Xv400 Clutch Return Spring Replacement HELP please(SOLVED)

[Coopster]

Hello,

I'm new to the Group.
I had a look around before posting to see if Anybody had the same issue before.

So I've brought my First Bike.

A 92 xv400 -
Needs some work but running.

The little Return spring for the Clutch is broken.
I've ordered a replacement but, and this is where I'm Stuck.

How do I go about replacing it

It's located right under the the engine and I can't see any access to it.

Would Anybody please be able to help advise me on how to go about it.


Thanks in advance

[Jake]

Coopster, once you have 5 posts to your credit, you can download a couple of repair manuals here. The XV400 is a smaller version of the XV535, so most information is the same.

Links to the manuals:

Haynes XV 535,700,750,920,1000,1100 Viragos '81-94

Clymers XV535 to XV1100

[Coopster]

Thank you Jake.

I have looked through a Workshop Manual

But it doesn't go in to the detail I need for the Clutch spring.

I found the diagram for the parts and ordered them.
Also I found a video on line but the placement is different.
Ill look through that link.

Thanks again

[Coopster]

Says

You are not authorised to download this attachment.

Maybe it's over 5 post and a little wait time.

All good I'm in no hurry and not going anywhere.

Ill take a futher look around

[Coopster]

Says

You are not authorised to download this attachment.

Maybe it's over 5 post and a little wait time.

All good I'm in no hurry and not going anywhere.

Ill take a futher look around

Never mind i was on my mobile - had to re log in to download -

[mark75]

Bonne chance.
the xv400 was sold in USA for only one year - in the 80s ['83?], so they are pretty rare here.

or was that the xv500??

[Flyingdog]

Well, gotta better chance getting the needed repairs over there than here. I'm still trying to figure out what (concerning the clutch), is located "under" the engine? Only spring I thought that maybe hidden was the tension spring on clutch actuation shaft. Probly by I don't mess with 535 types. Good luck. Least ya got CMS fairly close. They seem to carry lot more stuff, Virago related. Even though they're fairly pricey at times.

[Coopster]

Yep the clucth return arm is located under the head and looks like I'll have to remove the head to replace the return spring.

The big spring on the clutch cable should not be there, it is was added to help the clutch return (dont work) 

Few pictures for reference:

https://ibb.co/DkbZRyt
https://ibb.co/dLgwd8Z
https://ibb.co/VYFpd3C
https://ibb.co/nm9Pb3L

diagram - number 28 is the spring i have on order and need to replace
https://ibb.co/109qRxY

I've ordered a full engine gasket set - but I've never worked on bikes before so I'm unsure what I'm letting my self in for

[Cusstout 1100]

In your first picture, it appears the hooked end of the spring is not attached to anything, and so it is non-functional. I'd guess it's supposed to be hooked onto the lever that actuates the clutch (left edge of the lever as seen in your picture). I'd probably about turn myself inside out trying to rotate that spring back under the lever and get it hooked back where it belongs before having to remove the cylinder to get at it. Unless, of course, the spring is broken. Removing the cable might help give you some slack to work with.

[Flyingdog]

Yep the clucth return arm is located under the head

Ah..under head/cylinder. "Kinda" thought that's what you meant. When ya said under the engine..I literally starting wondering what clutch thing is "under" an engine?

I've ordered a full engine gasket set - but I've never worked on bikes before so I'm unsure what I'm letting my self in for

Gett'n into? That's too bad that piece has to be pulled, just to replace that spring. Nothing that can't be done, though, but I wouldn't expect a quick fix. (Hint: take lots of pictures)

Like I said..who at Yamaha, ever came up with this design, musta been 3/4s asleep.

Wow..you'd think that expansion spring set-up should work to compensate for the broken tension spring. All I see it as, it's just to "push" the clutch lever back. As much as I absolutely despise rigged stuff, I'd make something else work. Less ya wanna go for a rebuild. Hell, even different pull spring..back to that case bolt could work and "may" even look better than that other spring. But sounds like yer on your way, anywho.

https://www.yamahapartshouse.com/oempar ... dd3/clutch

[Coopster]

Thanks to all for your replies,

On my way with this now so you can close this post up as solved.

Coops

[mark75]

can you share how you fixed it?
that would add to the 'solved library' - for the next-guy...

[Flyingdog]

Bet it's going to take longer than a couple days, to get all those parts. Specially if their snail-mail is anything ours, at times.

[Coopster]

so - i bent the bottom of the spring around the top of the clutch return arm and threaded it downwards until the spring was under the the top of it, then bent the pin back into place to lock it in.

[Flyingdog]

Ah..Good.
So...Was the spring broke, or did it just come uncoupled/or slipped off the arm? Either way, ya saved yourself alotta work.

That was the pits someone got their panties in a wad and 86 ya. Takes all kinds, I guess.

[Coopster]

Ah..Good.
So...Was the spring broke, or did it just come uncoupled/or slipped off the arm? Either way, ya saved yourself alotta work.

yer the spring had broke and was rusty - i gotta a grip on it and it pulled out like a slinky - so just thought id try put the new one on but in reverse lol