gaj1917

Right. Keep all the components pictured from your original transmission. Shims #20 and #9 are unique to each transmission and ensure a proper "fit" of those helical cut gears. Speaking of shim #9 - there is usually more than one. When reassembling the cases, be careful, it's easy to damage these shims.

Good news. Make sure you retain all your original middle gear components, otherwise you'll get into gear lash/shimming issues.

For my money, I'd just buy a new 2nd gear wheel for about $100 or so. It's a thicker more robust version than the original. It's all you need, aside from thrust washers. A '86+ trannie will have that upgraded wheel but will likely cost more than $100.

I undertook 2nd gear repair on my '84 a couple of winters ago. (see link below for details.) It's a ton of work, with many challenges, but very educational and rewarding in the end. I didn't keep track of the hours I logged, but there were a LOT. I think the biggest job is just getting the engine out and back in again. The rest of the work is pretty straightforward. Aside from fixing 2nd gear, with the engine out it's a great opportunity to give everything a once over and repair as necessary. I installed a new clutch slave cylinder and 4-brush starter, for example. http://www.venturerider.org/forum/showthread.php?120493-Second-gear-repair-redux&highlight=redux

Yes, when repairing failed 2nd gear on my '84 I bought a used '89 transmission on eBay and installed most of its parts in my bike. One must be cautious doing that though. You must retain your original middle gear components, otherwise, you'll run into gear lash issues unless you're prepared to reshim things, and that ain't for the faint of heart - trust me.

Boy, I'd be inclined to replace the 2nd gear wheel while you have the trannie exposed. You'll never have a better chance. A new 2nd wheel (upgraded wider) can be had for around $100. The wheel, along with the thrust washers, caused the infamous 2nd gear failure in these early Ventures.

Re valves - here's a link to a source that helped me do the valves on my '84. http://www.venturers.org/Tech_Library/index.php?action=article&cat_id=001008&id=412

I don't think you can remove it without having either the entire engine out or the rear swing arm removed. That's the only times I've had it removed.

Yes, a challenge to get these bikes up on the center stand. Assuming your center stand is functioning correctly, here's what works for me. Your right leg muscles should do all the lifting, not your arm muscles. With left hand on the left handlebar, right hand grabbibg the rear crash bar, and with right arm completely straight and stiff, push center stand down hard using right leg thigh muscles while moving bike slightly rearward. It should pop right up on the stand. I'm 6'3" with long legs, so I may have some mechanical advantage that shorter folks may lack?

You'll find new windshields on eBay for $100 or so. Just search for "xvz1200 windshield". You might also try a plastic cleaning kit on your existing windshield. I've used the Novus kit with great success. You'll also find Novus on eBay, and likely at local auto supply stores. Search for "Novus Plastic Cleaning".

There are a number of Yamaha parts suppliers online. I use PartShark most often. I see they have new clutch slave cylinders for $81. Also, rear bake master rebuild kits.

An ATV lift will work but never instilled a lot of confidence in me. There are a ton of "proper" motorcycle lifts available - just do a Google search. I bought a Kendon one (https://www.kendonusa.com/stand-up-motorcycle-lifts/). Works great for me.

Yes, get a 4-brush starter. Installed one on my '84 and the difference is huge, even without a cable upgrade. Lots of used 4-brush starters on eBay. One from any '91 to '13 Venture or VMax will be 4-brush and will fit a 1st gen.

I also picked a used 4-brush starter on eBay for around $100 - can't recall the exact amount. One of the best things I've ever done for my '84. Just barely have to look at the start button and the engine rolls over! I exaggerate of course, but it does make a huge difference. Venture or Vmax starters from '91 to '13 are four brush.

When 2nd gear went south on my '84 there were no early warning signs that I recall. It just started to "slip" under load - getting progressively worse. Mine happened around 80k kilometres (50k miles).

A link to my adventures with plastic repair - http://www.venturerider.org/forum/showthread.php?126681-Plastic-repair&highlight=plastic+repair

I installed a RAM mount to hold my iPhone. Holds the phone very securely on the roughest of roads. The downside is that it's hard to see except in the darkest of days, and vibration doesn't help. Fortunately, I'm able to connect to the iPhone via my wireless headset, so more often than not I just toss the phone in the dash compartment and go by sound.

It's been a while since I dug into the clutch on my '84, but just looked at a parts diagram and I can see that there is a "thrust washer" that sets between the boss and the basket.

All of the above, and at the risk of totally discouraging you about these old bikes. The 83 and 84 years also had a problem with stator overheating and failure. This happened to me when living in Southern California some years ago - can get mighty hot inland. Yamaha later provided a simple stator cooling kit. You may want to determine if your bike has one. If not, they're pretty easy to install, if you can get one. Failing that, stay out of the desert, and avoid tooling slowly around city streets, and thus running hot. Good luck with the freeways around LA!

I have these installed on my '84. You have the correct part number (11-1112). I'm not sure why FortNine would indicate that these won't fit your '83. Give them a call and inquire.

I had this happen once on my '84. Was simply a stuck starter switch at the handlebar.

As above, but once you get the cover off, here’s a trick I found somewhere, perhaps on this site, for easing it back on. Getting the cover back on is tricky given the interference the magnet causes. Here’s something that will help. Locate three or four old cover bolts (or buy some) that are about 3” long. Cut the heads off. When ready to reinstall the cover, screw in the 3 or 4 bolts by hand, widely spaced. They will very nicely guide the cover on over the magnet. Also, I don’t use gasket cement anymore, but rather just grease on the gasket. Makes getting covers off subsequently much easier.

Roger that. Not sure where my head was on that one!

Re tach - I'm on my 3rd tach assembly on my '84! Prone to failure and really hard to get lube into. If your '89 is same as my '84, it's strictly a mechanical assembly driven by a cable from the front wheel. Before disassembly of the tach, I guess I'd check the cable to see if it's broken. If that's okay, then something amiss in the tach assembly. You could try lubing it. If that fails you can generally pick up replacement units on eBay. Re misfire - have you checked valve clearances lately?

I wasn't looking forward to removing and opening up the rear master cylinder, so decided to let the bike set for a week and then try bleeding the brake lines again. This time I got serious and used my MityVac to suck out brake fluid. I managed to get a good gulp of air at the left front anti-dive unit, and just a bit at the front and rear calipers. I don't know where that air was hiding, but I have brakes now.