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post #1 of 26 (permalink) Old 12-12-2018, 02:02 PM Thread Starter
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Location: Fairbanks, AK
Posts: 14
Hello from Fairbanks

Hi all - newbie here. I bought a crashed 2013 v-star 650 and am trying to put it back together. It turned out to be in pretty rough shape, but I nearly have it fixed and will post some pictures when/if it runs .
This is is the first motorcycle Iíve ever worked on so Iím learning a lot!

Last edited by Akjpl; 12-12-2018 at 11:38 PM.
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post #2 of 26 (permalink) Old 12-12-2018, 02:36 PM
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Welcome to the forum from Atlantic Canada. The 650 is a great bike and well worth fixing. Post any questions you may have and you'll get answers from our knowledgeable members. How about some pics?

Paul
2007 Vulcan Nomad
V&H exhaust

2000 V Star 1100 Classic (Sold)
All stock except for:
Kuryakyn Grips
4" Risers
Switchblade Quick Release Windshield
Ugly but somewhat functional saddlebags
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post #3 of 26 (permalink) Old 12-12-2018, 07:11 PM
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Welcome from Houston, Texas. Like NortherRider said, post questions in the Vstar section for suggestions. Here's a few interesting threads to check out when you get a chance.

https://www.starbikeforums.com/forum...ms-bike-month/

https://www.starbikeforums.com/forum...ighlight=Yammy

https://www.starbikeforums.com/forum...where-you.html

https://www.starbikeforums.com/forum...enced-you.html

https://www.starbikeforums.com/forum...ature-you.html

Ride often and safe.

2001 Vstar 1100 Classic (sold), Cobra Slash Cut full exhaust, Dropped 1 inch with lowering links, ORK, 4.5 inch handlebar risers, Ultimate passenger seat, Passenger pegs moved forward 4 inches, Handlebar clock, KN air filter, Viking saddlebags, Additional rear lighting
Loose nut "me" behind the bars
2006 Harley Electra Glide Ultra Classic

https://sites.google.com/site/vstar1100kb/home
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post #4 of 26 (permalink) Old 12-13-2018, 01:48 AM Thread Starter
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Location: Fairbanks, AK
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Thanks for the welcomes and the links! So I bought this bike sight unseen (unwise - won't be doing that again), and though it looked decent in the pictures, it actually had some pretty big problems. It has 2k miles on it. Here it is right after I picked it up:

https://i.imgur.com/9OUkXZg.jpg

Turned out the frame was quite bent near the kickstand, there was a hole in the bottom of the crankcase, a hole in the generator cover, a couple large dents in the fuel tank from the handlebars (because the stop had sheared off), various bent things, and quite a bit of scratches on most of the chrome.

I tried all sorts of things to straighten the frame (hammers, jacks, etc), but the tube just collapsed instead of bending back. So I cut out the damaged section, got inner sleeves, salvaged the bushings, and had a friend weld them back together. After quite a bit of grinding it turned out ok.

Here's the before:
https://i.imgur.com/dmhwNHt.jpg

Here it is welded up and cleaned a bit:
https://i.imgur.com/2ex13kA.jpg

And after painting:
https://i.imgur.com/4FsKzus.jpg

Here's the original sheared handlebar stop (just behind the shattered headlight):
https://i.imgur.com/o3nIyUc.jpg

I cut a tab out of stock, cut the old one off, and had my friend weld it. I cleaned it up, and painted it, and it seems to be functional again. Amazingly, the rest of the forks, tripletree and surrounding parts seem to be straight, and was able to get the wheel aligned.
https://i.imgur.com/hbBPIZz.jpg?1

Here's the tank just off the bike:
https://i.imgur.com/uwVkWDB.jpg

I used a bent metal rod to pop out what I could from the inside with some heat (tank filled w water), then used a really cheesy dent removal kit (the type with glue tabs). It took a ton of hot gluing, but eventually I was able to got most of it out. Next plan is to do a bit of bondo smoothing, then paint. Maybe next week.
https://i.imgur.com/wIBteOQ.jpg

Here's the bottom of the engine right after filling the holes (can't find the before picture of the hole, but it wasn't huge). I used high temp metal filler (the jb weld epoxy putty), made sure to get it really clean, and pushed it in. The top spot wasn't a hole, just some gouges. Not proud of this fix, but can't really afford a new crankcase. I was going to completely disassemble the thing and get it fixed right, but my welding friend advised me against it due to the metal type. I'm sure glad I didn't try that, because I can't imagine the engine going back together smoothly for me. I guess I'll just have to keep a close eye on it, and hopefully it doesn't leak over time.

