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xv750 to 1100 motor swap

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xv750 to 1100 motor swap

PostAuthor: highflying22 » Sat Feb 04, 2017 10:52 am

Ok, I've done a fair amount of research but I still have a few questions. I currently have an 83 xv750. Due to an issue with a broken bolt for the intake manifold I need to replace the head. We're doing complete rebuilds in school right now so it's the perfect time to take it in and freshen up the whole motor. I was looking around and found a 1990 1100 motor with 33k for $200, the only problem with it is the middle drive gear bolt broke off. I've looked at the part numbers and it matches the one from my 750 so I can just swap them out and do the rebuild on the 1100. I already know that the motor will bolt up, I know that I need the pressure sensor and the TCI for the 1100, both of which are included with the motor.

My questions are
On the xv1100 there is an air filter on the front, right side of the bike. My 750 does not have that. I plan to get the bip single carb setup, and I think that having that should be fine, even without the front air filter.

I've asked my instructors and they've told me that the drive shafts are different. I've checked the parts numbers and they are the same. anyone have any insight on that one?

I know that the 1100 can run off the gravity feed, but should I get the fuel pump and the 1100 tank?

last question. will the exhaust from the 750 fit the 1100?

any other information from someone who has done this swap would be awesome. Thanks in advance guys. :bg:

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Re: xv750 to 1100 motor swap

PostAuthor: faffi » Sat Feb 04, 2017 6:54 pm

I have fitted a 1990 1100 engine to my 1982 750. It is IMO a fairly big undertaking.

1: You will either have to build your own wiring harness or get one from the 1100
2: Unless you want to alter the harness from the 1100, you will also need the switchgear, fuse box, instruments and ignition switch. I retained the ignition switch and fuse box and instruments from my 750 and spent much time swapping pins from one connector block to another so that I retained the stock "plug-ability" and avoided scotch-locks and other bodge jobs
3: The 1100 engine is wider and will not work with the stock footpeg on the right. You will either have to use the 1100 pegs and brackets, go to rearsets, or fit the clutch and clutch cover from the 750 with upgraded springs. I will do the latter, having first done the former.
4: You must replace the stud bolts from that of the 750
5: You will need the top engine mounts from the 750
6: You will need the ignition coils off the 1100. They do not fit easily!
7: I use the stock exhaust system from the 750, but I have removed the end mufflers to reduce back pressure. Not sure if that was wise or silly, though.
8: You will have a hard time fitting all the relays from the stock 1100 harness into your frame. If you lengthen the wires to them, you can fit them where the stock 750 used to live if you are not planning to use it

I have a couple of threads on this forum with my frustrations, set-backs and suggestions if you do a little searching :r:
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Re: xv750 to 1100 motor swap

PostAuthor: Jake » Sat Feb 04, 2017 7:40 pm

highflying22 wrote:On the xv1100 there is an air filter on the front, right side of the bike. My 750 does not have that. I plan to get the bip single carb setup, and I think that having that should be fine, even without the front air filter.


As long as you have an air filter you are go to go. BIP intakes have had some unsatisfied customers on this forum, use at you own risk.

highflying22 wrote:I've asked my instructors and they've told me that the drive shafts are different. I've checked the parts numbers and they are the same. anyone have any insight on that one?


Your instructors are definitely wrong ! The same drive shaft was used all Virago 700, 750, 920, 1000 and 1100 shaft drives from '81 until end of production in '99.

highflying22 wrote:I know that the 1100 can run off the gravity feed, but should I get the fuel pump and the 1100 tank?


No. The 1100 tank will not fit the '83 frame, stick with your tank and gravity feed.

highflying22 wrote:last question. will the exhaust from the 750 fit the 1100?


