Reviving A -99 Tdm 850

[ChrisG]

<!--quoteo(post=216783:date=Wed 3rd Aug 2011, 05:22 PM:name=anda3243)-->QUOTE(anda3243 @ Wed 3rd Aug 2011, 05:22 PM) <{POST_SNAPBACK}><!--quotec-->One more thing. Does the tdm model have a oil pressure warning light? I can't find the light or the sensor. Why is that so? The 900 model has a oil level sensor in the oil tank, but, thats not the same thing.<!--QuoteEnd--><!--QuoteEEnd-->

No, which considering the amount of oil the 850's tend to use it's a bit silly.

Some have fitted their own though
http://www.carpe-tdm.net/ipb/index.php?showtopic=17013

[MikCoshell]

Gota sudden urge to buy some crash bungs [img]style_emoticons/<#EMO_DIR#>/sad.gif[/img]

[anda3243]

<!--quoteo(post=216836:date=Thu 4th Aug 2011, 12:17 AM:name=ChrisG)-->QUOTE(ChrisG @ Thu 4th Aug 2011, 12:17 AM) <{POST_SNAPBACK}><!--quotec-->No, which considering the amount of oil the 850's tend to use it's a bit silly.

Some have fitted their own though
http://www.carpe-tdm.net/ipb/index.php?showtopic=17013<!--QuoteEnd--><!--QuoteEEnd-->

Ok, thanks for the tip. I may build one someday.

<!--quoteo(post=216843:date=Thu 4th Aug 2011, 01:00 AM:name=MikC)-->QUOTE(MikC @ Thu 4th Aug 2011, 01:00 AM) <{POST_SNAPBACK}><!--quotec-->Gota sudden urge to buy some crash bungs [img]style_emoticons/<#EMO_DIR#>/sad.gif[/img]<!--QuoteEnd--><!--QuoteEEnd-->

I dont think that crash bungs would have helped in this case. I think he crashed in some kind of obsticle.
But I could glue the broken piece back.

[wicklamulla]

this is interesting as i tink the MKII 850 chassis is a bit more roomy than the 900's and slotting in a peachy 900 motor and running it off carbs is the way to go.

[TonyDevil]

<!--quoteo(post=217169:date=Sat 6th Aug 2011, 11:43 PM:name=wicklamulla)-->QUOTE(wicklamulla @ Sat 6th Aug 2011, 11:43 PM) <{POST_SNAPBACK}><!--quotec-->this is interesting as i tink the MKII 850 chassis is a bit more roomy than the 900's and slotting in a peachy 900 motor and running it off carbs is the way to go.<!--QuoteEnd--><!--QuoteEEnd-->Amen brother wickla [img]style_emoticons/<#EMO_DIR#>/wifgeni.gif[/img]

[anda3243]

<!--quoteo(post=217169:date=Sun 7th Aug 2011, 12:43 AM:name=wicklamulla)-->QUOTE(wicklamulla @ Sun 7th Aug 2011, 12:43 AM) <{POST_SNAPBACK}><!--quotec-->this is interesting as i tink the MKII 850 chassis is a bit more roomy than the 900's and slotting in a peachy 900 motor and running it off carbs is the way to go.<!--QuoteEnd--><!--QuoteEEnd-->

Its hard to say. I would gues they are about the same, but I did not have a 900 chasis to compare to.

[anda3243]

The work continues

I took of the damaged oil pump cover. The damage was not so big, only one small crack.


The bushing that centrates the cover was shered.


Out of interest I compered it to the cover from 850 engine.


The 5PS cover with the 4XT(?) gasket on it on left. The 4XT cover on the right. They fit between the motors.

I fixed the 5PS cover with chemical metal. I did the fix on the pustside so if the metal comes loose it will not end up inside the engine.




Next the water pump. It was to damaged to be rapaired.
The impeler was grinding against the housing.


And the housing was bent and cracked. Difficult to se the crack on the picture tho. Note the old cylinder head in the trash [img]style_emoticons/<#EMO_DIR#>/tongue.gif[/img]


A quick comparision to the 4TX engine, plausible


The 5PS water pump on the left, the 4TX on the right. The bolts that goes to the engine block are identical. One ore two of the bolts holds the water pump housing and cover together. These bolts are moved a little.
The shaft that goes in to the engine is identical. The gaskets are identical. The casting is different on the different models.
The 4TX water pump will fit on a 5PS and viceversa. Sorry for the bad pics, grease on the camera lens.


Great sucess, i wont need to buy a new water pump, rebuild the old one with gaskets from the newer one. And add some grease for the bearing inside the motor. It could take some time for oil to reach this spot on startup.


