I just got this 1996 Yamaha Virago XV1100.  The wiring harness was somewhat melted together.  I separted it and tried to start it and the starter kept turning even with the ignition off.  I replaced the complete wiring harness and the starter does the same thing.  The negative battery cable got real hot (I know this because the starter kept turning with the key off) and I had to unscrew the screw to stop the starter.  I waited twenty minutes and tried to crank it again and the starter would only spin.'

Does the starter need to be replaced?

Is there a "short" in the starter wiring?

I would really appreciate any advice.  Thank You.

Hi Defender1,
I had the same issue some years ago, pushed the starter button, and it didn't stop turning, even with ignition switched off. Short circuit in the starter solenoid was the failure. I bought a new one, and the issue was gone.

Juergen

Juergen:

Thanks so much very your answer Juergen.  I will remove the starter in the next couple of days and take a look at it.  Do you think a "Rebuild Kit" would fix the problem?

Thanks,

Edward

Does anyone know where I can find a solenoid?  Is it part of the starter or separate?  I can't seem to find one on a google search.

Please review the microfiche in the technical information, its #1 on slide F4 (electrical 2). It is above the starter motor from outside, covered by a plastic cover. Approx. 5cm diameter, 10 cm long. I don't know, whether it can be repaired, but it should still be for sale. It's identical from TR1 to XV1100 Virago.

Jürgen

Thank You.  

All this is new to me.

I can seem to find anything on the internet.  Maybe I am calling it something other than what it is.

Doing something for the first time can be intimidating.  

Thanks again!

Hi,

CMS in  the Netherlands stock many discontinued parts
the starter solenoid (part No. 5A8-886110-50) is available but it is 163euro!  :o
http://www.cmsnl.com/searchparts_other.php?s_product=5a88611050&make=YA
you should be able to find a used solenoid on ebay for 30-40euro - search worldwide for 'xv starter'
I think I would have a go at fixing the solenoid - it's likely the problem is welded contacts
If you can get inside the thing, prise the contacts apart and dress the surface with a needle file

Bob  :)

Thanks Bob.  I am going to try to repair it myself.  I found one tonight for about $140.00 US new.  No luck finding one on ebay.  After I get until I may have some questions.

Again, thank you.  

Hey Defender,

There's a starter bendix, including the solenoid, on ebay at the moment
ebay.com item #220300553427

http://cgi.ebay.com/ebaymotors/Yamaha-XV-1100-Virago-1995-Starter-Bendix_W0QQcmdZViewItemQQ_trksidZp1638Q2em118Q2el1247QQcategoryZ35599QQihZ012QQitemZ220300553427QQrdZ1QQsspagenameZWD1V#ebayphotohosting

Bob  :)

Thanks for the site Bob, you are the greatest!  I have bookmarked it.  I have to save for a couple of weeks but I believe I am going to replace the starter first unless someone can logically can talk me out of it.  For some reason I believe the short exist there.  

Hi Defender,

The problem cant be the starter itself as the starter spins the motor over
The starter is just a coil of wire and some magnets - if there was a short in the starter, or if the coil was open circuit, or the brushes were shot then it wouldn't work at all.

The problem must be linked to the solenoid
Inside the solenoid is a coil, a shaft and heavy duty contacts attached to the shaft
When you press the start button power is applied to the coil which produces a magetic field
The magnetic field moves the shaft which engages the starter bendix and closes the heavy duty contacts which applies power to the starter

try this:

Disconnect the small wire from the solenoid
reconnect the battery

if the starter spins the problem is either a stuck shaft in the solenoid or welded contacts
if the starter doesnt spin then the problem is linked to the starter circuit - you mentioned that the wiring harnes had been melted together, perhaps there is still a short somewhere in the wiring harnes

I am a qualified electrician and also a qualified bike mechanic
If you'd like to give me a bell to discuss your problems (bike related - I aint a shrink  :D )
please do so on 07747825932 (uk)

Bob  :)

Hi defender,
just to confirm what Phineus is mentioning: when I had this issue, after replacing the solenoid I disassembled it. the heavy duty contacts were burned and welded together, so there was a permanent bridge, and the starter got permanent power. Sorry for not mentioning this details before, but this was the "short circuit" I was talking about.

Jürgen

Thanks Bob & Jurgen for your sound advice.  I checked the wiring and it was good.  I took the side cover off of the Solenoid which exposed "the fork" (connects the Solenoid to the Starter)  that pushes in the Starter gear.  I turned the ignition on and pushed the Starter Button.  The Solenoid would only spin and "the fork" remained stationary.  Does this mean the Solenoid has to be replaced?

Again, thanks to the both of you for you most helpful advice.

