Tearing into the bike,,,part Deux,..

[DarrinGT]

Yes this is Part 2 of tearing into the bike,...or Re-tearing into the bike,

 

For those interested, this was part 1 from 2011:

 

http://venturerider.org/forum/showthread.php?t=56020&highlight=darrin+makeover

 

Since getting the bike Lori and I have put well over 25K miles on it in 3 riding seasons, This year being the least because of Lori's Mom's flailing health, and eventually her passing. Lori and her sibs were taking care of her for the last 8 months, basically 24-7.

 

We are hoping that next summer will be a big riding summer for us, and because of this I want to make some changes to the bike.

 

Here is a list of what I plan on doing:

 

*Replacing the 28MM carbs with Barons Big Air kit installed, and going with "stock" 32 MM carbs,

 

*Stock Air Box instead of 4 K&N Pods

 

*4 into 2 Exhaust with Vance and Hines Monster Ovals, and instead of the Barons Nasty Boys 4x4 exhaust

 

*Valve Adjustment, Not sure that it was done before I got it, and it has 57K miles on it now.

 

*New Heavy Duty Stator and Rectifier Regulator.

 

*Lower the Leather Saddle Bags by fabbing up new brackets.

 

*V-Max Rear End

 

* Other chrome goodies,.

 

*Fluid, Plugs, Filters, etc,..etc,..

 

Some of this stuff is necessary, some of this I just want to try,. but most of it is because I like tinkering on the bike during the winter,..

 

Here are a few pics, just getting started with mocking up the exhaust to see how best to lower the bags. I am waiting for a few more parts to come in for the exhaust, Then have it all installed to see how it sounds, before disassembling the bike and starting on the other stuff:

 

Venture Head Pipes:

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131121_190243_zps56494035.jpg

 

Monster Ovals:

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131121_190150_zps9897fd9c.jpg

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131121_190157_zpsaae9c3d6.jpg

 

Before:

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131121_190210_zps42201692.jpg

 

 

After:

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131121_190220_zpsb23b7fab.jpg

 

 

New Stator, and Regulator Rectifier:

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131121_190415_zps9d93d7a0.jpg

 

So that is it for now, It will be a slow start but will update when I get anything done, and am sure that I will be asking questions on some of this stuff as that I have not done before,..

 

Thanks for checking it out,..

 

Darrin

[djh3]

Why lower the bags? Are they leather or hard like Venture. Sorry I'm not real familiar with the TD. Were the bags location moved for the high 4x4 pipes? I dont know how you could stand to ride with them guys. I just took my RK muffs off because I cant stand the roar on longer trips.

More juice is good I supose, especially if you have had indications of system putting out. Good luck and have fun. I get board some to and just go out and tinker around.

[cowpuc]

Hi Darrin

I like what you got going on there bro.. I can honestly say that I have never seen a set of those 4x2 pipes before, pretty cool indeed.. I am over in Muskegon, and like you, a little bit of a tinkerer.. Come spring we gotta get together and let me see and hear what that sounds like!!

On another note, I have been riding old Ventures (never had one newer than 84) for years now and have put a lot of thought into switching over to the TD when we move into modern times LOL.. Its a head scratcher for sure cause the wife and both really like the modern Venture too..

Anyway, just wanted to give ya a thumbs up on your project and wish you a great season of spinning wrenches!!

Puc

[bongobobny]

My only comment is concerning valve adjustment. Unless it is hard starting and runs like crap regardless of tune ups and carb sync, you might be just wasting your time, but if you want things "perfect" then go ahead.

 

Most of the other stuff sounds like a good idea...

[DarrinGT]

Why lower the bags? Are they leather or hard like Venture. Sorry I'm not real familiar with the TD. Were the bags location moved for the high 4x4 pipes? I dont know how you could stand to ride with them guys. I just took my RK muffs off because I cant stand the roar on longer trips.

More juice is good I supose, especially if you have had indications of system putting out. Good luck and have fun. I get board some to and just go out and tinker around.

 

Lowering the bags are just for aesthetics, The bags are leather and sit higher with the 4x4 pipes from the factory than the hard bags with the 4x2 pipes.

 

Here is a pic of them installed with the 4x4 pipes:

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/IMAG0226_zps3e28f29f.jpg

 

 

When I go with the 2x4 pipes, there will be a space between the bottom of the bags and the top of the pipes, and to me that dont look good,..

 

You can see where the bracket at the bottom that holds the bottom of the bag here:

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131121_190220_zpsb23b7fab.jpg

 

So I want to lower them to take that space up, plus it will show a llittle more of the top of the fender as well, Should look good I am thinking,.

 

The 4x4 Barons pipes actually sound good and are not too loud, noise was never a problem for either of us, or anyone we rode with. We ride a lot with Road Star 1600's with strait pipes, they are way louder than our pipes for sure,..

