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2nd gen starter on my 82 xv750 (SOLVED)

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2nd gen starter on my 82 xv750 (SOLVED)

PostAuthor: totallyredvirago » Fri Jun 20, 2014 8:05 pm

had some time to play today. yes the 2nd gen starter is the first to do. so here we go..
first the factory pic with forwards.
beginning.jpg

drained the oil..
oil drain.jpg

next the forwards removed exposing the side cover.
bolts removed.jpg

next the clutch cable cover removed (there is a hidden bolt behind this cover).
clutch cable.jpg

next removed the cable from the lever (i know a bad pic)
clutch cable removed.jpg

next i removed the air box, seat and lifted the tank plate to unplug the pickup connector.
air box removed.jpg

next i removed the tool box to unplug the stator white wires.
tool box removed.jpg

next i removed all 13 side cover bolts.
side cover ready to remove.jpg

side cover removed.
side cover off.jpg

installed the lever rod and checked. slides good no binding in
the hole.
arm.jpg

next i installed the shaft and washer.
washer shaft.jpg

for those non believers. yes this is a 750.
xv750.jpg

along with the shaft, washer i installed the #1 gear.
washer shaft gear.jpg

next the #2 gear and hex gear assy. see the little rubber O seal?
hex gear.jpg

i used this seal to hold the hex and #2 gear back in place.
2 gear.jpg

this is the xv1000 side cover i am using. no stator or pickups. i am using the ones that was on the 1st gen cover.
new cover.jpg

this is the stator installed along with the stator harness bracket.
stator installed.jpg

this is the stator, bracket and pickups installed.
pickups installed.jpg

next i installed the clutch balls/lever assy.
clutch balls installed.jpg

the side cover is done. i am doing a dry install due to i cant find my RTV. i use 2 phillips screwdrivers 1 in each guide.
screwdrivers as guides.jpg

i place the screwdrivers in the cover holes that line up to the guides. i then slide the cover on.
cover install.jpg

the cover slides on nice while watching the harness wires and clutch lever. the cover went on flush with no gap.
clover flush.jpg

i installed 1 cover bolt to hold in place. i then installed the solenoid lever hat and bolt to the lever.
rod hat installed.jpg

next i installed the solenoid lever cover and my skull cover. the side cover and gears install is done.
finished cover.jpg


now the problem.. my forwards will no longer work due to the bar hits the solenoid cover.
fowards no longer fit.jpg

i can do 1 of 2 things.
1- put the forwards on red.
2- notch out the bar to fit around the solenoid.
i am going to work on #2.
next to do is seal the cover and wiring.
i am using the 1st gen starter so no 2nd gen starter clutch. i am also going to wire in a starter relay. more to follow later on............dan
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82 xv 750 skull on grips,levers,3rd brake and side covers.soft bags and tool bag, relay for coils, fresh inferno red, paint code PEL(red)

no time to do it right..always enough time to do it twice.
it is if is isnt :con:
If it went together easy... you forgot something.
when in doubt.... ground it out!

http://www.viragotechforum.com/viewtopic.php?f=140&t=35947 (bare bones wiring81-83 xv750)
http://www.viragotechforum.com/viewtopic.php?f=140&t=48895 (91 up xv750 bare bones)
http://www.viragotechforum.com/viewtopic.php?f=140&t=36987(84-85 xv700,1000 bare bones)

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Re: 2nd gen starter on my 82 xv750

PostAuthor: crdnick » Fri Jun 20, 2014 11:19 pm

did you use the updated #2 gear?

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Re: 2nd gen starter on my 82 xv750

PostAuthor: totallyredvirago » Sat Jun 21, 2014 6:58 am

no......dan
82 xv 750 skull on grips,levers,3rd brake and side covers.soft bags and tool bag, relay for coils, fresh inferno red, paint code PEL(red)

no time to do it right..always enough time to do it twice.
it is if is isnt :con:
If it went together easy... you forgot something.
when in doubt.... ground it out!

http://www.viragotechforum.com/viewtopic.php?f=140&t=35947 (bare bones wiring81-83 xv750)
http://www.viragotechforum.com/viewtopic.php?f=140&t=48895 (91 up xv750 bare bones)
http://www.viragotechforum.com/viewtopic.php?f=140&t=36987(84-85 xv700,1000 bare bones)

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Re: 2nd gen starter on my 82 xv750

PostAuthor: SirDocWolf » Sat Jun 21, 2014 8:19 am

Dan.
I had the same problem with my forward controls when I did this upgrade. I had made forwards similar to yours from highway bars.
My fix was to cut the top of the bars off and then weld 2nd gen foot stands to them. This kept then upright and from rolling forward under the weight of my feet. I do have some pictures somewhere.
I learned on the second set I made leave the highway bars on mount foot stands measure for the cut on the front.
Then do the cuts and welds to highway bars.
I also looked at welding 2 bars to the highway bars from side to side Then brace them up and cut out the side posts that hit starter. I thought I would mount a Oil cooler in here on the brace.