Edward :)

Hi defender,
if you have ignition switched on, and press the starter button, the following should happen: Power activates the solenoid (via thin cable), solenoid gets pulled in, inside the solenoid the contacts for starter power get closed (thick cables coming from battery, going to starter), starter gets power via thick cable and starts turning. At same time solenoid moves starter gears into position via "fork", spinning starter turns engine.
When you release the starter button, power to solenoid gets switched off, solenoid pushes back via springs in the solenoid, power to starter gets interrupted and starter gearings get disengaged. - The solenoid cannot spin, as it is an electro magnet only, no motor. It just can move in and out, move gears, and close or release contacts.
My experience was that I pressed the starter button, everything works fine until engine turned, but when I released the starter button nothing happened. Solenoid was kept in "pull in" position and starter remained under power, kept turning the engine. Burned contacts avoided that the solenoid could move back into release position, and power to starter was not interrupted.

In you case, when you push the starter button, the solenoid should pull the "fork". If this is not happening, and the starter turns already, the solenoid seems to be pulled in to maximum, and cannot be released for the same reason I had.
I would propose to pull back the shaft in the solenoid with a combination pliers, if possible, to disengage the solenoid manually. This might work. If yes, this cannot be the final solution, I'm sure the issue returns after some more starts. From my perspective, the solenoid should be replaced, or repaired.

Jürgen

[quote author=Defender1 link=1237158660/10#12 date=1237767365]I turned the ignition on and pushed the Starter Button.  The Solenoid would only spin and "the fork" remained stationary. quote]

Hey Edward,

that sounds a bit strange  :-?

if the contacts in the solenoid were welded, or the solenoid was stuck, the starter would spin as soon as you connected the battery without the ignition turned on and without pressing the start button

does it turn the engine over?
if the starter spins but the fork doesn't move and the engine doesn't turn over it could be a broken spring - item 13 in attached microfiche
http://www.thevirago.co.uk/viragomicrofiche/tvmicrofichemain.asp?catalog=tvMicroficheXV1100JJC1997SQL&Model=XV1100J%20JC%201997

I would strip and check the starter clutch assembly, if that's ok - spring not broken, fork not siezed - then look at the solenoid
as Jurgen suggests try moving the shaft on the solenoid manually

Bob  :)

Jurgen:

Thanks for the excellent description.  I helped alot.  I connected the battery in a tempory fashion so I could disconnect it quickly in case the starter stuck again.  I turned the ignition to the on position and pushed the starter button in.  The starter made a spinning sound.  I pushed in the "fork" in, at the coil, with my index finger.  Once I did this the engine almost cranked (started).  I released the starter button but the starter was still engaged.  I then quickly disconnected the battery.  I repeated the above steps again to closely inspect what was happening with the "fork" at the coil.  Once I pushed in the "fork", at the coil, it would not release the starter (in other words push the shaft back out of the coil) until I disconnected the battery.  I tried this several times with the same result each time.

I hope this aptly describes what I experienced.

Thanks for your advice,

Edward  

Bob:

The diagram was perfect.  Please read the post to Jurgen for a description of the process I did to check out the solenoid.  I inspected the spring (#13 on the diagram) and in my opinion it is working.  I did not see any breaks or other signs of stress.  Once I disconnected the battery the shaft would return to the out position.  I would think that the spring was working.  Maybe the Solenoid does not have a strong enough magnetic field to pull the shaft in?  It has enough of a magnetic field to hold the shaft once I pushed it manualy in?

Thanks for the diagram and the great instructions.

Edward  

Edward,
when you push the starter button, the first noise you should hear is a strong "klick" from the solenoid, when this pulls the shaft in. Once this has happened, the starter should begin spinning. If you don't hear the click, clack, or whatever you call it, and the starter beginns spinning immediately, whithout shaft of solenoid pulled in, there is something wrong with the solenoid. Solenoid controls the power coming to the starter.
Try this: disconnect the power cable from solenoid to starter (short one), and connect the battery. Don't switch ignition "on". Check, whether there is power at the power outlet on solenoid to starter (short cable without starter connected). - Inlet (from Battery) must have power, outlet to starter must not. If there is power already on the outlet, solenoid is defect. If there is no power on outlet, switch on the ignition, and press starter button. Solenoid must work now, pulling back the shaft. With starter button pressed, and activated solenoid, there must be power on the outlet. this is the normal case, solenoid should work.
Hope this helps.

By the way, spring #13 has no direct function to the solenoid, it's just a mechanical connection from solenoid shaft to starter gearings, supporting the fork to move back.

Jürgen

Jurgen:

I have been real busy for the past couple of days and have not had time to work on the Bike.  I will definitely be working on it this weekend.  Talk to you later and thanks for your advice, it is greatly appreciated.

Edward  

Finally took the time and replaced the Solenoid.  Just took my time after I read the repair manual on removal and installation.  Charged the battery.  When I was finished and tried to start it, it started!  Amazing sound.  

Thank you Bob!  Thank you Jurgen!  

It starts everytime!

Thanks,

Edward

Hooooray!  ;D

nice1 Edward!  ;)
welcome to the 'XV owners who've had problems with their starter and fixed it' club - lol, there's lots of members  ::)

Thanks again for your fantastic help.    Glad to be a member of that club.  It means more when you know you can repair the problems.