Question about 1981 Yamaha XS 650 H

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Need TSB's for my XV920MK

I have a 1983 920 ViragMK. I see on some sites there are TSB's for the starter shimming. However, my eyes are not able to focus on print that is .003 high. Can anyone tell me where I maight find this information on line that is readable?
I also seem to have inherited a ******** mechanics bike. THe carb boots are siliconed to the intake, and the front one is on the back cylinder, and vice versa. Can the vacume lines be rerouted to make a mess like that work, or is it more trouble than it's worth?

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The TSB on the starter motor shimming is really very basic. You put 3 shims on top of the planetary gear system and bolt it together. The purpose of that was to apply more pressure to the outer ring of the planetary gear system, giving it more resistance to slipping, and helping the starter function better. The outer ring is designed to slip in case of engine kick back. If it cannot slip, then engine kickback would be breaking pieces in the starter system.
Vacuum lines don't matter where they originate from, only where they terminate. My example would be if the petcock needed engine vacuum to open up and allow fuel to flow, it would not matter whether that vacuum came from the front cylinder or rear cylinder. Vacuum is vacuum and it is going to do its job, as long as it gets to the correct place. Both cylinders produce the same vacuum (providing they don't have problems of their own) so as long as you get it to where it is needed, it doesn't matter where it starts.
If the parts are still available, I would replace the intake boots with new ones. Air leaks at the intake will only exasperate an already finicky starting motorcycle. Also, to make it as easy to start as possible, you need to keep the valves in adjustment, as well as the carbs, sync, mixture and idle speed. "IF" everything is right, Viragos start pretty well. Start getting things out of whack, and they can be down right impossible. Another point or two to consider is to make sure you have sufficient tension on the wishbone spring on the gear under the left engine side cover for the starter clutch. The tension on that spring gives resistance to that gear from spinning which makes it kick out to engage the flywheel.
Another point, make sure the back of the flywheel gear isn't damaged beyond servicable use. If someone had not been maintaining the bike and just grinding away at the starter year after year, it will never engage properly so it is easy starting.

Here is a link to Yamaha's parts catalog where you can select the parts fiche for your motorcycle and then look at the individual components of each system. Especially check out the starter picture and starter clutch picture to see the items I mentioned.
Thanks and good luck!

Posted on Oct 05, 2009


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1 Answer

How to replace a starter

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use gloves an a mask or youll put ur eye out

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Shim location

Shims can be where the starter case meets the bell housing. There are not many models using shims anymore, they were used a lot in GM vehicles, not so much in Ford products.
The gear on the starter drive needs to mesh with the flywheel teeth. Sometimes a starter would rock loose in its mount and wear the starter case or the bell housing. When you try to align the 2 parts, it would throw off the mesh of the gears and teeth. The shims are usually patterned after the shape of the facing of the parts. You may need to go to the Dealer for these shims.

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How to remove a starter from a 1999 chevy silverado 4x4 pickup

1) Disconnect Negative Cable on Battery
2) Starters on right-side Close to Trans. Bell Housing
3) Remove the 2-Starter Bolts and Shim if it's
if it has shims.
4) Remove the wires off Solenoid: Mark Them:
5) Remove the Heat Gaurd Over top of Starter:
6) Take Starter on Out.

To Re-Install Reverse the Procedure that you Removed the Starter. NOTE: the Shims if there was any are only nessary if the Casting of the Starter is not Exactly or Close to The Original.

Be sure that All the Wires you Took off the Starter Solenoid are put Back on the Exact Same Terminal. And Snug them up .Be careful not to Over Tighten,:
Specs on Bolts Are :
Torque Starter Battery Cable Nut to 90 inch lbs
Torque Smaller ingnition wier nuts to 18 Inch Lbs
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Remember if your Old Starter Had Shims the New one MIGHT need Shims.All Starters Casting are just a Little Different. like by thousands of an inch. So if you have problems you might have to remove or add shims,they come in different sizes. Hope this has helped you,Please let me know how this solution Helped. Thank You: From d_hubbs

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I have a 1998 oldsmobile intrigue replaced starter but after starting its slow releaseing

You likely need to add a starter shim or maybe two.The replacement starters are made from the cheaper 5mt style starters and depending on where they where manufactured,you may or may not need the shims.Any auto parts store should have them,you don't need to take the starter back off to shim it,just take out the furthest bolt from the block and loosen the other one and then you can insert the shim.Try one at first,then the second if that made little difference.

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Starter not working after replacing: need shims???

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Installed a rebuilt starter in a Camaro.

Shims, are to space the starter drive gear away from the flywheel. The shim is inserted between the engine block, and the starter. The thicker the shim, the more the starter drive gear is further away from the flywheel.

Starter housings are machined from the factory, where they were made. No two housings come out the same, for the machined pad, where the starter bolts to the engine block.
The difference is minimal, granted, but thousandths of an inch count in this area.

It's generally a trial an error situation. This is why there are shim packs. Packs of shims with varying thicknesses.
Rule of Thumb, is generally that the starter drive gear, is 3/32nd's of an inch away from the flywheel.
If you hear a metallic grinding kind of sound, the starter is too close. A thicker shim is needed.

I suspect your problem is the starter drive itself. Definitely sounds like it from your description.
Granted, when bench testing the starter drive kicks out, but the roller clutch inside the Bendix drive is no good. (Starter drive)
Suggest you take the starter back, and get an exchange.

This rebuilt starter has a bad Bendix drive.

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Starter Problem

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