Yes.
faffi wrote:ou will either have to use the 1100 pegs and brackets, go to rearsets,


A third option is forward controls, easily made, several designs available on the forum, or buy them.
Forum Tutorials can be found here http://viragotechforum.com/viewforum.php?f=177

Forward Control Templates ( FREE ) http://viragotechforum.com/viewtopic.php?f=124&t=21556


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Re: xv750 to 1100 motor swap

PostAuthor: Jake » Sat Feb 04, 2017 7:50 pm

Forum Tutorials can be found here http://viragotechforum.com/viewforum.php?f=177

Forward Control Templates ( FREE ) http://viragotechforum.com/viewtopic.php?f=124&t=21556


“It ain’t what you don’t know that gets you in trouble. It’s what you know for sure that just ain’t so.”
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Re: xv750 to 1100 motor swap

PostAuthor: highflying22 » Mon Feb 13, 2017 7:34 pm

Thank you for the information guys. I decided to proceed with the build, I bought the 1990 1100 motor, all foot controls, pegs, handlebars, and hand controls, crash bars, saddle bags, tci, and coils, all for $300. The only thing I wish I would have remembered to get are the plastic connectors that plug into the tci, that would make it a lot easier to wire up. Any idea where I can grab some of those connectors? The motor is currently at the school waiting for me to rebuild it. I'll add what information I can in case it can help anyone else in the future. Thanks again. :thanks:

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Re: xv750 to 1100 motor swap

PostAuthor: mark75 » Tue Feb 14, 2017 12:22 am

wasn't sure if you meant connectors in general or the specific ones for TCI.
these folks have OEM style/type connectors - quick and easy once you get used to the crimp-tool [it's a quality tool, so definitely get/use it] ---> http://vintageconnections.com/

real/exact TCI connectors will prolly have to be scavenged from an old 1100 harness. :con:

IIRC all 700-1100 XVs had air-filter in the right and AIS/MCV in the left 'pod' but, you can run 'em how ever you want.
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Re: xv750 to 1100 motor swap

PostAuthor: gleam » Tue Feb 14, 2017 5:42 am

Take lots of pictures and show us how it goes. I like seeing people willing to try things that are hard, for the first time. Everyone started somewhere. Add your location to your profile.
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Re: xv750 to 1100 motor swap

PostAuthor: nanno » Tue Feb 14, 2017 7:09 am

Regarding the electrical side of things: If you have a working XV750 alternator and ignition-pickups, you can simply swap them over to the 1100 engine and that's the end of all the wiring worries. You do have some wiring to do, if you want to stick with the upgraded XV1100 starter and solenoid.
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

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Re: xv750 to 1100 motor swap

PostAuthor: highflying22 » Tue Feb 14, 2017 5:42 pm

nanno wrote:Regarding the electrical side of things: If you have a working XV750 alternator and ignition-pickups, you can simply swap them over to the 1100 engine and that's the end of all the wiring worries. You do have some wiring to do, if you want to stick with the upgraded XV1100 starter and solenoid.



I just started tearing down the motor today, it'll be a while before I get pictures up, but I'll post as many as I can (that I believe may be helpful or interesting). I'm currently doing some digging on the alternator/ pickups swap from the 750 to see if that would work, have you tried it or do you have any articles where someone attempted it? that would be a nice options since I have to tear down the 750 motor as well.

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Re: xv750 to 1100 motor swap

PostAuthor: nanno » Wed Feb 15, 2017 1:24 am

I've run an XV1100 left engine cover on my TR1 (which uses the older twin-pickup ignition) and now I am running an XV1100 crank in my TR1, so yes, both sides are the same and you can just swap stuff.

Cheers,
Greg
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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Re: xv750 to 1100 motor swap

PostAuthor: highflying22 » Sat Mar 04, 2017 12:08 pm

Alright guys, here's where I'm at so far

I just buttoned up the crankcase yesterday, the gasket kit and piston rings are in, so I should be finished with the motor in the next 1-2 weeks. I got held up because I couldn't find a middle drive gear, so I ended up just buying a used case half with the gear still attached.
15741
15742
15736

I'm pretty sure that I have the wiring down, but if anyone has some extra info that would be great. I have a 91 xv1100 tci being spliced into a n xv750 harness, so I believe the wiring goes like this:

R/G - gets grounded since it's for a fuel reserve switch and I don't have one
Gr - goes to the pickup coil
B - goes to the pickup coil
L/R - gets grounded since it's for the fuel pump relay which i don't have
R/B - is for the starter relay to the new style solenoid, I'm not sure what to do with that one yet.
B/R - goes to the pressure sensor
L/Y - gets grounded since it's for the side stand switch
O - O
Gr - Gr
G - gets grounded since it's for the fuel sender
B - goes to ground
R/W - goes to the pressure sensor

That's what i have for the wiring, if anybody who has done the swap or has links to an article for the wiring, let me know. :bg:

Also, all the relays on the 750 harness need to go, links to an article would be very much appreciated.

