Download: Yamaha Virago XV750 Cafe Racer Rebuild Project inc videos

By H Follis


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Firstly, credit to 'Fire on Dawson' for the use of their superb song - Stuck In Infinity

Yamaha Virago XV750 rebuild project. A 1982 scrapper finds a new look and a new lease of life. Wire wheels would have been nice but there was a limited budget. Single seat was not an option as my son likes to ride shotgun.

All was work was done at home. A 'DIY powder coating kit' (Electrostatic magic) was purchased to help with coating costs. This is a 'must have' bit of kit for any rebuild project. It payed for itself with superb results. A quick list of some of the parts used and the work done:

Suzuki GS850 Micron fork brace
Suzuki GSX1000r brake and clutch levers
Landrover suspension gaiters (front forks)
Speed boat rev counter
XV750MK Front mudguard
XV920 gear lever and linkage (cut down)
XV535 speedo
BSA tank/knee pads and brackets
Triumph Daytona fly screen (cut down)
Triumph T140 replacement tail pipes
Ammunition case (rev counter cover)

Mods -- performance/reliability

Starter motor ring welded
2mm spacer made for starter throw gear
#2 Idle Throw Gear return spring cut (shortened by approx half)
#2 Idle Throw Gear teeth recut @ 45deg
Carb pilot jet increase from .41 to .50 using .20", 0.50mm, #76 drill
Carb main jet increase from 1.20 to 1.25
2x JBM Industry Hitachi Carb Diaphragms
K+N RC-0190 chrome air filter
Suzuki GS850 Micron fork brace shaped for front mudguard
Suzuki GSX1000r brake and clutch levers

Mods -- cosmetic/appearance/security

Fuel tank cut, welded for flat bottom & rear mount lowered 30mm (to lift back of tank)
Front forks lowered 2" (2-1/4" s/s pipe under damper rod-2" cut off top of main springs.
2" mod reduces rake by 1º, from 29.5º to 28.5º, same as chain drive "E" model)
Wiring harness rewired, most relays removed to 'bare bones' spec
Fuse box moved to under seat
Ignition moved to frame side cover
Carb top/bottom stainless allen bolts
Rear suspension adjuster/ air pre-load valve moved to side panel
Battery moved from right side panel to under passenger seat
Seat subframe mounts extended for extra lift under rear wheel
Both side panels removed
Front foot rest brackets shortened by 4" (mid-sets)
Rear brake lever shortened and shaped
Rear brake light switch moved to inside footrest hanger
Rear mudguard shortened to fit under-seat battery box
Battery mounting lugs removed from right foot rest hanger
Landrover suspension gaiters fitted to front forks
Steering lock bracket on bottom yoke
Mini 'Jack Daniels' optic brake reservoir
Lionide hand rail grip
Custom bobber style sprung solo/ pillion seat with lionide cover
Custom fibreglass seat base
Custom taillight
Triumph T140 tail pipes
Acumen Cat1 Alarm fitted
Seat sub-frame welded with strengtheners and brace bar under seat
Front and rear wheels striped, repainted and rims polished

Rear reflector bracket

New Parts

Piston rings OEM
Big end bearings x 4
Oil pump chain
Alternator plug
Full gasket set
Cylinder head gaskets x2 OEM
Cylinder head gaskets x2 Pattern (spare)
Front wheel bearings and seals
Front brake calliper seals and piston kit
Front brake stainless steel hose kit
Front brake pads
Front fork seals x2
Rear wheel bearings x 3 and seals
Rear brake shoes
Fork Oil- 1 Litre Synthetic
Spark Plug NGK x 2
Oil Filter Champion
Choke Cable OEM
Throttle cable pattern XS650
Tapered Steering head bearings
Stainless steel nuts, bolts washers throughout
Ace bars
Beston style grips
Halcyon bar end mirrors
K+N filter
Motobatt battery MB16AU-YB16AL-A2
2 bullet indicators
Back brake light
Ignition switch
Starter lead
Wire connectors etc
Indicator bulbs
Indicator bulbs x4
Instrument bulbs x4
2 x Hitachi HSC40 carb diaphragms
Vinyl Lionide seat material
Stainless Carb top/bottom allen bolts
44m Exhaust extensions
Front and rear Avon Roadrider tyres
Petrol cap seal
2 x exhaust baffles
2 x seat springs

Parts Made

Speedo bracket
Rev counter bracket
Rev counter cover
Fly screen bracket & plates
Steering lock bracket
Grab rail bracket
Air cleaner cover and alloy bracket
Seat under tray
Rear shock adjuster bracket
Front foot rest brackets (mid-sets)
Rear brake lever
Rear brake light bracket
Rectifier bracket
Under seat battery box
Gear lever bush (Ivor)
Front brake reservoir stem (Ivor)
Clutch cable bullet 'brass' (Ivor)
Clutch cable adjuster 'brass' (Ivor)
Solo 'Bobber' style rider seat
Matching pillion seat
Fibreglass seat base
Fibreglass pillion base (battery box)
Fabricated steel seat frame
Vinyl lionide seat covers
Vinyl lionide grab rail cover
'Spanner' speedo cable holder
Indicator extensions (Ivor)
Seat spring retainers (Ivor)
Brass exhaust nuts x 4 (Ivor)
Ignition lock case and side cover
Front and rear exhaust flanges
Front and rear exhaust supports
Horn/ coil cover bracket
Seat subframe panel (fuse panel)
Seat subframe side panels (welded)
Seat subframe strengtheners & brace
Seat subframe cable cover
Rear tank support bracket

Any reference to 'Ivor' is my father in-law who kindly made those parts on his home lathe.