Bill
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Re: 2nd gen starter on my 82 xv750

PostAuthor: bstig60 » Sat Jun 21, 2014 9:37 am

Nice job Dan. Since you are using the first gen starter, is there a concern about kick back taking out the starter since there isn't any clutch. Don't you have your gears JB Welded inside the stock starter?
Bill
"It´s a friggen motorcycle, it´s not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you s**t your pants every now and then. "

Please take the time to edit your profile to show your location. City, State/Province and Country. It is easier to help you if we know where you are.

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Re: 2nd gen starter on my 82 xv750

PostAuthor: kiwibob » Sat Jun 21, 2014 10:44 am

Nice job. I like the idea of screwdrivers in the dowel holes to line 'er up!

I have a long starter shaft (only) here if you want it? Then you'd just have to find a clutch and matching #2 gear. I've run the same no-clutch setup as you have in two bikes, one sheared the starter shaft (who knows why), and one was just noisy.
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Re: 2nd gen starter on my 82 xv750

PostAuthor: totallyredvirago » Sat Jun 21, 2014 11:50 am

part 2 wiring.
first i removed the starter nut at the starter cable.
002.jpg

then i removed the cable from the starter stud.
003.jpg

then i installed the solenoid cable to the starter.
004.jpg

then i removed the nut at the solenoid cable to the starter.
005.jpg

then i removed the battery cable from the solenoid.
006.jpg

now this is just temporary!! i used a bolt and connected the 2 cables together. now the cable starts at the battery then bolted to the cable to the 2nd gen solenoid (battery side).
007.jpg

i then again temporary!! connected the solenoid cable to the battery cable at the starter.
008.jpg

009.jpg

i then taped the connection.
011.jpg

then i taped the bolt connection i made by the battery.
012.jpg

the starter cables are done.
now for the relay install. i removed both wires from the solenoid red/white and blue/white.
013.jpg

red/white to relay terminal 85. this is key on power.
014.jpg

blue/white to terminal 86 this is the ground signal from the start button.
015.jpg

next i temporarily tapped into the main fuse battery power to the relay terminal 30.
016.jpg

next i connected the starter solenoid wire to relay terminal 87.
017.jpg

i grounded my push button since i had to remove it to remove the tool box.
018.jpg

relay is hooked up now to install the battery and check power.
019.jpg

i have battery power to the relay
020.jpg

i have power to the red/white wire to the relay with the key on.
021.jpg


hit the starter button and OOOOHHH YEA BABY!!!! she turns over nice!! a short video.
https://www.youtube.com/watch?v=-oIKKjY ... e=youtu.be

now all that needs to be done is the side cover sealed, oil added, wiring fixed.
i did find a solution to my forwards. since i cant weld i am going to shim the bar out past the starter.
i know another bad pic.
023.jpg


i have 2 long nose starters and both need clutches. this is the reason i am using my welded ring gear 1st gen starter. so far it is working and working great!!!
not only is the bride looking like a H.D. but now she turns over like one :bg: ...lol just kidding............dan
You do not have the required permissions to view the files attached to this post.
82 xv 750 skull on grips,levers,3rd brake and side covers.soft bags and tool bag, relay for coils, fresh inferno red, paint code PEL(red)

no time to do it right..always enough time to do it twice.
it is if is isnt :con:
If it went together easy... you forgot something.
when in doubt.... ground it out!

http://www.viragotechforum.com/viewtopic.php?f=140&t=35947 (bare bones wiring81-83 xv750)
http://www.viragotechforum.com/viewtopic.php?f=140&t=48895 (91 up xv750 bare bones)
http://www.viragotechforum.com/viewtopic.php?f=140&t=36987(84-85 xv700,1000 bare bones)

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Re: 2nd gen starter on my 82 xv750

PostAuthor: madhatter4119 » Thu Jun 26, 2014 3:25 pm

where's the video....the link just take you to google...then back to the forum...?
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Boy do I ever need to stop buying bikes...Know a good Doctor ???

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Re: 2nd gen starter on my 82 xv750

PostAuthor: totallyredvirago » Thu Jun 26, 2014 8:07 pm

try it now.............dan
82 xv 750 skull on grips,levers,3rd brake and side covers.soft bags and tool bag, relay for coils, fresh inferno red, paint code PEL(red)

no time to do it right..always enough time to do it twice.
it is if is isnt :con:
If it went together easy... you forgot something.
when in doubt.... ground it out!

http://www.viragotechforum.com/viewtopic.php?f=140&t=35947 (bare bones wiring81-83 xv750)
http://www.viragotechforum.com/viewtopic.php?f=140&t=48895 (91 up xv750 bare bones)
http://www.viragotechforum.com/viewtopic.php?f=140&t=36987(84-85 xv700,1000 bare bones)

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Re: 2nd gen starter on my 82 xv750

