Hi all, after a bit of lateral thinking, banging my head on the wall and milling bits of alloy to develop the 900 conversion, I have now made one in brass 18mm hex which uses the Intermotor 50770 5.8 -10.2 psi normally closed Citroen sensor. The solution came to me after looking at another bike in bits and measuring. The Citroen sensor must be turned down to 10.2 mm dia, 12mm long and threaded 10mm x1, or whatever 10mm thread you put in the adapter. It does however need a fine thread.
![[Image: IMG_0567.jpg]](http://i923.photobucket.com/albums/ad73/leehenty/TDM%20900%20Oil%20Pressure%20Switch%20Modification/IMG_0567.jpg)
You will have to make a custom spaced banjo bolt. This will be in stainless so carbide tips and lubricant is a must or go very slowly with HSS tools.
Start with A4 (316) Stainless 35mm M10 x 1.25 Allen bolt, drill 1.4mm holes at 6.0mm and 17.0mm from head into centre drilled 4mm bore up shaft of bolt. 4mm wide grooves centered over side holes down to 9.15mm dia to provide flow to banjo. ( Drawing to follow) ( The ideal bolt for this but somewhat expensive, is a 40mm cap screw threaded 20mm. I have only found them here:
www.a2stainless.co.uk/M10-x-1-25-x-40mm-Socket-Capscrew-A2_AEDT.aspx select part threaded 20mm.)
Turn down top of head to 7mm high. Size length of shaft from head shoulder to 32.1mm, don't forget to chamfer thread and countersink bore slightly.
CLEAN this very carefully, make sure no swarf remains. Install with a cut down end of 8mm allen key and 8mm spanner.
This is the full photo guide here:
http://s923.photobucket.com/albums/ad73/le...20Modification/
You will have to use the top circuit in the pdf below to make a normally open sensor work as it should.
The best switch for this is Intermotor 50770, normally closed where the switch earth's the light. I have tried other sensors, but this is the best I have found. If you use a normally open sensor the circuits are provided below.
You will have to make a custom spaced banjo bolt. This will be in stainless so carbide tips and lubricant is a must or go very slowly with HSS tools.
Start with A4 (316) Stainless 35mm M10 x 1.25 Allen bolt, drill 1.4mm holes at 6.0mm and 17.0mm from head into centre drilled 4mm bore up shaft of bolt. 4mm wide grooves centered over side holes down to 9.15mm dia to provide flow to banjo. ( Drawing to follow) ( The ideal bolt for this but somewhat expensive, is a 40mm cap screw threaded 20mm. I have only found them here:
www.a2stainless.co.uk/M10-x-1-25-x-40mm-Socket-Capscrew-A2_AEDT.aspx select part threaded 20mm.)
Turn down top of head to 7mm high. Size length of shaft from head shoulder to 32.1mm, don't forget to chamfer thread and countersink bore slightly.
CLEAN this very carefully, make sure no swarf remains. Install with a cut down end of 8mm allen key and 8mm spanner.
This is the full photo guide here:
http://s923.photobucket.com/albums/ad73/le...20Modification/
You will have to use the top circuit in the pdf below to make a normally open sensor work as it should.
The best switch for this is Intermotor 50770, normally closed where the switch earth's the light. I have tried other sensors, but this is the best I have found. If you use a normally open sensor the circuits are provided below.