 

Thanks for the props!

[DarrinGT]

Hi Darrin

I like what you got going on there bro.. I can honestly say that I have never seen a set of those 4x2 pipes before, pretty cool indeed.. I am over in Muskegon, and like you, a little bit of a tinkerer.. Come spring we gotta get together and let me see and hear what that sounds like!!

On another note, I have been riding old Ventures (never had one newer than 84) for years now and have put a lot of thought into switching over to the TD when we move into modern times LOL.. Its a head scratcher for sure cause the wife and both really like the modern Venture too..

Anyway, just wanted to give ya a thumbs up on your project and wish you a great season of spinning wrenches!!

Puc

 

Thanks for the thumbs up! Would love to get to gather next spring and take a ride, we will have to do that!

 

The mufflers are Vance and Hines Monster Ovals made for Harleys, so I am adapting them to the Venture Pipes. they have a nice deep tone to them,..should sound pretty good with the V4!

 

I don't think you can go wrong with either the Old Ventures or the New ones, They are all great bikes! Run with what you are comfortable with.

 

Thanks again!!!!

[DarrinGT]

My only comment is concerning valve adjustment. Unless it is hard starting and runs like crap regardless of tune ups and carb sync, you might be just wasting your time, but if you want things "perfect" then go ahead.

 

Most of the other stuff sounds like a good idea...

 

It runs awesome, just didn't get good mileage, but since it was supposed to be done at 32K, and now with 57K,,,figure it is way past time for it,..Just figured it will need it. I dont know what other signs of it needing to be done?

 

Thanks for the input!

[DarrinGT]

Got some parts coming in,

 

32MM Carbs, New Yamaha Carb Boots, and a stock Air Box with a K&N Air Filter:

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131125_172636_zps332be3a5.jpg

[DarrinGT]

Got a little work done today also,

 

I purchased the Monster Ovals used, and the previous owners had removed the Baffles,.. Ya know, HD Owners,..lol,.. I installed one and didnt really care for the sound, so it needs some baffles,..

 

The prob is that they baffles are not replaceable, once removed they are gone, So I found some V&H Baffles from a Slash Cut Oval and made them work.

 

They came in today, and I tore the mufflers apart and started fabing the baffles to fit:

 

Here is a pic of the new Baffle, Muffler, and Outer muffler:

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131125_162709_zpsa60a0898.jpg

 

 

Here is the baffle installed in the Muffler:

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131125_164836_zps7aa7bd97.jpg

 

and Completed Muffler:

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131125_165640_zpsdaa20905.jpg

 

 

Right now I have one installed, the other still has the 4x4 on it, It sounds Sweet! nice low rumble...

 

Thats it for now,..

[DarrinGT]

Quick update, I have the exhaust bolted on both sides, but will have to make muffler brackets after I lower the saddle bags.

 

When going from 4x4 to 4x2 exhaust, you dont have to change the front head pipes, just the rear head pipes. Another thing that you have to change is the rear exhaust hanger.

 

Here is the 4x4 one shown on the passenger side:

 

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131201_151510_zps0e46a272.jpg

 

Here is where the bracket needs to go for the 4x2 exhaust:

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131201_142845_zpsb4961b14.jpg

 

The problem is that the 4x2 bikes have the muffler hanger integrated in the lower hard saddle bag bracket,

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131201_142852_zps3ab45920.jpg

 

 

So I instead of cobbling up my own brackets I bought a set of them, cut off what I didnt need, Here is the bracket installed:

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131201_145201_zpsbcac16f8.jpg

 

 

So,,..Hows it sound,..Check it out:

 

[ame=http://www.youtube.com/watch?v=URVtupIbbdw]1997 Yamaha Royal Star Vance & Hines Monster Ovals - YouTube[/ame]

[DarrinGT]

No comments on the Exhaust?,.. Like,.?,..No Likey,,..?

 

Made some progress today:

 

Started to get it disassembled:

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131207_114611_zps373cd41e.jpg

 

Got the 28mm Carbs off:

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131207_114619_zpsc6f3343d.jpg

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131207_114628_zpsb29c30b2.jpg

 

Looks like a Royal Star blew up in the back of my truck,..

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131207_114645_zps7d500068.jpg

 

 

The Barons Kit came with the 4 K&N Pods, so when I installed the fairing a few yers ago i was able to put the Oil Pressure Gauge Sending Unit on the frame were the stock air box would go,. It had to get relocated,.

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131207_115455_zpsdda41b1a.jpg

 

 

Since I will be going with a stock air box with the 32mm carbs so the sending unit had to be relocated: Found a little room in the neck behind the plastic covers:

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131207_121727_zps8b4baab3.jpg

 

Then started working on the stock air box fitting them to the 32MM Carbs. It is a tight fit but it does work as per the article:

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131207_150731_zps46ad6b3f.jpg

 

That's it for now,..

