dingy

Starter o-ring is an AS568 Dash # 213, 1/8" wide x 0.921 ID. I beleive all Venture starters are interchangeable as well as VMax's 85-07. 4 brush starters were begun in 94 on Vmax's, I think. Picture attached of external difference between 2 & 4 brush stock starter. Top one is a 2 brush, note Phillips head screw in case at midline, there are 4 of them. Bottom is a 4 brush case, partly disassembled, no screws around mid line. Gary

Haven't done much too it the last few months. Did some upgrades to Tweety. I finally have the exhaust relocation issues fixed with the Hybrid. Will be getting back to working on it this week. It has been very cold this winter, even with a somewhat heated garage. Right now it is back to a bare frame with only front forks & front wheel on it. Going to paint frame to cover areas that have been modified on it, now spot coated with gray primer. Goal was to have it running for Oberlin MD, but now hope to be able to bring it to WNY rally & get some pin striping on it. Tweety has gotten wave rotors all around, a revamped rear brake setup, clear side covers, some more powder coating and mac exhausts. Gary

Don't scare him Carl, I will sell him a brand new aftermarket one, much better than stock, for under $300.00 Gary

It could still be an issue with the fuel pump circuit in TCI. Pump will engage for about 4 seconds when key is turned on, after 4 seconds without the motor starting the TCI will disengage the fuel pump. This is a safety circuit designed to turn off fuel pump in a wreck. What this could be doing is running pump long enough to fill carbs, bike is starting, quickly draining carbs. The 90-93 TCI's have the fuel pump cutoff circuit in the TCI. 83-89 Ventures had a seperate fuel pump relay with the circuitry inside the relay housing. 90-93 stills has a fuel pump relay, but it is a standard style relay. Do you here pump run again after it dies and you turn key off, then back on. If it's running for the 4 second time, it would seem it is pump circuit. This is just a possibility and not a 100% sure fire thing. Gary

It appears you are correct Carl. I looked in the 83-85 Venture, 86-93 Venture and VMax service manuals. Only real reference to rear wheel bearing removal was in the 83-85 manual and it said "Rear wheel bearings replacement is similar to procedure for the front wheel" Front wheel bearing description is in attached picture. So it appears my previous ideas will not work, hard to believe!! Gary

Got Tweety out for a ride this afternoon. Still waiting on on more wave rotor to arrive from China, but old one stopped us fine. Gary

Look at the add linked below from Harbor Freight. Picture shows a bearing puller. Principle is a sliding bar on the shaft can be dropped in the bearing center hole, then extracted by tightening against washer and shaft. http://www.harborfreight.com/rear-axle-bearing-puller-set-66380.html Knowing this concept, you can possibly improvise on it. Or improvise on a slide hammer concept http://www.harborfreight.com/blind-hole-bearing-puller-95987.html Gary

1st picture shows TCI wiring for a 1990-1993 TCI 2nd picture shows TCI pin outs. This is for a 1983-1989 TCI. Kill wire is on pin 'D' as shown in 2nd picture. Kickstand kill switch. Should be a Black wire with a White tracer. Ohm reading on pickup coil should be 81-121 ohms. You also could have a fuel pump power issue, the fuel pump is controlled by TCI on 1990-1993 Ventures. This is the Blue wire with red tracer. Shown on 2nd picture on pin #5 of the 6 pin connector. Gary

Part #'s are the same in parts fiche, so they will interchange. Gary

Here is a picture of a cutaway fork tube. Cut part is lower fork tube. Spindle is brighter aluminum piece to right, going through spindle is Cylinder Comp., Front Fork. This is parts fiche description. 1st picture is from 83-85 set of forks. 2nd~4th pictures are from a 90 (I think) set of forks. Note the Plate,Seat in bottom of tubes. Last picture is side by side comparison of early & late fork tube bottoms. Measure the distance between the brake mount holes on the forks tubes. If they are not 100mm (3.937"), they are 83-85 vintage. 83-85 holes are 80mm spacing, I think. If they are 100mm and the anti dives mount to the front, they are 86 or 87. If they are 100mm and the anti dives mount to the side, they are 88-93. Just because bike is titled an 83 doesn't mean parts haven't been swapped in 31 years. Gary

Possibly a failing pickup coil or the connection from it to the TCI module. Gary

I have not seen a Venture without them. I don't have vast experience with them, maybe 8 sets I have seen. MiCarl, Squidley or Skydoc_17 may have more info. You might try PM'ing them Gary

Attached is a picture of a lower fork tube cut open. Also attached are a few pictures of CAD models of the forks as I understand them. Gary

