Motorcycle Repair: 83 yamaha virago, starter clutch, clanks


Question
starter clutch clanks and grinds and wont turn the motor over been told it is a common problem but noone can tell me how to fix it parts don't look workout what do i need to do to fix the problem

Answer
Logan,

the virago starter fix is different
depending on the year and model.

-your 1983 starter "fix" is usually checking
the starter gears for damaged or rounded edges
and either replacing or grinding them
for better engagement.

-Also the spring clips need to have a certain
level of tension to make the gears engage
properly. These can be replaced or some
people sell little clamps to help increase the
tension. These are probably on eBay.

-the coil spring should be kept in as it
pushes the gear back out of engagement.

-sometimes a spacer can be added between
the gears so it does not have to travel
so far before engaging. It needs to
be an exact size though. The info
should be on one of the following links:

http://www.drpiston.com/
http://www.dansmc.com/virago_starter.htm
http://old.ccworks.org/index_files/starter.htm
http://www.drpiston.com/81_83_Starter_Paper.html

-Finally, Yamaha suggests changing the large tension clip
Part # 904-68291-06-00 on the idler gear.
Look for wear in the clip groove. Hand grind smooth.
Replace the idler gear also. Use a spring gauge to
check the tension of the spring clip.
It should be 4.9 to 5.1 lbs. per inch.
If the groove is worn excessively then install
washer part # 902-01356-68-00 between the idler gears.