, then when I hit the starter everything just shut down. Took the seat off, fuses seem ok--battery is brand new. Tried to push start, got a little grumble and light flickering but ultimately nothing. My baby is sitting alone in the parking lot at work now.
+Garry Collins sounds just like a bad battery. Get it tested out and get a new one if necessary.
try checking the starter solenoid. same thing happened to my ybr.
+primarymaster01 Took it to my mechanic, the voltage regulator was shot and fried the battery.
factory has superseeded the original gear with a gear that is much harder steel. ir you take a pair of channel locs and compress clip, is is workable. i modified my clip with steel ring. bitch to get on though.
its much easier if you disconnect the clutch cable. You did it the hard way.
From a guy named peter pasko. I would search for a different person to do buisness with he is a rather rude guy. But if you do go with him use paypal.
Six hours ?!?!
I can do that in a half hour. ALL Viragos have starter issues.