Reviving A -99 Tdm 850

[anda3243]

The chain cont.



The chain needed to go inward. And the frame needed some work too.

The rear sprocket spacer was removed.

The bushing behind the front sprocket needed to be shortened. But it was stuck on the shaft. It is interference fit. I did not want to heat it upp to much as the rubber seal could be damaged.

Here I am drilling a hole for the puller.



First a small drill, then a bigger one.

The outgoing shaft seems to be case hardened. Hard on the surface, but quite soft/easy to work with inside.

You can see the first failed attempt to weld the puller to the bushing.



The protective plate behind the sprocket (the one with 3 screws) will be removed later to make space for the chain.





Succes with the bushing.







Lathe again. Carefull not to damage the surface for the rubber seal.





Done

I don't remember by how much I shortened the bushing.







One of the shoulders was machined away so its flush with the side surface. The visible side on the photo goes inward against the bushing.





On the frame. The footpeg bolt were grinded down, and some grinding was done on the frame as well.











Then assemble everything again.







The gear lever mechanism and the generator cover is from the 850. It is the same spline on the gear lever shaft on the 850 and 900 motors. By using the 850 gear lever and generator cover one can get the right distance to the footpeg.

The inner sprocket cover is also from the 850, but a hole was needed for the protruding shaft and nut.

But the top sprocket cover cannot be fitted. The 850 cover does not fit because the gear lever shaft is sticking out from the motor too much. The 900 sprocket cover does not fit because the gear lever mechanism is routed as on the 850.



With these mods, rear sprocket as is, front sprocket moved inwards, the bike was ridable. There was a little interference sometimes, but it was ok.

Also the front sprocket was for a 520 chain, the chain in the bike was 525. Rear sprocket was also 525. This allows for some misalignment.

Now i have ridden several thousands of km and there are now abnormal wear.



Also with the 18 tooth front sprocket the gearing was quite high.