Prepping my novice paint booth:
https://i.imgur.com/duBmXVS.jpg

Here's the engine after paint:
https://i.imgur.com/oNdWnqV.jpg

Same procedure with the generator cover, though I was able to epoxy both sides, add high temp silicone sealer to the inside, and I haven't figured out how to fix the damaged chrome on the outside. I think this hole was caused by the shifter pedal and footrest. You can see in the picture that it's bent way too close. New parts are on the way for those.
https://i.imgur.com/yhLm29p.jpg

A couple weeks ago I started reassembly. Was not feeling very good about finding where all the bolts came from at this point. I took it apart a year and a half ago and got distracted with other life things. I relied on the Yamaha exploded diagrams and the shop manual pretty heavily. I sure wish I would have taken more pictures when I was taking things apart, or at least had better organization with the bolts.
https://i.imgur.com/4k8Zktj.jpg

Here's where I'm at currently:
https://i.imgur.com/us1zZqN.jpg

I have a long ways to go but I'm feeling a lot more optimistic. A couple wires have me pretty stumped, so I might reach out for help on those if I don't get it shortly. Unfortunately, it won't be a 'pretty' bike any time soon because of all the scuffing, but hopefully it will be ride-able and safe.

Thanks for looking!
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post #5 of 26 (permalink) Old 12-13-2018, 06:38 AM
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Wow, that's quite a project but it looks like you're on track to have her ready for spring. Thanks for the pics and I hope all goes well with the repairs. There's a lot of knowledge here and I'm sure someone here can help with your electrical issues. Keep us posted!
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Paul
2007 Vulcan Nomad
V&H exhaust

2000 V Star 1100 Classic (Sold)
All stock except for:
Kuryakyn Grips
4" Risers
Switchblade Quick Release Windshield
Ugly but somewhat functional saddlebags
NorthernRider is online now  
post #6 of 26 (permalink) Old 12-13-2018, 08:40 AM
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Great project. Very good progress. From years of similar projects I now bag and tag each thing I take off anything. And I mean everything. Guess the memory isn't as good as I think it is 😁. Keep us informed and pictures coming.
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2001 Vstar 1100 Classic (sold), Cobra Slash Cut full exhaust, Dropped 1 inch with lowering links, ORK, 4.5 inch handlebar risers, Ultimate passenger seat, Passenger pegs moved forward 4 inches, Handlebar clock, KN air filter, Viking saddlebags, Additional rear lighting
Loose nut "me" behind the bars
2006 Harley Electra Glide Ultra Classic

https://sites.google.com/site/vstar1100kb/home
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post #7 of 26 (permalink) Old 12-13-2018, 09:05 AM
KCW
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Curious how much you got the bike for, its taking a lot of work just to make it ride able again.

Double check all the bolts that go into the engine - there are a few places like the oil filter cover, the clutch cover, the alternator cover... where the cover has two or three different length bolts. If you put a long bolt where a short one goes it can hit something inside the engine.

One guy here did that and put a bolt into the alternator stator while fixing something else, and it destroyed the stator when he started the engine. (funny the spell check on a motorcycle forum thinks stator is not a word).
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post #8 of 26 (permalink) Old 12-13-2018, 03:23 PM Thread Starter
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Thanks for the interest NorthernRider! Ok, after yesterday, I’m still stuck on the wire so I put the question here:
https://www.starbikeforums.com/forum...tml#post988182
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post #9 of 26 (permalink) Old 12-13-2018, 03:27 PM Thread Starter
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Lesblank: 'Bag and tag' is a really good idea. Iím down to about 10 washers and bolts that I still have to find homes for. I think theyíre related to the fenders and tank, but it would have helped a ton to keep better track of them in the first place. Someday Iíll get smarter..

If itís ok Iíll keep posting pictures here as I make progress Ė if thereís a better spot please let me know.
Also, I tried to follow the sticky tutorial on how to post pictures, but they are still showing up as a link rather than a photo, anyone know how to fix that? I didn't see it on google but I'm sure it's there somewhere.
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post #10 of 26 (permalink) Old 12-13-2018, 03:48 PM
KCW
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let see if this works:

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