[DarrinGT]

Also,.I found tube with a PCV type vent at the top behind the plastic covers behind the radiator,...not hooked up to anything,. and I cant see where it goes.

 

Does anyone know what it is and where it goes,...?

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131207_120346_zps11bb94e6.jpg

 

Any input is welcome.... Thanks!

[dingy]

By the looks of the valve at the top of the line, I think it is the overflow line to the fuel tank.

 

I have a spare air cleaner like yours, in case you need it. Was going to use it on the Hybrid I am building, but realized it would not fit the 1st gen carbs. Don't need it so it is yours for shipping if you find you need one. Sometimes spares come in handy when plan 'A' doesn't work!!

 

Gary

[DarrinGT]

Overflow for the tank makes sense, I have had the tank off a number of times, but have never seen that, or disconnected it. I will check on the tank when I get back to the shop on Monday to see if there is a hook up for it.

 

I will take you up on the air cleaner, Thanks. Just PM me your address and Ill pay you when you have the price for shipping.

 

Thanks again,

Darrin

[dingy]

Overflow for the tank makes sense, I have had the tank off a number of times, but have never seen that, or disconnected it. I will check on the tank when I get back to the shop on Monday to see if there is a hook up for it.

 

I will take you up on the air cleaner, Thanks. Just PM me your address and Ill pay you when you have the price for shipping.

 

Thanks again,

Darrin

 

Sent you PM on air cleaner shipping.

 

What fairing and quick connects did you use? Interested in that for the Hybrid.

 

Your Photobucket pictures will be helpful. Haven't seen many detailed pictures of this bike disassembled like you have there. Got the bike in pieces, and all my experience with Ventures has been 1st gen.

 

Gary

[DarrinGT]

Sent you PM on air cleaner shipping.

 

What fairing and quick connects did you use? Interested in that for the Hybrid.

 

Your Photobucket pictures will be helpful. Haven't seen many detailed pictures of this bike disassembled like you have there. Got the bike in pieces, and all my experience with Ventures has been 1st gen.

 

Gary

 

 

Got it Gary Thanks!

 

The Fairing was off of EBay and it was for a Road Star. I figured that since the windshields were the same from as the Royals, the Fairings should work as well,.and it did. It just uses the stock windshield mounting bolts. 4 bolts and one plug and it is removed. I still have the stock Road Star windshield but have never used it.

 

Glad ya like the pics,..if you need any others let me know,..I will be doing the valves, Stator and V-Max rear as well, so more to dissasembly will be taking place before it starts going back to gether.

[StarFan]

Also,.I found tube with a PCV type vent at the top behind the plastic covers behind the radiator,...not hooked up to anything,. and I cant see where it goes.

 

Does anyone know what it is and where it goes,...?

 

http://i1306.photobucket.com/albums/s564/Darrin-GT/1997%20Yamaha%20Royal%20Star%20Makeover/20131207_120346_zps11bb94e6.jpg

 

Any input is welcome.... Thanks!

 

This would be the rollover valve for the gas tank. Hooks up to the breather hose that runs from front of the gas tank. This valve prevents gas flowing out of the breather tube if the bike tips over. Remeber this because when I had my 1998 Tour Classic apart the first time this thing was just hanging there doing nothing so I had to figure out what it was for.

 

BTW - NICE WAY TO GO ! LOVE THE SOUND OF YOUR MONSTER OVALS

Did you think about going all the way and put in V-MAX CAMS ? Did that on my bike and have to say that it made all the difference. That bike realy goes.

Pictures of the bike can be seen at: http://s1281.photobucket.com/user/jonaslill/media/Maximus/SAM_1521_zps054851af.jpg.html

[Squidley]

The V&H do sound really nice from the video, probably better in person. I will say 1 thing, I noticed electrosport charging items. You may or may not want to hear this, but I have dealt with them and I will never do so again. Had multiple issues with a R/R I installed on one of my '99's and the customer service was terrible.

 

I hope your experience is better than mine was, but keep your receipt handy in case there are issues....

[DarrinGT]

This would be the rollover valve for the gas tank. Hooks up to the breather hose that runs from front of the gas tank. This valve prevents gas flowing out of the breather tube if the bike tips over. Remeber this because when I had my 1998 Tour Classic apart the first time this thing was just hanging there doing nothing so I had to figure out what it was for.

 

BTW - NICE WAY TO GO ! LOVE THE SOUND OF YOUR MONSTER OVALS

Did you think about going all the way and put in V-MAX CAMS ? Did that on my bike and have to say that it made all the difference. That bike realy goes.

