Progress

[dna9656]

Well it's been a little over a year since I bought my '83.5 XVZ12DKC2 but it's really a '84. The bike came with a new clutch and springs in the trunk, still boxed and a PAPER Yamaha Service Manual that had been in the trunk (for 2 years) right under the new clutch. The bike had been sitting out side all this time so you know what the manual looked like....It went in the trash as I had one from my first Venture Royale ownership back in 1996, THAT manual is pristine. Now I use a digital one on my computer. When I got the bike I got a lot of extra parts, another set of saddle bags and trunk, some other stuff...I bought a group of parts found on craigslist, a seat, wire harness, nuts bolts, foot pegs, mirrors, radiator, etc. The sides and lowers were cracked and had broken tabs, the bike had been dropped so the fairing on both sides where the mirrors are were cracked and had small pieces missing. I found the '84's travel bag would hold 1 helmet only so I took the bigger one (with it's mounting rack) off the '85 and the saddle bags, cover locks and ignition (so I would have ONE key) and put them all on the '84. I installed the clutch even before I got the bike running, installed new plugs and checked out the plug wires. Cleaned the OUTSIDE of the carbs, THAT took a while...I had found this forum and with the help of members here got through the clutch install and learned about Sea Foam, it has NOT solved my plugged pilot jet issue yet so my plan is to get the (3?) gaskets and I don't know how many O rings and replace ALL the jets, re-set the floats, and get a synchronizer. I have a bucket of carb cleaner, a compressor, the service manual (I can view it of a 40" flat screen in my shop, makes the pictures MUCH better!) and the good people here on the forum to help me. I found the fuse panel almost not used with many of the fuses modified into in-line locations. I bought a 10(?) circuit fuse block and moved ALL the fuses to it, including the ones Yamaha has in "In-Line" configurations. It simplifies checking and changing the fuses, trust me. The fuse block fits right on the battery like the original one. I mounted it on to the original fuse panel though I did modify the panel to make it work. I traded a cheaper guitar I didn't play for a '85 Venture hoping it being newer would become the one I would pay most attention to but when I removed the oil filter cover I found a welded crack between the O ring seating surface; one side to the other but INSIDE the inner ring. Also I didn't notice the 3/16" aluminum crash plate under the floor boards, WHO rides a 750 odd lbs. dirt bike with a 1200 CC engine and what; 97 horse power? NOT ME! This bike is No. 4 (or so) off the assembly line with the factory 2nd gear issue resolved. That's why I'm keeping it. Not sure it's worth it. But it's got lots of parts too! So far the '84 has no 2nd gear issue with 65 to 66k miles showing on the odometer.

Anyway I got the plastic repair all roughed in during the last 2 weeks using black PVC plumbers glue and a sheet of PVC obtained through E-Bay. When cutting, filing or sanding the PVC wear a dust mask, breathing plastic dust is not a good idea, there is NOTHING in that plastic you want to have in your body. Anyhow I will be finessing the repairs (filling in low spots, sanding and getting it ready for painting next summer. While I repaired the "fingers" that the hold 4 screws and the rubber strip along each side of the battery (I actually made one and I had the thin the 1/8" PVC stock using the Dremel so the screw plates would fit) cover (false gas tank) I found better panel, inner (on E-Bay) that holds the screw plates (they slide on to the aforementioned "Fingers") and a few other pieces that I will replace. Three of the screw plates on the outer right fairing were gone, the outer fairing on the '85 had them (so that fairing being in worse shape that the '84's) I sawed them off and transplanted them to the '84. Using the liquid ABS I set them in place buy screwing them in place on the top cover and in turn screwing the cover in place using the in-board mounting screws. As there is some shrinkage when the ABS dries I have been sanding and filling the low spots. I found you can't hurry the ABS with heat, cold temps seem to slow it down but this stuff doesn't react to heat like epoxy does; it just gets THIN FAST! Anyway I got my Dremel tool out and widened the cracks into a V shape and applied the liquid ABS and clamp(s) and/or duct tape as appropriate. After the glue dried I used my Dremel with the sanding barrel on it to shape the ABS stock and glued pieces that was applied into proper tabs. I miss-drilled almost all the screw holes at least once but with more liquid ABS and some duct tape on the back side of the tab you can fill the drilled hole and try again. The larger travel bag had an issue though, the latch hooks had broken off; they were there, but laying in the bottom of the travel bag. The liquid ABS seems to be doing a good job holding them in place but I plan on re-enforcing the repair with more ABS flat stock and glue. I want to upgrade the ignition to the one Dinky has, I have added a few LEDs, the tail/brake and side markers that replace the reflectors, also I put LEDs in the front fender maker. I did the LED in the dash thing but couldn't dim them so I removed them. I'd LOVE to find a YAMAHA (or equivalent) flasher designed for LEDs that would integrate with the cancelling blinker and not require some sort of dummy electrical load. I got a new seat for my Birthday, Anniversary, Sweetest Day, Christmas, New Year's and any other day I might want some thing. Any ideas on the LED Flasher?