Here is the damage on the engine. The piece thet has broken of contains threads for one of the water pump bults.


Fitting the new/old water pump


The damaged part of the engine was glued with chemical metal and hold in place by the water pump. It sits on the bolt thats missing in the picture. Not optimal but i think it will hold. I do not have pictures of this, will try to take a photo and post later.

With this the damaged motor was usable.

Next post, fitting the engine in the frame.

[markallinson]

Excellent project. Keep up the good work [img]style_emoticons/<#EMO_DIR#>/wink.gif[/img]

[Studley Ramrod]

Great stuff ! Thanks for posting up the info & photos ! [img]style_emoticons/<#EMO_DIR#>/good.gif[/img]

[wicklamulla]

ohhh i'm enjoying this project !

[TDMick]

Me to [img]style_emoticons/<#EMO_DIR#>/good.gif[/img]

[anda3243]

It is nice to hear that people are enjoying this. [img]style_emoticons/<#EMO_DIR#>/smile.gif[/img] I will write more as soon i have more pictures uploaded. There will be more comparing engine parts posts.

I have a questione in the meantime. Can you help me recognise this windscreen? I am quite sure it is not the original one, it is a bit higher I think.
I find this windscreen useless. At about 80 km/h it starts to flex and vibrate, push around the helmet and vibrate the visor if its open. Very anoying. It is better about 100 km/h and again worse at 120+ km/h. I have read a little on this forum, and this seems to be a common problem.

I have been thinking about buying a MRA vario touring screen, but are unsure. Do these screens flex and vibrate at some speeds? The variable peace should add some wieght far out on the screen, which should make it more likely to vibrate.

[markallinson]

That looks like a yamaha touring screen, I've got an MRA Vario screen on my 9er. The vario screen is really good, I've tried a tall touring screen and much prefer the Vario. [img]style_emoticons/<#EMO_DIR#>/smile.gif[/img]

[wicklamulla]

It's a Givi touring screen, identical to mine.

[anda3243]

<!--quoteo(post=218110:date=Tue 16th Aug 2011, 10:54 PM:name=maximuspetrolhead)-->QUOTE(maximuspetrolhead @ Tue 16th Aug 2011, 10:54 PM) <{POST_SNAPBACK}><!--quotec-->That looks like a yamaha touring screen, I've got an MRA Vario screen on my 9er. The vario screen is really good, I've tried a tall touring screen and much prefer the Vario. [img]style_emoticons/<#EMO_DIR#>/smile.gif[/img]<!--QuoteEnd--><!--QuoteEEnd-->

Ok. How thick is the MRA Vario screen? The screen I have is quite thin about 2 to 3 mm. A thicker screen should be better

<!--quoteo(post=218114:date=Tue 16th Aug 2011, 11:48 PM:name=wicklamulla)-->QUOTE(wicklamulla @ Tue 16th Aug 2011, 11:48 PM) <{POST_SNAPBACK}><!--quotec-->It's a Givi touring screen, identical to mine.<!--QuoteEnd--><!--QuoteEEnd-->

Are you sure it's givi? It has a Yamaha logo on it.


Thanks

[markallinson]

Yeah the Vario screen is really good quality, doesn't bend about at all (not that I've ever noticed anyway).

[wicklamulla]

<!--quoteo(post=218123:date=Wed 17th Aug 2011, 09:03 AM:name=anda3243)-->QUOTE(anda3243 @ Wed 17th Aug 2011, 09:03 AM) <{POST_SNAPBACK}><!--quotec-->Ok. How thick is the MRA Vario screen? The screen I have is quite thin about 2 to 3 mm. A thicker screen should be better
Are you sure it's givi? <!--coloro:#FF0000--><!--/coloro-->It has a Yamaha logo on it.<!--colorc-->
<!--/colorc-->
Thanks<!--QuoteEnd--><!--QuoteEEnd-->


so does mine and i bought it new in Givi packaging.

[wicklamulla]

so come on then any news ferrous ??? i have logged in from Germany especially to read this FFS !!!

[dapleb]

I did wonder when you have engine mounts to fabricate, wiring, ECM and fuelling decisions to make and start worrying about the screen options. [img]style_emoticons/<#EMO_DIR#>/laugh.gif[/img]

Hope the project is still going. The 900 injun in mkI has been done before so there should be noubt stopping it from going in a mkII.

This post was last modified: 17-09-2011, 04:35 AM by dapleb.

[wicklamulla]

sling it in and run it on the MKIIa carbs i say ! be interesting to see if it'll have to run the TDM900 CDI or will he be lucky and it'll run off the MKIIa CDI ? !