Good evening to all of you !

I'm new in here as I recently bought a XV 1000 SE with a blown motor.
So, I've got a few questions for you. I searched for some answers but couldn't find what I was looking for, sorry  :(

My motor is a 23W model and the intake valve from the front head broke and made a big hole in the piston. The result of this is a broken piston and a broken head (the cylinder and the crank seem to be OK).

Now I need to rebuild it and am looking for different possibilities as it's really difficult to find parts for these 23W motors.

First option :
I've got an opportunity on a complete 1992 XV 1100 motor (the serial number looks to start with something like "OLV" but can't find anything related to this...). As I don't want to change the entire motor, my plan will be to use the crankshaft / cylinders / pistons from this motor.
Could you confirm me that they'll fit ? If I understood what I saw in this forum, it will fit without boring the cases or things like that ?!

Second option :
I found a XV 1000 top end but don't know its condition. As I want to rebuild a nice engine, I'll just use the head and put some new pistons ... But here comes the problem : Can I use pistons (and possibly cylinders) from later XV 1000 as the ones designed for the 23W motor are discontinued  :( ? Do you think that it's a great idea to use my old cylinders with new pistons ? My bike is about 75k kms ...


Many thanks for your answers !
Arthur

Hi Arthur,

swapping in the XV1100 rotating assembly is a direct fit. But I am more than curious to find out about your source of XV1000 pistons?

Cheers,
Greg

Hi Greg,

for TR1 or XV1000 Pistons look here: https://www.tr1.de/cgi-bin/yabb2/YaBB.pl?num=1549803644  ;)

cu
Dieter

Many thanks Schraubaer !
My only fear is to put new pistons in old cylinders ... What do you usually do on these bikes ? Measure the cylinder and then use the correct piston ?
Moreover, I'm not sure about my crankshaft as one of my pistons broke :(

Other question : Can I use a gasket kit which is made for a newer 1000 Virago ?

Once again thank you !

Hi Arthur,

when using new pistons, we usually bore the cylinders to the next oversize. In used cylinders, the surface is usually no longer in good condition.
We would also advise you to use the cylinders of the newer XV 1000 or XV 1100, because then you can use the flat cylinder head gaskets from the newer generation.

Or you are using the complete XV 1100 rotating assembly include cylinders and pistons, which is easily possible, as Greg has already described.

Best regards,
Dieter

Good afternoon to all of you !

I'm finally back after a busy summer, sorry !  :(
I bought new pistons from Schraubaer, I also found used cylinders/cylinders heads and I bored them to fit my new pistons, ...

So, I'm nearly ready to put the motor back together ! I just have deux more questions.

The first one concerns the plastic sleeves around the front cylinder's studs, what are they designed for ? They were destroyed but I can't find them on the Yamaha parts list. Can I replace them with some heat-shrinkable sleeves ?

My second question is about the con rod bearings.

As I don't have a press to take the crankshaft out of the left case, my crankshaft is still in the left case and I can't see the number on it in order to know which color of bearings I need to choose.
Rear rod - Number 6 : I can see the green marks on the old bearings
Front rod - Number 4 : I can't see the color on the old bearings

Using the formula : Rod number - crankpin number = bearing number, I guess that my crankpin number is 2 (using the number + color on the rear rod).

Do you think that it's safe to put green bearings on the rear rod again and black ones on the front rod ?


I'm pretty lost at the moment and that's the only thing holding me back from putting the motor together  :-/

Many thanks to all of you,
Arthur

Hi Arthur,

get the bearing shells and some plastigauge and measure the clearances. If it's too wide, you'll have to order another (tighter) set of shells, if not you're lucky. Last time I was unsure Sepp basically said: get the black ones regardless, as the fitment is usually a lot sloppier than what Yamaha recommends.

Cheers,
Greg

Oh ok many thanks, that's what I thought initially  :( I'll buy new ones and test them with Plastigauge, I hope I'll be lucky and get the correct ones on the first time  ;D
I also saw this message where a guy advise to put black ones, I'm not really sure that it's a good idea  :-?

Concerning the plastic sleeves, do you have more information ? I couldn't find anything online  :-[

Hi Arthur,

the plastic sleeves are never offered separately. Only the complete studs include the sleeves are available. Part No. 4X7-11363-01.
But you can replace them with heat shrinking tube, I had done it in the past too.

Because the rod bearings: I always use the black or blue ones, because the bearing clearance in original is to big, so you loose oil pressure.
In all machines I've build over the years this was a good solution.

Cu
Dieter

I quite frankly ended up doing the same, more or less, as I ordered the black ones and thought that if they were too tight, I'd swap them out, but they were spot on. It's just not a practice I can recommend from an engineer's point of view.

Hi Schraubaer,
Many thanks, I'll use heat shrinking tubes  :)
I think I'll use black ones instead of the the green ones I had on the bike and blue ones instead of the black ones ! I'll let you know :)

Once again, many thanks !

Thanks to you my Virago is alive again ! Many thanks for all your help !  :thumb:
I'll take care of him now  :D