made2care

There is a retaining wire that holds the first metal clutch plate in place. This wire is broken. Do i need to get another or can i go without it. thanks

Neutral switch came in. Easy Peazy "switch ". This little guy cost $22 but hey, whose keeping track. I enjoy this and know one day, this bike will be putting on the miles!

Not being familiar with clutch parts I did notice this plate and no clutch springs. So this plate has replaced the springs. Will the torque be the same for the clutch screws, manual says 8 nm.

This is sad !! https://springfield.craigslist.org/mpo/d/springfield-1983-yamaha-venture-1200/6893740802.html

Went with brand new vmax. Crucial parts on this bike should be new if possible. Even though I tried to rebuild this one, the more I thought about it, better to get new and 4 brush. Didn't test this one but just too much rust!! i am not selling this bike when I'm done !! And I hope it will run!!

I think you are correct here. Even though i cleaned it, I had no idea that the rust would cause issues. i found a replacement using a RSV and it should bolt right on.

I managed to remove quite a bit of the rust. Hopefully it will work!! Or maybe I should just get e new one. Anyone purchased a new replacement? Can't seem to find one.

Good thing I took starter apart!! Filthy !!

Water pump has updated impellar . I will clean the starter. Will also check the stator. Thanks for the reminders.

Okay, cases are back together. Note to others, I used a small crafts type brush made of horse hair to apply yama bond. I only applied a thin layer to the upper case being careful to stay 2 mm from bearing edges. The small brush made application pretty neat and easy. Bearing retainers are in, along with oil pump and oil pan. Used new o rings , seals and of course Oem gasket which I dry fitted. Before I buttoned everything up, I made sure the transmission shifted through all gears. Gear lash appears fine with very slight movement. So far a great learning experience. I've decided to not paint any parts since most of these are covered anyway. More work planned for tomorrow!

Beautiful work !! Gives me some hope on mine. Well done so far !!

So I am officially off from work for almost 3 months, yippee!! Then my wife gets the brilliant idea for me to remove all of our mulch from our flower beds and replace with 3 " river rock !! I unloaded almost 2 tons today! I know tomorrow I'm going to feel it! Anyway, I'm going to put the cases back together tomorrow morning. Hope all goes well! later

Well, the neutral switch basically fell apart upon install. I overlooked this part , so will get it this week, pricey too !! I can still go ahead and put case halves together. Still waiting on yamabond 4 sealant though. I'm not going to use anything else. chow 4 now, pics coming soon. Oh, I was in OKC this weekend, just missed the tornado that hit El Reno, Oklahoma, made the national news ! I purchased a 20-100 ft/lb torque wrench at harbor freight for a mere $80. I have a smaller one and needed a larger one for parts of the crankcases.

I'm assuming i just use a syringe to oil the inner portion of the bearings? should i try to fill various channels in upper crankcase too in hopes of priming and preventing damage or will oil pump kick in pretty fast?

Quick update. I did a dry fit placing lower crankcase back, shifted through the gears and all is good. Will double check gear lash but think it will be okay. Last part is arriving today , so will probably button everything up this weekend. Friday is my last day at work and will finally be on my summer break. Yes, I'm a high school teacher, 20 plus years. Love my summers since i get to do what I want to do: travel, work on bikes, etc, etc. Anyway, will keep you posted. I'm excited to get the engine back in frame. I haven't forgotten to check the valves.

Its not good on inside.

New parts still coming in. Decided to just go new with the slave clutch cylinder since it still had original. Little pricey but much needed! Old on left, new on right.

I will be careful. What's interesting is that there is only one dowel. I checked the schematic and it only shows the one dowel which aides in lining up everything.

Okay, got it, thanks

So do i just apply a thin layer to the upper crankcase only, or do I apply to upper and lower. To me, applying to both would be too much.

I just watched part 8/12 video series and it shows technician applying yamahabond with finger, just a thin layer.

Okay, I'm getting close to mating to crankcases but waiting on some more parts. I'm going with yamapartsnation but the only downfall is they take too long to ship, anyway, I have a couple more questions; Do i apply yamabond sealant to upper crankcase only or do i apply to both crankcases. I'm thinking just upper and how big of a bead, i realize surface area changes but don't want to put too much on. Also, the manual states that i stay clear of the bearings about 2mm , so do i still attempt to place sealant around bolt holes near the bearings? Maybe my thinking is overkill but i really want to make sure i don't screw anything up. Thanx again.

Okay, I went back and shifted again through each gear and no issues. I have cleaned off some the old gaskets and still have quite a bit left to remove. some more questions: do I oil/grease the outer surface of all bearings. Also, shop manual shows I must oil interior/ inside of bearings. What oil or grease do I use? Or do I just oil them?heres a pics of upper crankcase with old gasket removed.

Yes, i'm paying close attention to those pins on bearings and as far as the forks go, great idea. I have more and more questions. I've noticed that there are two bearing circlips that are just half moons so i'm assuming these fit half on upper and half on lower crankcase or maybe it doesn't matter. The big bearing does have a full circlip around it. Also, I am shifting through the gears with them sitting in the lower crankcase, seems not all gears are shifting but maybe its just the way i'm trying to shift them.All forks are in their respective slots too.

Quick question. Does the oil pump idle gear have to engage with a gear wheel? Or does it sit snug to the crankcase wall not engaged with gear wheel.