Grafting a modern starter clutch onto a virago

[Southclaw]

Keep in mind, I AM NOT A MECHANIC! I didn't grow up working on bikes, only cars.

Looking at the first gen virago starter system always makes my brain hurt, it's just SO BAD! But each time I do, I wonder if it would be possible to stuff a modern starting system inside there. So I started looking at what a modern system does different, I'm not to far yet, but looks like most use a clutch system or something of the like.

So my question is could you fit one on the flywheel and make a spacer to go between the case and the cover to keep everything aligned? Sure you'd have to replace some parts and some maybe a spindle, but could it be done? Or am I just crazy.

I got the idea when I saw a video of a Suzuki GS 1000, it's some sort of gear with three notches in it that disengaged when the engine started to spin on its own, and it only looked about a 1/2 inch thick, you need a reduction gear anyway so take out the #2 idler gear and replace it with one that's the right size and shape.

[Flyingdog]

"Looking at the first gen virago starter system always makes your brain hurt?"


That is called a brain aneurysm. You outta get that looked at. Specially before you start cutting/rearranging stuff. Could pop!

[mark75]

Yamaha went with - adding a solenoid, lever, and sprag type Bendix.

what you have - Gen-I ---> http://www.mrcycles.com/oemparts/a/yam/ ... ter-clutch

what Yam did - Gen-II ---> http://www.mrcycles.com/oemparts/a/yam/ ... ter-clutch

if you have your own machine shop you can prolly come up with an other fix, but bring a lunch 'cause it's going to take a while.

easier to get a donor side case, etc. and swap up to Gen-II.

[Southclaw]

Mark, after a bit more research it looks like the gen 2 system is basically what I was thinking of, I had just seen it mounted behind the flywheel compared to what Yamaha did. I always hear about the gen 2 upgrade but I thought it was a solenoid that pushed the gears together instead of the spiral gear that pulled the #2 idle gear into the flywheel, hence why I was looking at doing something different, turns out I was just reinventing the wheel!

[Flyingdog]

Haven't checked around, but I 'think' the 920 did have the machined hole in the case to except the sliding gear paw. Think they did, not entirely sure bout the 920s. Someone here will. But if it did, sometimes you can score a side cover that excepts the solenoid, lever gear and all the goodies to convert gen I to gen II even on Ebay. Or scoring a donor bike might be the way. I saw a totally annihilated bike sell for $150 before some salvage yard stripped it. It had all them gen II goodies. Someone got lucky.

[Southclaw]

Yeah most xv920 bikes do have the hole, I know mine does.

[rantingsmith]

Still, there's a lot of 1st gen 750's out there that cannot be upgraded, working out if there is a modern starter gear to replace some of the parts and get the system to work could be a little goldmine..

I have one such 750 and my only option in (hopefully) the distant future is swapping the left case half for one that can be upgraded as I really want to keep the matching engine and frame nos..

Cheers,

Rant.

[Flyingdog]

Yea..but above it all, if Southclaw could come up with a system, he'd be: Sharpen thee ole pencil...oh wait..those aren't used now-a-days.

[Southclaw]

I'll keep poking around and see if I can come up with some ideas that could work without the milled upgrade hole. Might be able to fit something in there

[beltdrive]

I am currently working on a XVS 1100 starter system for Gen 1
I am double jobbing, I live in Denmark, so I have to make a lot of tax, before I can go home, so the project is moving a little slow.
BUT ------ IN SHORT ---- IN THEORY
1. I am fitting a XVS 1100 flywheel to the crank of my Gen 1 XV920J
2. On the inside of the XVS flywheel, it has a one way clutch system for the starter, it is x,x wide, making the flywheel wider by x,x - - I think
3. I think the middle gears, have the same centre, as the middle gears in Gen 1, so I might only have to make bushings, to use the same holes.
4. The starter motor fits in the same hole as Gen 1, the gear on it is different, but will fit the XVS middle gears, as these belong together already.
5. As the flywheel is wider on the XVS, ( I think - I do not know, as I do not have one yet) the stator has to move x,x outwards.
6. I need a spare left side cover, on that, I cut the round part of, very close the flat part, on the other left side cover - ON - the engine, I cut the round part of x,x out from the flat part - if you follow - here I weld the spare round part on, so the stator is now placed x,x further out, and will clear the wider flywheel.
7. now this is my plan, as I do not have all the parts yet, I cannot tell the hole story, But I will, when I get that far, - - - and who knows, maybe their is a reason for it cannot work, but right now I cannot see why not.
If anybody have more time, they are very welcome to outdo me, I am not here for the fame, I am here for the fun and for the help we can give each other, getting the most out of these "Wonderful" bikes, that we love so much and sometimes hate a little.

Have fun - hi from Erik

[rantingsmith]

Hey Erik, that sounds like it might work. Make sure you take plenty of progress pictures even crappy phone ones and post them here!

I have both 1st and 2nd gen spare covers so let me know if you need any dimensions.

Cheers,

Rant.


Nothing worth doing is ever easy.

1983 XV750SE CAFE/BRAT - 1981 TR1.1NCENT PROJECT - 1982 XV750/920 upgrade SIDECAR PROJECT w. WATSONIAN MONACO CHAIR