Reviving A -99 Tdm 850

[anda3243]

<!--sizeo:4--><!--/sizeo-->Cooling system, and pre startup stuff<!--sizec--><!--/sizec-->

With the new inlets, a startup was closing in. But before the startup, the cooling system needed to be in order.

I now realized that my new engine bracket (the upper piece I welded to the frame) was in the way for the coolant hose. [img]style_emoticons/<#EMO_DIR#>/sad.gif[/img]


But no problems. I bought some house pieces from a scrapyard,


And made a piece that fits (above) instead of using the original (below). It looks quite terrible. The outlet from the thermostat housing is straight and points directly into the welded bracket. I am thinking of trying with the 3VD thermostat housing, the outlet from it is pointed slightly forward, which could reduce the number of twist.
So if someone has one to sel, I am interested.


Here is the radiator installed, and the twisty coolant hose with it. Notice the idle adjusting screw moved to its new position on the bracket.


The vacuum hoses for carb balancing are routed to this side for easy access.


Other side of the bike


Then installing of the carbs. Some wires and hoses needed to be rerouted due to the same bracket. Choke wire was a pain.
Here is a pic of the oil fill hose.


And all the tubes and stuff surrounding the carbs. Here I also discovered that coolant is circulating into the carbs and heating them :/


Then on with the air filter box.


The spark plug caps did not fit, the spark plugs are "deeper" in the valve cover than on the 850. But I could make it fit by removing the upper rubber seal. Not optimal, but now I wanted to get the beast going.

Does the 900 have ignition coils similar to the 850? I have read that one can fit spark plug caps that contain the ignition coils from Yamaha R1. Has anyone tried that? What would be the pros and cons?

Then I started to fiddle with the ignition covers. The bolt patterns are identical, the same gasket can be used on the 850 and 900 engines.
I wanted the 850 cover, because the gear lever is bolted to it, and the 850 cover gives the correct distance between the lever and footpeg. On the 900 footpeg and gear lever are further back, and therefore the hole in the generator castings is further back.
The 900 generator to the left, and 850 to the right. It is also quite easy to figure out the electrics. 3 cables from the generator winding. And 2 from the pickup coil.


One difference that I noticed, was that the 900 engine has a bigger generator, both windings and the rotor. I wanted to use the bigger generator, but the windings are mounted on different depths in the cover. The 900 winding can mot be mounted on the 850 cover, and then on the 900 engine with 900 rotor.

The winding. The bigger 900 winding on the left.


Measuring the mounting depth in the cover. The 850 cover is more "shallow" and will not allow the 900 winding to be fitted. Winding will interfere with the rotor.


In the end I used the 850 cover with the 850 windings, but with the 900 rotor. Both 850 and 900 rotors has the same number of magnetic poles, and both winding has the same number of "slots". So it should be no problems. Since I am using the 850 cover and windings the connections to the bikes harness are no problems.

Then fit the exhaust. The 850 header pipe I had did fit to the cylinders, but the bolts were too short. And it was interfering with the bottom off the engine.


I fitted new longer bolts in the cylinder head. I used stainless threaded rod that i cut in wanted lengths. One can hop that they will not rust.
Then bend the pipes so some clearance can be achieved. These pipes are really hard to bend without damaging them.
I have some clearance, but it is not looking good.


Then fill oil, fill coolant, charge battery (a new battery was fitted while the engine was out).

Click the starter, but it wont turn, not even click. Only lighting some warning light. [img]style_emoticons/<#EMO_DIR#>/ranting.gif[/img]

Next post will be about ignition and neutral light sensor. And removing the rotor.

This post was last modified: 08-01-2012, 02:34 AM by anda3243.