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+---- Thread: Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] (/showthread.php?tid=32954)
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - Guest - 14-12-2008
Don' Panic Mr Mianewaring. Probably just stuck, patience and oily stuff will cure it. Happens to mine over Christmas every year.
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - Guest - 14-12-2008
<!--quoteo(post=105923:date=Sun 14th Dec 2008, 02:04 PM:name=celticbiker)-->QUOTE(celticbiker @ Sun 14th Dec 2008, 02:04 PM) <{POST_SNAPBACK}><!--quotec-->Don' Panic Mr Mianewaring. Probably just stuck, patience and oily stuff will cure it. Happens to mine over Christmas every year.<!--QuoteEnd--><!--QuoteEEnd-->
Mine moves freely but still doesn't go left when it's warm! And I'm MRS Mainwaring! [img]style_emoticons/<#EMO_DIR#>/tongue.gif[/img]
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - Guest - 14-12-2008
If the linkage itself is free, it could be worth checking the pin on the thermo valve thingy is free to move also. Are you getting an increase in revs when the engine is cold, or is it idling slower than your normal idle of 1200ish rpm?
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - Guest - 14-12-2008
<!--quoteo(post=105919:date=Sun 14th Dec 2008, 12:09 PM:name=Kelpie)-->QUOTE(Kelpie @ Sun 14th Dec 2008, 12:09 PM) <{POST_SNAPBACK}><!--quotec-->Had a look at the cold start thingy yesterday. It's moving freely, but it's not moving left when the bike's warm. Sounds like the wax element is fupped. Now what? [img]style_emoticons/<#EMO_DIR#>/unsure.gif[/img]<!--QuoteEnd--><!--QuoteEEnd-->
Take it off the bike and have a look at it, it's easy to dismantle, take alook at the wax cartridge and see if it looks fecked.
Bare in mind my comment that you can't buy the wax cartridge..well you can for £1200+...so I would consider checking out thoroughly first!
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - Guest - 14-12-2008
[img]style_emoticons/<#EMO_DIR#>/wifgeni.gif[/img]
What he said.
The steel pin seizes in the alloy housing.
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - baron - 15-12-2008
<!--quoteo(post=102552:date=Tue 11th Nov 2008, 09:52 AM:name=divvxj)-->QUOTE(divvxj @ Tue 11th Nov 2008, 09:52 AM) <{POST_SNAPBACK}><!--quotec-->if i can reach the plunger with a pair of curved pliars would i be able to push the plunger in and then give it a good soak with oil!!!!!<!--QuoteEnd--><!--QuoteEEnd-->
That's exactly what I did with my 04 9'er and it worked a treat.
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - Guest - 16-12-2008
<!--quoteo(post=105962:date=Sun 14th Dec 2008, 07:36 PM:name=E.T.)-->QUOTE(E.T. @ Sun 14th Dec 2008, 07:36 PM) <{POST_SNAPBACK}><!--quotec-->Take it off the bike and have a look at it, it's easy to dismantle, take alook at the wax cartridge and see if it looks fecked.
Bare in mind my comment that you can't buy the wax cartridge..well you can for £1200+...so I would consider checking out thoroughly first!<!--QuoteEnd--><!--QuoteEEnd-->
Thanks ET. I'll do that. Got a day off today to go Xmas shopping (YUKYUKYUK) so it'll be hard to resist the temptation to tear into the bike! [img]style_emoticons/<#EMO_DIR#>/rolleyes.gif[/img]
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - shaftdrive - 16-12-2008
<!--quoteo(post=106072:date=Tue 16th Dec 2008, 01:49 AM:name=Baron)-->QUOTE(Baron @ Tue 16th Dec 2008, 01:49 AM) <{POST_SNAPBACK}><!--quotec-->That's exactly what I did with my 04 9'er and it worked a treat.<!--QuoteEnd--><!--QuoteEEnd-->
this is what i did and i havent had any problems since ,where the plunger comes out and presses on the slide i have been giving that a little push and pull and a wee spray of oil now and again
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - GrahamI - 21-01-2009
Thanks to this great description from ET I managed to clean up my plunger last night (ooh err missus) so a big cheers to ET for his work [img]style_emoticons/<#EMO_DIR#>/drinks.gif[/img]
A word of warning for anyone who is using the wiggle and spray method, i had tried this and the pliers had marked the plunger a little, this made it a bit difficult to remove the plunger and clean it up - but repeated twisting and plungin in and out (stop it) sorted it - I guess if you have been using the pliers a lot and are as heavy handed as me with them then you may come in to a problem if/when you do remove the unit to clean it up
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - GrahamI - 03-02-2009
<!--quoteo(post=48556:date=Sat 28th Jul 2007, 09:02 PM:name=E.T.)-->QUOTE(E.T. @ Sat 28th Jul 2007, 09:02 PM) <{POST_SNAPBACK}><!--quotec-->One other point was I found it difficult to get the air box located onto the throttle body air intakes. In the end I split the box took out the airfilter so I could guide the rubbers over the intakes - lot easier.<!--QuoteEnd--><!--QuoteEEnd-->
I had the airbox off today and this time I put the securing screw in place (not tight) and then pushed the airbox on to the throttle bodies, it seemed to go on a lot easier than previous attempts - might be worth a try!
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - Guest - 25-04-2009
My fast idle has been stuck since I got the bike in October. I decided to tackle it the other day and thanks to this thread, I've partially sorted it.