I've decided to use the carb from the 750 for the 1100, I can find the jets and everything, but the y-33 needle might be difficult to track down. I figured it'd be easier to just go with a 6 sigma jet kit.

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Re: xv750 to 1100 motor swap

PostAuthor: faffi » Sat Mar 04, 2017 1:11 pm

nanno wrote:I've run an XV1100 left engine cover on my TR1 (which uses the older twin-pickup ignition) and now I am running an XV1100 crank in my TR1, so yes, both sides are the same and you can just swap stuff.

Cheers,
Greg


If I can ever be bothered to do the job, I may have to source an old TR1 LHS engine cover as the find the XV1100 rather, uhm, unattractive.
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Re: xv750 to 1100 motor swap

PostAuthor: highflying22 » Thu Mar 16, 2017 7:58 pm

Alright guys, the motor is done and ready to be mounted up. I'll be mounting it later this weekend and getting everything set up. The last thing i need to get is a jet kit for the Hitachi carbs.

15755

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Re: xv750 to 1100 motor swap

PostAuthor: highflying22 » Wed Mar 29, 2017 7:21 am

Alright, so this is where I'm at so far. The motor is mounted in the bike, I've got the tci wired and I've extended the wires so I can mount it where the document holder is.

I thought I was done with my wiring (91 handlebar controls) until I put the battery to it and the headlight didn't work, the right turn signal came on but didn't flash, the left turn signal didn't do anything.... until you hit the horn button, the signal indicator on the dash would flash with the horn button and the horn would kind of... hiccup lol.

I think I'm going to use my old controls lol.

Only question is about the red and white wire for the 750 side of the harness that came from the tci, which wire if any from the 1100 tci would go to that one?
15777

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Re: xv750 to 1100 motor swap

PostAuthor: highflying22 » Fri May 05, 2017 9:22 am

15818

Well, the motor is in, i installed a dynojet kit in the carbs, everything is hooked up but there's no spark..... :ops: back to the drawing board I go.

I'm thinking there's an issue with the tci. I'm going to triple check my wiring tonight and see what I can find.

If I had a known, good tci to test with that would be a lot easier.

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Re: xv750 to 1100 motor swap

PostAuthor: mark75 » Fri May 05, 2017 3:19 pm

re-check battery/grounds/connections/safety switches/fuses
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'13 - FXDC Super Glide Custom
'82 - XV750

Time flies whether you're having fun :yahoo: ... or not ... :fan:
And ---
Any day above ground is a good day. so Laissez les bon temps roulez ...
just roll safely

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Re: xv750 to 1100 motor swap

PostAuthor: highflying22 » Sat May 06, 2017 5:08 pm

I've got power to the coils from the red/white wire from the kill switch, the orange and grey wires from the tci have power. The pickup coil is testing at 208 ohms. The ground for the two is good. The only other thing I could think would be the pick up coil is testing good but is actually bad.

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Re: xv750 to 1100 motor swap

PostAuthor: highflying22 » Mon May 08, 2017 12:43 pm

I tested the pickup coils and it's putting out .26 VAC.

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Re: xv750 to 1100 motor swap

PostAuthor: mark75 » Mon May 08, 2017 3:39 pm

highflying22 wrote:I tested the pickup coils and it's putting out .26 VAC.


?
pick-up coil resistance should be 155 ohms
The views, opinions, and experiences expressed in this post are mine and may not necessarily represent views and opinions of other VTF members, so feel free to agree, disagree, or ignore them.
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"Over the Mountains of the Moon,
Down the Valley of the Shadow,
Ride, boldly ride" ... E.A. Poe

'13 - FXDC Super Glide Custom
'82 - XV750

Time flies whether you're having fun :yahoo: ... or not ... :fan:
And ---
Any day above ground is a good day. so Laissez les bon temps roulez ...
just roll safely

"I hear and I forget,
I see and I remember,
I do and I understand."
... Confucius*

If you don't read the news you are not informed.
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Re: xv750 to 1100 motor swap

PostAuthor: highflying22 » Tue May 09, 2017 8:07 am

mark75 wrote:
highflying22 wrote:I tested the pickup coils and it's putting out .26 VAC.


?
pick-up coil resistance should be 155 ohms



The resistance for my pickup is 208 ohms which is in spec for my motor. The output to 4th the tci I believe should be 5 VAC

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