YAMAHA XV535 STARTER CLUTCH PROBLEM | DETAILED REMOVAL TUTORIAL | 4K | ENGINE NOISE FIX | #7
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- čas přidán 24. 04. 2021
- In this video, I show you what caused the engine noise, took 3 days to take the flywheel of and couldn't beleive what I've found....
If not interested in the tutorial and removal then here you go 12:04
#motorcycleproject #bikebuild #viragotutorial
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Tools I recommend for beginner/ DIY mechanics
Sealey 4pc JIS screwdriver set ebay.us/IPnnTk
Cheap internal bearing puller kit ebay.us/dqsgMf
Wera 9 piece Long Allen keys ebay.us/jQqlHb
Wera 9 piece Extra long STAINLESS steel allen key set ebay.us/k61h1m
Wera 9 piece Short Allen keys the one in the video ebay.us/GSp19W
Wera 9 Piece Short BALL END Allen keys ebay.us/YwEiE4
Wera 6 Piece Screwdriver lasertip set ebay.us/C1stL5
Clarke CDM35C Multimeter in MachineMart bit.ly/2uNOKA8
Parts I purchased for the Virago 535 build
Air filter ebay.us/xBWCSz
Spark plugs BPR7ES ebay.us/n6SKB3
BP7ES ebay.us/yuRqPp
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Thank you for sharing this great video with us all.. It was very well explained in every way.. And well done for reaching 1k subscribers..
Thank you very much, I really appreciate your kind words...every time I read a comment like this, reminds me why I do it👍😉
@@MidlandCruiser You are more than welcome..
+1, your channel would deserve a lot more subscribers and views.
very good explanation, doing this myself
I wish I had a video resource like this, 15 years ago. I passed since then thru every "narrow" moment illustrated in this video multiple times. Once I had to collect a broken starter clutch from the engine piece by piece. However I still have my 535 along with a '97 XV1100. I've ordered my own custom built puller and a rubber hammer, just for this operation. I bought a new rotor as the old one got hit encouraging further deformations. The design of the original three roller starter clutch drove me crazy as it is flawed from conception. At this time my 535 engine is undergoing a complete overhaul followed by a six roller starter clutch. God please go easy on me this time and thank You I have another Virago to ride. Nice video, I bet it would still alleviate a lot of heartaches around the globe. Thanks!
Hello, thank you for sharing your experiences. As you can see I had to get a lot stronger puller too as the general cheap one wasn't strong enough. The design itself is a lot better in my opinion then the early 750 and 920...that starter system is just crap. No wonder it's called "box of rocks"😄
I also ordered the 6 roller clutch, we'll see how it works, and definitely put some thread lock on the bolts to avoid this headache again...thanks again and wish you the best with your bikes😉👍
@@MidlandCruiser Please don't forget to share your experience with six roller starter clutch. Thank you Sir! Bests!
Masterclass again. Thank you.
You're very welcome , I'm glad you liked it😉
Great tutorial well done for reaching 1k subscribers
Thank you very much my friend, has been a lon journey, but was worth it😁
You must hit the puller bolt with the hammer several times and the flywheel fall easy. BUT. When you untie the scentral bolt of the flywheel you must leave it inside, only untie 2-3mm. Than use it like a base for the puller main screw. Screw it hard and bag with the hammer... :). Done it several times
Thank you for the suggestions I appreciate it. I hope I don't have to do this again, but if I do I will try to use a shock method or something similar...👍
to break a taper, tension the puller, then hit the clutch hub a sharp blow with a dead hammer
Hey. Thanks for the video. Just bought a 535 and it drives fine, but sometimes it's hard to start and it looks like the starter is making some whining noises. Maybe you could point me in the right direction?
Hello. In these bikes the starter mechanism is quite simple...basically the motor drives the starter gear directly. Then the starter gear is inside the starter clutch as you saw in the video, the only thing could make it cause a whining noise during starting, if this clutch is slipping on the boss of the gear. I hope it makes sense
The rollers in the clutch maybe worn or the boss on the starter gear is worn, or both..unfortunately you will have to take it apart and have a look
@@MidlandCruiser I will take a look as soon as I can. Thanks for your answer
Top notch explanation!
Is there any way of contacting you?
I wonder if you may help me
@Rui Carvalho Yes go to my Facebook page and there you can send me PM if you'd like to.👍
Hello, I want to ask about the starter clutch. Have you decided to buy the same kind of clutch with 3 rollers or the heavy duty one with 6 rollers? How is it holding up? Are you satisfied?
(Also another question - the spark plugs in the description - I am also in Europe, and my manual says that the BP7ES is for US motorcycles while the BPR7ES are for UK and EU motorcycles. Currently I have the BP7ES plugs in and I am wondering if it could cause any problems to the engine if I ran the spark plugs without a resistor?)
Thank you in advance for your time!
Hello, yes the correct plug is the non resistor type BP7ES. I have fitted the starter clutch and went for the 6 roller version, 2 times the gripping surface in theory it should last longer. Seems well made and fits perfect. I used red (permanent) loctite on the bolts and hit them with a cold chisel to lock it in the metal, like they do it in the factory. I hope I will have time to make videos again soon. Hope this helps
@@MidlandCruiser Supercool! Thanks for the response. I think I will purchase the 6roller starter clutch as well.
Can you just magnetize the bolt? Or would it not be sufficient
Hello, no that wouldn't make a difference. The vibrations make them come loose, so the best thing to do is to use red Loctite on them, which I will do when I put it together.