Edited November 23, 2014 by dna9656
Make points more clear....

[cabreco]

Nice Job Doug. I know what you're going through, I rebuilt my 84 from sad to not bad at all.

Here's an Idea you may not have thought of since you were asking about LEDs.

Found these at Walmart gives me added visibility on the road. I also have LED driving lights attached

to the chin. They are all chrome bullet halogens which I replaced the halogen bulbs with LED replacements I found at Home Depot.

 

Good luck on the progress, have you decided on what color to paint her?

[Venturous Randy]

This bike (85) is No. 4off the assembly line with the factory 2nd gear issue resolved. That's why I'm keeping it. Not sure it's worth it but so far the '84 has no 2nd gear issue with 65 to 66k miles showing on the odometer.

 

 

Unless I am missreading your comment, it sounds like just because the bike is an 85, it does not have the 2nd gear issues. Actually, the 2nd gear extended into 85 to about the 1413 bike. I don't think the 2nd gear issue is an absolute on a 83/85 1st gen, but it is highly likely from what I have seen.

RandyA

[Prairiehammer]

This bike (85) is No. 4off the assembly line with the factory 2nd gear issue resolved. That's why I'm keeping it. Not sure it's worth it but so far the '84 has no 2nd gear issue with 65 to 66k miles showing on the odometer.

 

 

Unless I am missreading your comment, it sounds like just because the bike is an 85, it does not have the 2nd gear issues. Actually, the 2nd gear extended into 85 to about the 1413 bike. I don't think the 2nd gear issue is an absolute on a 83/85 1st gen, but it is highly likely from what I have seen.

RandyA

 

What Doug is saying about his '85 is that his is the fourth SINCE the factory second gear fix.

[dna9656]

That's correct; my VIN is JYA59J001FA001416. My '83.5 ('84 DKC2) has 65K miles and there's in no indication of a 2nd gear issue but I have no idea if it were fixed or not. When I ask Yamaha about it they say they have to check for files NOT in their current data base and they promise to call me back yet they are to do so. After warranty repair (and I assume after an OUT of warranty repair) the dealers were supposed to leave 3 stake marks on the transmission housing next to a "pad" cast on the left side of the transmission housing; they are missing on my bike .

Edited November 23, 2014 by dna9656
readability

[dna9656]

cabreco

 

I think they look best in Gold or some sort of white....

I like the touch of LEDs around the front blinkers! How did you attach them? Wired to the running light circuit?

The air scoops on the front lowers... after market or OEM? I can't find one in the parts catalog though I have seen a few different style...

Edited November 23, 2014 by dna9656
address to cabreco

[cabreco]

cabreco

 

I think they look best in Gold or some sort of white....

I like the touch of LEDs around the front blinkers! How did you attach them? Wired to the running light circuit?

The air scoops on the front lowers... after market or OEM? I can't find one in the parts catalog though I have seen a few different style...

 

I agree on your color choices ESPECIALLY with that awesome 2 toned seat!

The LED are wired to the running light circuit on the directional signals.Simple connect with quick wire splice connectors.

The chrome air scoops (The Chin) on the front lowers I believe are aftermarket. IDK the manufacturer, but they show up on Ebay. I did replace the original lights with LED units because the light housing were cracked on mine. I got it from a parts bike I bought.

[Prairiehammer]

Andy and Doug,

Check out this currently running thread about the VentureLine air dam (chrome chin spoiler) where Brian posted a link to buy a brand new NOS VentureLine chrome air dam. http://www.venturerider.org/forum/showthread.php?90485-Help-identifying-and-finding-a-part

[Venturous Randy]

What Doug is saying about his '85 is that his is the fourth SINCE the factory second gear fix.

Yep, I now remember us talking about that before. Like I said, unless I was misreading and I was.

RandyA