Due to lack of time and resources, I couldn't take the whole unit off, but accessed the siezed pin through the end of the unit by removing the small pipes and undoing the screws with a very long screw driver, though the gap in the frame. I drifted out the well-and-truly-stuck pin using a bit of wood and a hammer and now my idle is down to normal (it was permanently around 1500 rpm and bloody annoying)although the pin still isn't free. It means I have to screw up the idle a wee bit for cold starting but this won't be a problem, I don't think, till the colder weather comes in.
Several bleeding knuckles later, I've left it all covered in copper grease and I've a mechanic mate coming to service both bikes next week and he's going to take a look at it to try and get a permanent solution to the problem.
Thanks for such an informative post!
Katie
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - sparra99 - 29-07-2009
Just did mine. Managed to get the screws out with a pair of vice grips, so no need to undo radiator hoses. Replaced the screws with M5 30mm allen key head screws as per instructions. Wasn't as bad a job as I expected. Thanks for the instructions guys.
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - OldGreyWizard - 13-02-2011
I spent most of this morning sorting out myFast Idle Plunger. It was well siezed. One of the plunger screws came out using the bit held in molegrips method, the other with a hammer and cold chisel. I managed to avoid having to drain down the read. I replaced the screws with M5 bolts, Halfords didn't have any suitable allen bolts and I need to use the bike tonight. Getting the Airbox back on was tricky, you need to undo the clamps to the max. The Fast Idle now working again and the bike is running better.
Thanks for all of your previous posts, potentially saved me lots of £'s. I recon a dealer would charge at least 3 hours labour for the job.
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - chris-red - 14-02-2011
Do what I do and whenever it gets stuck get a 1/2 inch extension and a rubber mallet find the plunger on the LHS of the bike and git it a few taps, always has freed it off for me.
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - SteveK374 - 29-03-2011
On the advice of kind persons I have stripped the fast idle plunger assembly off my 9'er. What a job! Not wishing to go through this again I resolved to affect a 'permanent solution' after all my 1957 BSA Bantam had lube points all over it!
The problem was indeed corrosion but as the pin is stainless steel (and clean) I can only assume the alloy of the housing is to blame.
All cleaned up and working freely I took measurements of the 'neck' of the housing (where the pin exits). I made a brass collar, from a spare pneumatic fitting, and drilled out the centre to be a push fit over the neck. This collar has a 2.5mm hole drilled through the wall to match up with a similar hole I drilled in the neck. A small bore brass tube is soldered into this collar hole forming a press fit 'banjo'.
A tube (actually the insulation from a multimeter test lead) is a push fit over the brass tube and leads out, through the frame, near the headstock. I can now lubricate the pin using a syringe containing 3in1 oil.
As you can see I also took the oportunity to replace the Crass head screws with cap heads and studs/nuts - just in case!
I'm sure Mr Henty could make a better job of the banjo but I dont have his facilities (jealous!!)
![[Image: DSCF0168.jpg]](http://i826.photobucket.com/albums/zz186/stevek374/DSCF0168.jpg)
![[Image: DSCF0171.jpg]](http://i826.photobucket.com/albums/zz186/stevek374/DSCF0171.jpg)
![[Image: DSCF0172.jpg]](http://i826.photobucket.com/albums/zz186/stevek374/DSCF0172.jpg)
![[Image: DSCF0176.jpg]](http://i826.photobucket.com/albums/zz186/stevek374/DSCF0176.jpg)
![[Image: DSCF0177.jpg]](http://i826.photobucket.com/albums/zz186/stevek374/DSCF0177.jpg)
![[Image: DSCF0180.jpg]](http://i826.photobucket.com/albums/zz186/stevek374/DSCF0180.jpg)
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - dmmsta - 29-03-2011
Gotta love the Carpe "fettles".
Genius idea.
Now, i've got to get mine off again to investigate this...only problem is the taffy screws that Yam decided to use to affix it to the engine are on their last legs so need to replace them.
Go on be a devil - what are the details of them there threads so I can source replacements...
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - SteveK374 - 29-03-2011
<!--quoteo(post=200729:date=Tue 29th Mar 2011, 02:30 PM:name=dmmsta)-->QUOTE(dmmsta @ Tue 29th Mar 2011, 02:30 PM) <{POST_SNAPBACK}><!--quotec-->Gotta love the Carpe "fettles".
Genius idea.
Now, i've got to get mine off again to investigate this...only problem is the taffy screws that Yam decided to use to affix it to the engine are on their last legs so need to replace them.
Go on be a devil - what are the details of them there threads so I can source replacements...<!--QuoteEnd--><!--QuoteEEnd-->
I knew someone would ask that question,
Both types M5
Screws to injector block 30mm thread length.
Screws to hold housing together, thread length 13mm (I've used 16mm with no problem).
Steve
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - dmmsta - 29-03-2011
<!--quoteo(post=200732:date=Tue 29th Mar 2011, 02:37 PM:name=SteveK)-->QUOTE(SteveK @ Tue 29th Mar 2011, 02:37 PM) <{POST_SNAPBACK}><!--quotec-->I knew someone would ask that question,
Both types M5
Screws to injector block 30mm thread length.
Screws to hold housing together, thread length 13mm (I've used 16mm with no problem).
Steve<!--QuoteEnd--><!--QuoteEEnd-->
Top man [img]style_emoticons/<#EMO_DIR#>/smile.gif[/img]
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - jbx - 29-03-2011
I'm sure someone will feed that device with a scottoiler !
Fast Idle Plunger Repair (TDM 900) [ie Cold Start ] - leehenty - 29-03-2011
Sizes ... The bore of the banjo that fits over the nose that's what we need to know.