Fast Idle Plunger Repair (TDM 900) [ie Cold Start ]

[SteveK374]

<!--quoteo(post=200742:date=Tue 29th Mar 2011, 04:26 PM:name=leehenty)-->QUOTE(leehenty @ Tue 29th Mar 2011, 04:26 PM) <{POST_SNAPBACK}><!--quotec-->Sizes ... The bore of the banjo that fits over the nose that's what we need to know.<!--QuoteEnd--><!--QuoteEEnd-->

With the casting lines carefully removed from the housing neck, 9mm bore, 6mm long. wall thickness ~ 2mm. I have 4 more of the small bore brass tubes in stock if required.

Steve

Edit, Care must be taken when orienting the banjo so as not to foul the throttle cables.

[aircooled68]

Is that brass bit the end of a lokring???



Dave

[SteveK374]

<!--quoteo(post=200748:date=Tue 29th Mar 2011, 05:17 PM:name=aircooled68)-->QUOTE(aircooled68 @ Tue 29th Mar 2011, 05:17 PM) <{POST_SNAPBACK}><!--quotec-->Is that brass bit the end of a lokring???
Dave<!--QuoteEnd--><!--QuoteEEnd-->
Close. its the plain section of an Enots fitting.

[fredtucker]

I don't understand why Yamaha made such a crude mechanism for mixture control. Surely as this is a fuel injected engine with various electronic sensors sending signals to the management computer, than a sensor controlled enrichment system for cold running/fast idle would be more reliable. I'm sure BMW have been using them for some time.

[Catteeclan]

I was thinking of putting a gaiter over the end but that looks just the job. [img]style_emoticons/<#EMO_DIR#>/good.gif[/img]

[wicklamulla]

looks a good mod.

[dablik]

<!--quoteo(post=200748:date=Tue 29th Mar 2011, 05:17 PM:name=aircooled68)-->QUOTE(aircooled68 @ Tue 29th Mar 2011, 05:17 PM) <{POST_SNAPBACK}><!--quotec-->Is that brass bit the end of a lokring???
Dave<!--QuoteEnd--><!--QuoteEEnd-->

Dave you dont know how glad i am that your reading this fella [img]style_emoticons/<#EMO_DIR#>/laugh.gif[/img]

[fruitcake]

<!--quoteo(post=200765:date=Tue 29th Mar 2011, 08:23 PM:name=Catteeclan)-->QUOTE(Catteeclan @ Tue 29th Mar 2011, 08:23 PM) <{POST_SNAPBACK}><!--quotec-->I was thinking of putting a gaiter over the end but that looks just the job. [img]style_emoticons/<#EMO_DIR#>/good.gif[/img]<!--QuoteEnd--><!--QuoteEEnd-->

I was thinking exactly the same, the lube tube is a brilliant idea, but with the addition of a gaiter as well would stop the gunk getting in in the first place [img]style_emoticons/<#EMO_DIR#>/good.gif[/img]

[SteveK374]

<!--quoteo(post=200802:date=Wed 30th Mar 2011, 08:37 AM:name=fruitcake)-->QUOTE(fruitcake @ Wed 30th Mar 2011, 08:37 AM) <{POST_SNAPBACK}><!--quotec-->I was thinking exactly the same, the lube tube is a brilliant idea, but with the addition of a gaiter as well would stop the gunk getting in in the first place [img]style_emoticons/<#EMO_DIR#>/good.gif[/img]<!--QuoteEnd--><!--QuoteEEnd-->

Something like this from a model power boat supplier,
http://www.prestwich.ndirect.co.uk/bellows4off1.jpg

Steve

[chris-red]

Just twat it with a mallet when it sticks, it always free mine up [img]style_emoticons/<#EMO_DIR#>/tongue.gif[/img]

[Catteeclan]

<!--quoteo(post=200804:date=Wed 30th Mar 2011, 08:45 AM:name=SteveK)-->QUOTE(SteveK @ Wed 30th Mar 2011, 08:45 AM) <{POST_SNAPBACK}><!--quotec-->Something like this from a model power boat supplier,
http://www.prestwich.ndirect.co.uk/bellows4off1.jpg

Steve<!--QuoteEnd--><!--QuoteEEnd-->

Could well do the job although there'll be some stretching on the body end. No a prob if it's good rubber.
I was looking at one off a car hand brake cable but it's pretty much the same as your pictured.