Hello I have a 2015 TTR 230 I replaced the starter clutch Fly wheel does not turn only the starter clutch gear turns
I'm sorry but I'm not familiar with the TTR230...also not entirely sure what do you mean.
The starter motor doesn't turn the flywheel?
hello, tell me, on a Yamaha Virago 1100, is there a similar problem? I have a thud at idle and at medium temperatures. There is no knock on the cold one and there is no knock on the hot one, but it knocks on the medium ones.
Hello. That seems to be a wierd one.
There is a little ticking noise from the top when it is hot, and considered normal (it's the valve lifters)
The starter mechanism is completely different on the 1100, and it isn't noisy once the engine is running. I've heard that, there could be a deeper sound coming from the engine but normally when it's cold and it is normal, because of the bigger tolerances in the air cooled engine, once warmed up, it goes away (mine has this, and seems to be fine)
Hope this helps, really hard to help without actually hearing the engine
@@MidlandCruiser
1. Hello. Here is a video of my motorcycle - czcams.com/video/_7RJqxC-vBA/video.html
2.Here is a video of motorcycles from an auction in Japan, and the same sound is present - czcams.com/video/MyHINRywRG0/video.html
czcams.com/video/Dmoims22MNE/video.html.
This happens at average temperatures, about 50 degrees Celsius. on a hot engine, the sound almost disappears. Please tell me, have you ever encountered such a thing? Is this normal?
@@Gofffsky Normal. Most big Viragos have a slight thud, it is clutch noise.
No need to worry about it.
how did you get the flywheel not to move, trying to get mine of ,
I used a bar through the bolts on the flywheel puller, but you could put it in 5th gear and blocking the rear wheel or press down on the rear brake.
@@MidlandCruiser mines very well glued on, bent 3 yambit pullers, waiting on a better one coming, Thanx for answering, , yea tried a heavy screwdriver to hold the flywheel, does the job but being very stubborn, , tried a sliding puller, had to grind the claws to fit, snapped, . tbc , good explanations
Mines of now, heavy duty puller , cheers
I ended up using a 16mm thick tool steel plate and got it off with that. Used the threaded bit from a silverline cheap puller, and cut out 3 slots for the bolts with an angle grinder. Ugly but worked fine. Glad you got it off
At 7:10 is this normal?? when is there a video of the assembly?
No it is not normal...there can be a little movement but not this much...
The assembly video coming in a few weeks/months hopefully...unfortunately I couldn't do anything on the bike in the last few months due to being busy with other things. I'm hoping to finish it over the winter...
Heat one bolt at a time..
Hello. I replaced the stator on my bike and for a day everything was fine. The next day when I started the bike, it made a noise... like something was scraping the metal. I opened again the stator cover but no signs of something to be wrong... Dont have the tools to remove the clutch... :(
Hello. Try to move the starter clutch behind the flywheel with your fingers, if it's loose you'll ne able to move it left to right, if it moves than you'll have to remove it, check the starter clutch, if it's ok the replace the bolts and use red (permanent) loctite on it. It is a good idea to change the clutch tk a new one if you took it apart, just in case. There is refurbish kits available or you can buy a full new one if needed....
Regarding the tools, many people managed to remove the flywheel with a fairly cheap harmonic balancer puller, so you could give that a go...
@@MidlandCruiser Flywheel moves ONLY IN ONE DIRECTION... guess this is good!
I meant grab the actual starter clutch and try to move it left to right like I show it in the video from 12:20. You can do it while the flywheel still on the crankshaft.
Just to make sure we talk about the same things.
Flywheel = big round metal with magnets inside
Starter clutch = smaller round metal bolted to the back side of the flywheel
Starter gear = big gear which only spins 1 way
Which one did you try to turn?
@@MidlandCruiser Starter gear!
Yes that is a good sign if it only spins 1 way however the clutch bolts can be still loose, jut like they were on mine. So try to spin that behind the flywheel, shouldn't be possible...
That sits between the the big gear you spun and the flywheel with the magnets..hope this helps
It is look like the clutch is not in stock condition. When I disassemble my one I saw that bolts were riveted on the back side. And I am sure that it was a stock.
Riveted? That's strange, it should be bolted in case you need to replace it...never heard about riveting it to the flywheel..🤷♂️
@@MidlandCruiser They aren't riveted. They only stake the bolts in the factory. That's why they often come loose.
Hey man, Thanks for the video, very informative! My 535 won't start and when i push the start button, it makes an horryfying/loud metal on metal noise. I opened the engine and all i can teel is that i can turn clock wise and anti clock wise the crankshaft and the starter gear will move both ways, not good right ? also if i turn slowy clockwise, the starter clutch and starter gear move at the same speed(that's ok i think) but as soon as i apply some force to make it spin faster, it won't move at the same speed like the starter gear(or clutch) is not sticking properly when some force is used. Don't know if i'm very precise haha, but i think that is not supposed to act like that and i will have to, change the starter clutch right ?
By the way, how did the upgraded starter clutch goes ? where did you buy it ?
Thanks again man for your work !
Hello, sorry for the late reply but the comment went straight into hold.
What you described is definitely caused by the starter clutch and you may need to change the big gear too as that has the surface which the clutch grabs, and probably very worn if you can turn that gear both ways, either way need to be checked and measured.
Believe it or not I still haven't put it together as I am busy upgrading the house. That being said I want to sell it this year so I'll have to find time to finish it, as I need the space...
@@MidlandCruiser No problem man, thanks for the reply ! i changed the starter clutch, and the big or small gears looks perfect so i hope it will solve the probleme with only the new starter clutch, i just have to reassemble everything to test it !
@@antoineduclos8706 how did it go ? I'm having the same problem