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Submitted by Bill Anton If this is something you may need to do (Sunday or Monday when bike shops are closed) print the procedure and put it in your owners manual. DISASSEMBLY PROCEDURE ===================== NOTE: This info is specific to the 1983-1993 Yamaha Venture motorcycle. Make intelligent (safe) changes for other motorcycles. Included in the procedure are REASSEMBLY torque specifications. The size listed is for the socket or wrench, not the bolt thread size. Initial tools required: - ratchet - 3" extension - sockets: 12mm, 14mm, 19mm - 14mm box-end wrench (if you loosen/remove the final drive) - 27mm flat wrench (rear axel nut) - 6mm Allen wrench (front axel pinch bolt) - pliers (for cotter key) OR get a get a 5/32" $0.75 hitch pin clip (Lowes / Home Depot) and never have to hassle with the archaic cotter key again - tie-down strap(s) - carpet / cardboard (for under forks) !! IMPORTANT: Control the bike's weight balance to make it safe to work around. You may have to ADD some WEIGHT to the REAR of the bike (saddlebags & trunk) BEFORE starting the procedure, so the front of the bike doesn't fall when the front wheel is removed in step 13. You should REMOVE everything from the saddlebags & trunk AFTER the front wheel is removed so the rear of the bike doesn't fall while working on the rear wheel. 1. Put the bike on the centerstand. 2. Connect tie-down straps from the bottom of the centerstand legs, to the engine guards. Pull them as snug as practical. 3. To keep the fork tubes from getting damaged in step 10, place a cardboard or carpet (from a car?) under the front tire area. 4. Loosen the right muffler-to-exhaust clamping bolt - 12mm. REASSEMBLY - Torque 14 ft-lbs. 5. Remove the right muffler mounting bolt - 14mm, and remove the muffler. REASSEMBLY - Torque 18 ft-lbs. 6. Remove the rear brake caliper - 2, 12mm bolts. REASSEMBLY - Torque 32 ft-lbs. TIP: Use axel wrench flat end to spread the brake pads during reassemble. 7. Loosen (not remove) the rear axel pinch bolt - 12mm. REASSEMBLY - Torque 14 ft-lbs. TIP: If the cotter key is aligned vertical, file marks on the pinch bolt end of the axel for easier future alignment. If it isn't aligned vertical, make the marks when you have the axel out. 8. Remove the rear axle nut and washer - 27mm flat wrench. *** DO NOT REMOVE THE REAR AXEL NOW *** REASSEMBLY - Torque 110 ft-lbs. TIP: Replace the cotter key with a 5/32" hitch pin (Lowes / Home Depot). 9. Front wheel remove: 1. Remove both brake calipers (2 bolts each) - 12mm. REASSEMBLY - Torque 32 ft-lb TIP: Get 2 pieces of cardboard 4"x4" and fold them in half and insert them between the pads to hold them apart TIP: Use axel wrench flat end to spread brake pads during reassemble. 2. Loosen the front axel pinch bolt - 6mm Allen wrench. REASSEMBLY - Torque 14 ft-lb 3. Remove the front axel bolt - 19mm. REASSEMBLY - Torque 75 ft-lb 4. Remove the front wheel. TIP: When you pull the wheel out, the speedo cable and drive will fall away -- don't worry unless you are over a dirt surface. REMINDER: On reassembly the speedo housing top-tab goes into the fork notch. 10. Carefully lower the front of the bike until the fork tubes are on the cardboard or carpet. 1. Start slowly pulling down on the fairing near the mirrors 2. As the pull-down becomes easier, slide one hand under the fairing for support 3. Squat a little as the fairing gets lower 4. As the weight increases, bring the other hand down for more support ****** REMOVE WEIGHT from the saddlebags & trunk for better counter balance. 11. Remove the rear axle. Notice the caliper bracket washer, it goes between the bracket and the swingarm. 12. Remove the brake caliper bracket. 13. Remove the 4 final drive attaching nuts - 14mm. then reattach one lower nut 1 1/2 turns so the drive shaft can't pull out of the U-joint and waste a lot of time to put it back together. REASSEMBLY - Torque 30 ft-lb 14. Pull the final drive rearward until it is against the nut. This gives a little more clearance to get the tire past the final drive. CAUTION: The wheel and tire weigh about 42 pounds. Be prepared for step 15. 15. Pull the wheel away from the final drive, and out of the swing arm. 16. Roll the rear wheel out under the fender and do what you removed it for. *-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-* Removal of the final drive unit at this point is recommended to lube the driveshaft splines (Molybdenum Disulfide Grease) as long as the wheel is off anyway. See the FINAL DRIVE REMOVAL procedure below. *-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-*-* 17. Reverse the DISASSEMBLY procedures from 14 to 1. - in step 10, do the sub-steps in 3-2-1 order. ---------------------------------------------------------------------- FINAL DRIVE REMOVAL PROCEDURE (optional) ============================= 1. Remove the 4 final drive attaching nuts - 14mm. REASSEMBLY - Torque 30 ft-lbs. 2. Pull the final drive out of the swingarm. NOTE on 86-93 models: The driveshaft oil seal makes the shaft "stick" to the final drive. The driveshaft can be pulled out with a firm force. DO NOT lube 86-93 driveshaft rear splines, final drive fluid lubes them. BE CAREFUL if you pull the shaft out of the final drive, oil can drain from the final drive. FINAL DRIVE REASSEMBLY PROCEDURE ================================ 1. Reinstall the driveshaft: 1. Pull (hard on 86-93 models) the driveshaft out of the final drive. Set the drive aside, being careful to keep it tilted up to prevent fluid loss. 2. Put the transmission in neutral. 3. Use a flashlight, and insert the driveshaft into the swingarm, and use it to align the U-joint so that the yoke is vertical (12 & 6 O'clock), and angled down toward the bottom of the swingarm. 4. Put the transmission in gear (so the U-joint can't turn). 5. Reattach the driveshaft to the final drive. 6. Insert the driveshaft into the swingarm, letting the front end drag on the bottom of the swingarm. 7. Wiggle the wheel mating gear on the final drive to mate the driveshaft with the U-joint - then put the 4 nuts on http://www.venturerider.org/firstgenwheel/Rear%20wheel%20removal%20-%201%20Kneeling%20position%20-%20rear%20view%20(Small).JPG http://www.venturerider.org/firstgenwheel/Rear%20wheel%20removal%20-%202%20Kneeling%20position%20-%20side%20view%20(Small).JPG http://www.venturerider.org/firstgenwheel/Rear%20wheel%20removal%20-%203%20Kneeling%20position%20-%20front%20side%20view%20(Small).JPG http://www.venturerider.org/firstgenwheel/Rear%20wheel%20removal%20-%204%20Kneeling%20front%20view%20(Small).JPG http://www.venturerider.org/firstgenwheel/Rear%20wheel%20removal%20-%205%20Parts%20removed%20in%2010%20minutes%20(Small).JPG http://www.venturerider.org/firstgenwheel/Rear%20wheel%20removal%20-%206%20Centerstand%20tie-down%20strap%20(Small).JPG http://www.venturerider.org/firstgenwheel/Rear%20wheel%20removal%20-%207%20Wheel%20out%201%20(Small).JPG http://www.venturerider.org/firstgenwheel/Rear%20wheel%20removal%20-%208%20Worms-eye%20view%20of%20rear%20wheel%20well%20(Small).JPG http://www.venturerider.org/firstgenwheel/Rear%20wheel%20removal%20-%209%20Rear%20brake%20caliper%20bracket%20position%20pin%20(Small).JPG
