is it a manufacturing fault

[derek taylor]

the bike is a xv1100 1996 model only done 9000mls.
the fault is the gearbox is what i call clunkey whene you change gear it clunks into gear
thats going up the gearbox and down.
what i've done is stripped the cluch down filed off the notches on the cluch basket which was hardley
anything, everything else looks ok.
i've put the correct oil in it made sure all the cable adjustments are correct took it for a run
"ha" the fault is still there. so i'm beginning to think this is a built in fault with this model,
the problem is i don't know anyone with the same model to ask them if they have the same problem
has any fellow riders got the same problem!        thank's   "derek"
 

[bstig60]

Derek,
It is not uncommon for Virago's to make some noise when shifting gears, particularly downshifting, and more when shifting into 1st at slow speeds. Its usually clutch adjustment. You will have to play with the clutch adjustment a bit. The fine adjustment is done on the handlebar end and the major adjustment is done on the case end of the cable. I find my bike makes more noise when I use 10w40 oil and much less when I am using 20w50. What oil are you using?

Bill

[stingypaperwaffles]

My 700 does the same thing. It is really obnoxious. I'm using 15w40 right now, with some Lucas. I tightened my clutch cable until I have very little to no free play, and it still does it. I have found though it is a lot better when I squeeze the clutch as much as I can and shift slowly. It is much worse when I am trying to shift fast. I realized when I shift fast I don't pull the lever as much as I could, must be a habit from my Rebel or something...

[derek taylor]

yes i'm using 20-50 oil the strange thing is the fault seems to be worse when the bike is up to running temperature it's also hard to change gear especially when changing from 3rd to 2nd.    ?

[bstig60]

Shifting problems are usually clutch adjustment. Go to your Clymer's Service Manual and check the clutch adjustment specs and procedures and go through the clutch adjustment again. Does the bike want to creap when you put it in 1st gear at a stop?

[derek taylor]

no bike dose not creep and cable adjustment is as Manuel says 2mm free play at the lever but just had a thought i never checked the clutch plates for flatness when i had it stripped down

[bstig60]

With that low mileage, there shouldn't be any problems with the clutch disk or plates unless someone has run the bike without oil and that would create other problems. When you changed the oil, did you check the drain plug magnet for any metal filings?

[derek taylor]

no filings in the oil, one thing i did try which i never mentioned was tightened the clutch cable up so there was no slack for a while! it made know difference.

[bstig60]

Without hearing it, I can't say if it is normal or not, but Virago's are a bit noisy when they shift sometimes. I wouldn't worry about it unless it is causing some problems.

bill