Detroit Venturer Project

[Radioguylogs]

The complete '81 manual is $75 +$9 shipping.

After I reported the latest purchases of the drive shaft boot and the replacement bearings to the wife, I sensed a little apprehension.

Then I had to replace the pressure switch and circuit board in the garage heater.

I think I better lay low for a few weeks. Hopefully it will still be around.

[MPittma100]

Yamaha Manual

Hi Mike,

Look at this item number on EBay. 113442378801. $30 free shipping. Better be quick. Very good deal.

[Radioguylogs]

I grabbed that manual immediately. Thanks Mike!

There are several supplimental manuals for ~$25+Shipping, but it's nice the have the whole correct manual.

This was the only one I recognized as the full manual when I looked before:
https://www.ebay.com/itm/Yamaha-XS-1....c100227.m3827

It appears the one you suggested is supposed to be the full manual, but the cover is plain white and the eBay picture doesn't look like it has many pages.

Since the P/N LIT -11616-XS-13 is same between the white cover version and the full manual, the white cover version might be a later re-printing?

Wish I had this manual when I started.

[kboehringer]

Assembly and Supplemental Manuals

Mike,
I have these if you want them they are yours for FREEBIE.

This one is still in the plastic cover......

Back when I was in HS I use to put the bikes together (out of the crate) and used this one for assembly.








I use to have your address but can't find. Please send via PM.

Kurt

[Radioguylogs]

Kurt:

I'd love to have those manuals to help route cables and figure out how thinks are supposed to be, but you are waaaayyyy too kind!

I'll take it offline (PM).

[MPittma100]

Yamaha Service Manual

Hi Mike, The manual you ordered has much info on all of the previous year models as well. Lots of info.

[Radioguylogs]

Stuck in the Rear

Rear Wheel Bearings

I am still puzzled by the tight rear bearing. I put some oil on it and moved it around and I see muddy lubricant coming out:



I studied the inner race:



I think I see what's going on. I remember bought an extra NA-5904 and put it on the shelf because it was supposed to be rare. I must have used the second one on the Bagger and saved the old bearing in the nice packaging. When I installed it in the Voyager, perhaps my hammering disturbed some grease with fine rust particles, and the particles are just big enough to bind the bearing when the inner race is inserted.

Still, I am listening to Schming's advice, and his suggestion seems like a good idea. So tonight I made a Schmingolater:





I have the RH bearing and both seals in hand. I hope to receive the new bearing tomorrow, so I can try to do this over again.

Shocks

While I was waiting for new bearings and seals, I was working on other things. I noticed the rear shocks don't seem to have the same spring on both sides. The Right side seems linear, and the left side seems progressive:



Isn't that peculiar?

Swingarm Assembly

I forgot to grab a picture, but I have the Swingarm and Final Drive back on. I had to wait for a new driveshaft rubber boot. That all went back together nicely.


More to come...

[skids]

The funny thing is that there are 10 wraps on each coil. You are right though, one looks like a progressive coil.

[skids]

The funny thing is that there are 10 wraps on each coil. You are right though, one looks like a progressive coil.

Only you would know it if you just installed it that way. There might be some slight frame twisting forces however.

[Ranger_xs1100]

shocks

You made me curious about the 2 different shocks so I checked mine just to see if they were the same or not. My 81LH shocks are both the same type, (linear as you defined it). However, my 80LG has one of each with the progressive springs on the right side, which is something that I never noticed before. Unfortunately, I have no explanation for this since I am not the original owner, but it sure does seem odd!

BTW, I've really been enjoying following your project progress, looks like a fun one!

[motoman]

Bob, the spring diameter is slightly larger on rear KYB shocks of the 81 Venturer ONLY. If I remember correctly, the KYB rear shock dampening adjuster has the same 4 adjustment positions on all year model of Standards. Just the spring diameter is ever-so slightly larger with the Venturer model only.

[motoman]

Also, since Venturer model has the oil cooler, the initial engine oil capacity is 4.4qts. This puts oil level at top edge of sight window, which compensates for the oil cooler and oil lines additional capacity when moter is running. This capacity is specified in the original owners manual that comes with bike when new,both of which I still have.

[Radioguylogs]

LH Bearing - Bear is the Operative Syllable

So, I removed the bearings and seals in the rear wheel and replaced everything with new parts.

The sticky LH bearing became un-sticky when I removed it.

The new LH bearing was loose before I installed it. I used the press ideas suggested by Schming.* The new bearing became tighter when I installed it!!!! It was less tight than the previous bearing, but was surprising that every bearing gets tighter when I install it. The latest bearing has some stiff resistance to insert and removed the center race, but it still rolls OK, so I will leave it. I wonder if the wheel center hub slightly our of round or it is normal for it to require some break-in to seat.

* BTW the press work well, except it is a three handed job to get it started. The LH bearing actually went in slight bit deeper than the previous one I pounded. This method is certainly more gentle on the bearing.

[Radioguylogs]

Onward

Huge thanks to Kurt for the manuals.

I did receive the manual Mike P suggested. I have great documentation now.
__________________

Rear Wheel is back on, complete with brake:



Now, I move onto the tedious job of polishing the aluminum cases.

I chose to do the clutch cover first. It makes sense to rebuild the clutch with new frictions while I have the cover off:



It seemed virgin inside, and it looked surprisingly good for 38k miles. It really didn't need to be done, but it's peace of mind to know I shouldn't have to go in there again.

[Radioguylogs]

Next

Got the clutch back together, polished the cover and buttoned it up:



Removed the Shift Linkage Cover for polishing and scraped the gasket:



I decided to lose the aftermarket oil pressure gauge. It's cool, but it was so tired looking I decided to lose it. There is an idiot light to protect me anyway. The gauge was installed in the oil galley circled in the picture above.

I was surprised to find the part of the gauge that threaded into the engine was a banjo bolt. The dimensions are unique. I took the OE bolt off of the Bagger to compare it:



It is M10 x 1.5 x 30mm and not listed on the Yamaha parts fiche.

I looked into the galley and realized this is important. This bolt provides a passage for oil to the left-hand bearing on the Primary Shaft.

I could only find a close replacement at Belmetric:
https://www.belmetric.com/brake-flui...ik1dfp0311vh63

So ordered a couple of those to study.

Stay well,