Pictures of the bike can be seen at: http://s1281.photobucket.com/user/jonaslill/media/Maximus/SAM_1521_zps054851af.jpg.html

 

Thanks StarFan,,.I saw your bike a while back and it is a beautiful ride!

 

I would consider V-Max Cams, how much more is involved installing them from doing a valve adjustment,..?

I also wondered what it does for Fuel Mileage? since that is what really sparked me to do a lot of the changes on the bike this winter.

 

Thanks again,..

Darrin

[DarrinGT]

The V&H do sound really nice from the video, probably better in person. I will say 1 thing, I noticed electrosport charging items. You may or may not want to hear this, but I have dealt with them and I will never do so again. Had multiple issues with a R/R I installed on one of my '99's and the customer service was terrible.

 

I hope your experience is better than mine was, but keep your receipt handy in case there are issues....

 

Thanks Squidley, I bought the items from another vender not from Electrosport, but yea,..I hope it works for me. Some people seem to be happy with the product so well see. For me it seemed to be best bang for the buck since I got both for $255.00 shpped, I was good with that.. but thanks for the heads up!

 

Glad ya like the sound, Cant wait to get it on the road next spring but I have a lot of work to do first,...

[dingy]

Thanks StarFan,,.I saw your bike a while back and it is a beautiful ride!

 

I would consider V-Max Cams, how much more is involved installing them from doing a valve adjustment,..?

I also wondered what it does for Fuel Mileage? since that is what really sparked me to do a lot of the changes on the bike this winter.

 

Thanks again,..

Darrin

 

Have never done this on a motor in the bike, but have numerous passes at doing it on bench.

 

To change the cams, you need to remove the cam adjuster that are on the rear of each head. 2 ten mm hex head cap screws in each adjuster. You will probably need to replace gasket under each tensioner. This will allow cam chains to have maximum slack.

 

Remove cap screws from each of the 4 cam shaft caps. These caps are numbered 1~4 on each head, cast into cap, but there is no notation on them for front or rear head. They MUST be placed back in same head as they are removed from. They are snug fit over 2 dowel pins into the head, takes a little jiggling to get them off. You can put a screw into the valve cover screw hole to use to help remove them.

 

The cams are somewhat difficult to get clear of the chains, not much slack in them. Gently work them out. This is in service manual under 'Engine Disassembly' section. I think if cam gears are unscrewed from cam, it would be a little easier to get cams out.

 

Putting cams back in is basically reverse of above, but now cam timing marks must be set correctly. The front and rear heads are different on setting. This is detailed in service manual in 'Engine Assembly and Adjustment' section. When cam chain tensioners are replaced, the large nut on tensioner is removed in order to allow the ratchet mechanism to be retracted.

 

You will need to check valve clearances after swapping cams. Shims should be close to stock cams.

 

I have 1 pair of VMax cams in good condition. $100 and shipping. Front & rear head cams are identical, position of cam gear is in different though on intake & exhaust cams.

 

Not sure what it will do for mileage, wasn't a concern when I was VMax'ing my 83. It will help improve power somewhat. To further help power & RPM range, valve spring change to VMax springs is very helpful. This requires heads to be pulled. There is a way to do it with heads on, but I wouldn't recommend it.

 

Picture attached of rear of motor on bench, cam tensioner is not in head in picture. Hole for it is to right of left exhaust where it connects to head.

 

Front head tensioner hole is shown in top view of motor, front of motor to left. Tensioner hole is between the 2 intake ports on front head, this will be under carbs.

 

Last picture is looking into rear head with valve cover off.

 

All pictures are of 1st gen 1300 motors, but it should be very similar to yours.

 

Gary

[SummerBreeze]

I realy like everything you have done and /or plan on doing. Want to do the changes to my 96 RSTC in the future as $$$allows.

If you would be interested in selling your 4x4 pipes and carbs I might be interested.

Again I like it.

[DarrinGT]

Gary,

 

Thank you for the info on the cam swap, I am still thinking about it, but probably will just stick with stock cams.

 

If I knew it would affect fuel mileage I may do it, but I know that if I have the power I will use it,,,,,and that WILL affect fuel mileage.

 

Also Thank you again for the Air Cleaner, I appreciate it!

[DarrinGT]

I realy like everything you have done and /or plan on doing. Want to do the changes to my 96 RSTC in the future as $$$allows.

If you would be interested in selling your 4x4 pipes and carbs I might be interested.

Again I like it.

 

Thanks for the props, I will be selling the carbs and pipes eventually and will let you know when it happens.

[DarrinGT]

I would like to start doing the valve adjustment after the Holidays but will need a shim tool and the gaskets.

 

I know that Skydoc has the tool to loan, and I can buy the parts from him but I have not been able to get ahold of him. Is there anyone else that I can get the parts from and loan the shim tool from?

 

 

Thanks,..and Merry Christmas!