Attached is a Microsoft Excel 2003 spreadsheet that can be used as an aid in selecting replacement valve shims. This should work for 1983 through 2013 models, I did not see any variances in the sizing charts in the service manuals. 1st sheet in each file is in Metric format. 2nd sheet in each file is in Inch format. I expanded upon the valve clearance charts that are in the service manuals to include the shims end in 2 and 8. The reason for this is that these shims can be reused in the bike if available. I don't believe you can buy the --2 and --8 sizes. Screen shot below shows cylinder 2 area. The only cells that are selectable are the "Shim in Now" & "Measured Clearance" data fields. The "Shim in Now" field will only accept valid shim sizes. There is a pull down menu for valid sizes or size can be keyed in. The only other value that is accepted as input is a zero. I included this to set chart to neutral setting. The "Measured Clearance" field has no error checking built in. Use millimeters on Metric sheet or inches on Inch sheet. The decimal point needs to be entered, the "mm" or "in" does not need to be entered. Below the "Measured Clearance" field is a calculated field for "Shim Needed". This field will display the correct shim size to set valve clearance to the high end of acceptable range. Next is "Expected Clearance" field. This is a calculated field to show what valve clearance should be with the shim size shown in "Shim Needed" field. Next is "2nd Choice Shim" field. This field will display the next larger size shim that will work. This shim may be selected due to "Shim Needed" is an odd size or not available. This shim will set valve clearance to the low end of acceptable range. Next is another "Expected Clearance" field. This is a calculated field to show what valve clearance should be with the shim size shown in "2nd Choice Shim" field. In the upper right hand example, the lower "Expected Clearance" field is highlighted in Red. This will happen when any of the calculated sizes fall outside of acceptable range. If value cannot be calculated the "Shim Needed" field will be blank and error will display in "Second Choice Shim" field. This will happen if an out of range clearance value is entered. The two right hand charts in screen shot do not have data entered in so there are errors shown. This should print out on 8 1/2" x 11" paper very readable. This is just an aid for shim selection. Verify clearances if you use this after shims are installed. There is a separate spreadsheet for Ventures & Vmaxs, the Vmax exhaust valves are different settings than a Venture. Gary

To move one from an 83-89 bike to a 90-93 bike requires a different adapter cable and the TCI to be reprogrammed. I have extra adapter cables & MAP sensors I can get you. Difference in cables is due to change from single to 4 pickup coils. Reprogramming TCI can be done via a USB-Com cable. If you don't have the cable I will reprogram tci or get you part # of cable I furnish atTigerdirect.com. The cable is not readily avaliable at radio shack or best buy stores. Gary

83-89 Ignitech TCI's are the same, I supply a plug that will block of the port on the carbs for an 83 bike. The vacuum is then attached to the #2 intake port where the sync hookup is done. I do not have any feedback other than Twigg said he experienced a little lower mileage on one of his long distance runs I believe. This was one of the ones from the 2nd group, that was experiencing the very rare but disconcerting dropouts for about a second at low RPM's. Gary

Current software version is 131203a_tcip4A_v88.exe Model name is TCIP4 - 4 channel Other than the 2nd group I bought in January 2012, I have not had a single complaint. I have sold 66 TCI's after that 2nd group purchase. I personally think it is fixed. I am running a TCI from the 2nd group with later software in it and have not had the hesitation problem in 2 years. I have 4 TCI's left right now. It's spring time and they are starting to sell again, sold 4 in the last week, none since February before that. Gary

I am fairly sure I have extra parts needed. If you can get me everything you need, I can take a look. Gary

Came across a picture of a crank for a Venture on Ebay, I put some arrows at the points on the crank that I mentioned there could be an interference point. Picture the rods attached, piston is at the bottom of its travel, the piston skirts will be in close proximity to the points I highlighted on crank. Gary

I am not saying the ends of the crank that the rods are attached to are different, it could be that the central part of the crank has been made larger. The possible reason to do this is to increase low end torque of motor. I think this might be a low probability, because I know Yamaha reduced the mass of the rotor (flywheel). I don't see a valid reason to reduce mass at one point of the assembly, then increase it at another. I have an RSV rotor here which I am putting on the Hybrid/RSV/VMax/1st gen project. I know the rotor will fit on the crank of a 1st gen 1300 motor properly. This is tells me that part of the crank machining did not change. (Picture of motor attached for no particular reason). The reason Yamaha would want the crank to have a higher mass on the crank assembly is that higher mass increase low end torque. Lower mass helps the ability of the motor to increase RPM's faster, it's one or the other. The RSV was a heavy touring bike, it needed the low end torque to get it moving smoothly, not the fast ramp up in RPM's. This is just a worst case scenario. You asked if they would fit, I'm not going to say "He!! yes". My day job is a mechanical design engineer, so I am very use to looking at what can go wrong and not standing back and saying "Ship it" Gary

I am not sure if they could be swapped. The rings, wrist pin, circlip & rod's are all same P/N's. The possible issue I see is that the crank is different P/N#, Where this might be an issue is the counterweight throws on the crank "MAY" have been made larger, and the piston skirts reduced in size to clear the counterweights when the piston is at the bottom of the stroke. Other than that, they will fit. Another thing that I just thought of is the top of the piston to the C/L of the wrist pin could be different. If it is shorter, compression would be low. If it is higher, valves will crash into piston. Gary

If you have a 6 point socket it may grab the head of the bolt. Shouldn't be an SAE, but anything could have been done in the past. Gary

12mm I believe. Gary

Brian, Here is a fix to your battery issue. http://www.justdeals.com/tripod-flashlight?utm_content=gary%40dinges.com&utm_source=VerticalResponse&utm_medium=Email&utm_term=&utm_campaign=Tripod%20Flashlight%2C%20Adjustable%20Head%2C%20Stable%20and%20Portablecontent Gary

84 will not fit an MKII, they are different O.D.'s. I have one that will fit an MKII, I just replaced all the rotors on Tweety with wave rotors. This one was on the rear. Two I took off front are from an FJR, they won't fit an MKII. It is the correct rotor for the front of a stock MKII, I had to customize rear brake to get it to fit with VMax rim. Gary