[leehenty]

found the right bellows for this.

http://www.prestwich.ndirect.co.uk/hdwraccs.htm

The bit we want is GA19, has 9mm wide mouth to go over the housing.

I have two of these so when I've done the job I'll post pics.

[dmmsta]

Mr Henty, would these do the trick based on SteveK's info on the bolts?

I've not real idea about threads, and pitch, and all that...

M5 x 16

M5 x 30

I'd quite happily make the purchase, and then send spares out to those that need them too...my way of giving back to Carpe.

[leehenty]

<!--quoteo(post=201798:date=Wed 6th Apr 2011, 09:28 AM:name=dmmsta)-->QUOTE(dmmsta @ Wed 6th Apr 2011, 09:28 AM) <{POST_SNAPBACK}><!--quotec-->Mr Henty, would these do the trick based on SteveK's info on the bolts?

I've not real idea about threads, and pitch, and all that...

M5 x 16

M5 x 30

I'd quite happily make the purchase, and then send spares out to those that need them too...my way of giving back to Carpe.<!--QuoteEnd--><!--QuoteEEnd-->

Er yes they would do the trick no problem. Can I advise using M5 stainless spring washers under the heads to stop them coming loose, this is a vibration area after all.

I do hold all these sizes in stock of course.

This post was last modified: 06-04-2011, 01:38 PM by leehenty.

[dmmsta]

<!--quoteo(post=201838:date=Wed 6th Apr 2011, 02:33 PM:name=leehenty)-->QUOTE(leehenty @ Wed 6th Apr 2011, 02:33 PM) <{POST_SNAPBACK}><!--quotec-->I do hold all these sizes in stock of course.<!--QuoteEnd--><!--QuoteEEnd-->

Kinda thought you probably would, but didn't want to take the michael so to speak... [img]style_emoticons/<#EMO_DIR#>/blush.gif[/img]

Could I possibly request a set (2 of each type I believe)...

Let me know cost & I'll PP you the money.

[SteveK374]

<!--quoteo(post=201774:date=Tue 5th Apr 2011, 11:58 PM:name=leehenty)-->QUOTE(leehenty @ Tue 5th Apr 2011, 11:58 PM) <{POST_SNAPBACK}><!--quotec-->found the right bellows for this.

http://www.prestwich.ndirect.co.uk/hdwraccs.htm

The bit we want is GA19, has 9mm wide mouth to go over the housing.

I have two of these so when I've done the job I'll post pics.<!--QuoteEnd--><!--QuoteEEnd-->

Just a thought, do you know that the compressed length of the bellows is sufficient for the amount of travel of the plunger. Would'nt want the bellows restricting full movement. This is something I did not measure so no idea of the range.

Steve K

[Catteeclan]

<!--quoteo(post=201774:date=Tue 5th Apr 2011, 11:58 PM:name=leehenty)-->QUOTE(leehenty @ Tue 5th Apr 2011, 11:58 PM) <{POST_SNAPBACK}><!--quotec-->found the right bellows for this.

http://www.prestwich.ndirect.co.uk/hdwraccs.htm

The bit we want is GA19, has 9mm wide mouth to go over the housing.

I have two of these so when I've done the job I'll post pics.<!--QuoteEnd--><!--QuoteEEnd-->
[img]style_emoticons/<#EMO_DIR#>/clapping.gif[/img]

Good find, now ordering.

[leehenty]

Done mine today, tried both bellows, GA18 and GA19, GA18 with the narrow neck snipped off at the fourth bump is just right. The advantage is that GA18 comes in fours. Stainless allen screws and spring washers to put back. Used aCf50 to lubricate.

Cut off FORTH bump near NARROW end, not the other end or you will ruin the job works a treat.

This post was last modified: 09-04-2011, 07:22 PM by leehenty.

[TonyDevil]

anyone think this worthy of be moved to the knowledge base?

[dmmsta]

<!--quoteo(post=202238:date=Sat 9th Apr 2011, 07:05 PM:name=TonyDevil)-->QUOTE(TonyDevil @ Sat 9th Apr 2011, 07:05 PM) <{POST_SNAPBACK}><!--quotec-->anyone think this worthy of be moved to the knowledge base?<!--QuoteEnd--><!--QuoteEEnd-->

With all the problems us 9ers have with the CSM I give that idea the [img]style_emoticons/<#EMO_DIR#>/good.gif[/img]