PostAuthor: totallyredvirago » Sat Jul 05, 2014 6:45 pm

got to play again.
mocked up the forward spacers. this is the bottom and middle spacers.
bottom spacer.jpg


this is the top spacer. had to remove the coil to use a longer bolt.
top spacer.jpg


i removed the assembly to do the side cover.
removed the side cover and cleaned the engine case.
case cleaned.jpg


cleaned the rtv off of the pickup grommet and placed in its place.
pickup harness in place.jpg


did the same for the stator harness grommet. got both harness's in the guide at the side cover so the harness's dont get pinched when assembling.
stator harness in place.jpg


opened a new tube of RTV poked a hole in the RTV top and used the narrowing tip. put a nice bead of RTV all around the side cover.
rtv side cover.jpg


placed the side cover on and installed all the bolts. added oil and checked for leaks. none yet. checked the harness's for pinching. none found. adjusted the clutch. installed the forwards and have good clearance.
clearance with spacers.jpg


next i installed the solenoid cover and hooked up the starter cables.
solenoid cover on.jpg


side cover, starter, solenoid, forwards are all done. have to clean up the relay wires, pickup harness, stator harness, install the tool box, air box, add gas and see if she runs................dan
You do not have the required permissions to view the files attached to this post.
82 xv 750 skull on grips,levers,3rd brake and side covers.soft bags and tool bag, relay for coils, fresh inferno red, paint code PEL(red)

no time to do it right..always enough time to do it twice.
it is if is isnt :con:
If it went together easy... you forgot something.
when in doubt.... ground it out!

http://www.viragotechforum.com/viewtopic.php?f=140&t=35947 (bare bones wiring81-83 xv750)
http://www.viragotechforum.com/viewtopic.php?f=140&t=48895 (91 up xv750 bare bones)
http://www.viragotechforum.com/viewtopic.php?f=140&t=36987(84-85 xv700,1000 bare bones)

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Re: 2nd gen starter on my 82 xv750

PostAuthor: bstig60 » Sat Jul 05, 2014 10:18 pm

Nice work, Dan.
Bill
"It´s a friggen motorcycle, it´s not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you s**t your pants every now and then. "

Please take the time to edit your profile to show your location. City, State/Province and Country. It is easier to help you if we know where you are.

SERVICE MANUAL DOWNLOAD LINK
http://viragotechforum.com/viewtopic.php?f=220&t=31501#p279545

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Re: 2nd gen starter on my 82 xv750

PostAuthor: totallyredvirago » Mon Jul 07, 2014 12:34 pm

finished up this part of the project today. i can officially scratch this off the to do list.
i heat shrunk all the relay terminals.
relay heatshrunk.jpg


then i cross taped the relay to the harness so the wires wont come unplugged.
cross taped the relay.jpg


then i taped around the cross tape to hold the tape in place. (i dont think that the wires are going to come unplugged).
relay harness taped.jpg


i spliced into the main fuse wire to power my relay.
battery power heatshrunk.jpg


made the 2 splices to the red/white and blue/white wires then heat shrunk.
solenoid heatshrunk.jpg


the final splice. the wire from the solenoid to the relay. i ran a new wire at the solenoid and routed it with the starter cable to the relay. the wire is hidden so its hard to see in this pic.
solenoid wire routed along starter wire.jpg


put the relay under the tank and assembled the bike.
right side done.
finished right side.jpg


left side done.
finished left side.jpg


this is one reason for the upgrade. this is the old #2 gear spring that i cut in half. i dont recommend in cutting this spring anymore after seeing this.
the old #2 gear spring.jpg


one more heads up. sorry no pics on this one due to i thought i would have to remove the side cover again..
when i went to install the clutch cable to the arm. the arm was no where close to the cable. if i backed off the center adjusting screw the arm would raise but still no where near the cable. even with the cable backed all the way off.
i removed the nut and arm backed out the set screw and turned it. this did not help due to the arm would not line up with the shaft. so i turned it again. this put the arm closer to the cable. i installed the cable and adjusted the clutch tighten the nut then adjusted the lever. clutch works as before the update.
so what does this all mean?
if you remove the clutch arm and turn the shaft. there is only 1 way to hook up the lever to the shaft even tho the lever will slide on the shaft 2 ways there is only 1 way for it to work.

all in all this was a fun project. i did learn some things that will be helpful for those that want to do this. just dont rush it take your time and all will be fine.................dan
You do not have the required permissions to view the files attached to this post.
82 xv 750 skull on grips,levers,3rd brake and side covers.soft bags and tool bag, relay for coils, fresh inferno red, paint code PEL(red)

no time to do it right..always enough time to do it twice.
it is if is isnt :con:
If it went together easy... you forgot something.
when in doubt.... ground it out!

http://www.viragotechforum.com/viewtopic.php?f=140&t=35947 (bare bones wiring81-83 xv750)
http://www.viragotechforum.com/viewtopic.php?f=140&t=48895 (91 up xv750 bare bones)
http://www.viragotechforum.com/viewtopic.php?f=140&t=36987(84-85 xv700,1000 bare bones)

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Re: 2nd gen starter on my 82 xv750 (SOLVED)

PostAuthor: geo » Sat Feb 21, 2015 5:23 pm

awesome job on this one.
pics are great too. :rock:
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