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

[leehenty]

if you snap a head off it will be injection bodies off time, and some very careful fettling.

[muddy]

I've got this exact problem, to which my local Yam dealer reckons is 2.5 hours work. Which to be fair, it is, but at £60 per hour, it's £150 I don't have.

two and a half hours for them, a whole bloody day for nitwits like me. This is the second time I've had to do this and this time I had a full tank and no container to syphon out petrol into. Bloody murder.

[dapleb]

Yeah but oi bet it was done with some love and care though muddster?

[muddy]

Yeah but oi bet it was done with some love and care though muddster?

No, afraid not Daps. I'm more from the Basil Fawlty tradition when things stop working.

[dapleb]

[jonathanD]

Did this job today as mine was stuck in engine cold position and running too fast. What a b$÷#&*do job. Screws holding it onto throttle body ground of in a second so had to loosen throttle body, drill heads and use stud extractor. Got it off and screws holding two pieces together were rusted on and no amount of penetrative oil would loosen, so drilled the heads off and removed. Luckily I got the bolt sizes off an earlier thread and had replacement ones ready. Went back together like a dream and now have bike running properly cold and warmed up. Tied it in with changing coolant and spark plugs so all up took a while.

[Limbo]

I did the job in 2 hours.


My tank was full, and I dumped him into a large canister with a hose.

The tank I lößte and laid him without the hoses to separate on a blanket in the place of the seat.

The air filter I built from.

The cooling water I did not remove.

The two screws I remove first with hammer and chisel. To form a shock to a notch on the edge and a 2 strokes to create the first rotation.

Unscrewing the screws I could with only a bit, I turned with a modified wrench.

The element was only at the water hoses hanging.

I cleaned and oiled the piston the unscrewed  element.

Then mount a bellows of Mr. Henry.

Then I began to assemble with new screws.

 

Limbo

[dablik]

Oh well job done eh jonathon..mole grips got mine off  lucky me..

[jonathanD]

I was pissed off. I think the bike hates me

[dapleb]

At least ya went to da bodder of puttin Henty bellows on so you wouldn't have to repeat a procedure that wee wee'd you oft................you did do the Henty bellows.....didnt you?

This post was last modified: 27-11-2013, 07:17 PM by dapleb.

[jonathanD]

What are henty Bellows?

[dapleb]

Doh....they is in this ear thread.  Such as post #78 #88

[jonathanD]

No Henty bellows. Maybe next time. Fitted Allen cap heads so can get unit off easily next time. Hoping next time won't be for a while...

[m0rt]

Fast idle when warm

slow idle when warm

fast tickover when warm

slow tickover when cold

difficulty starting when cold

Cold start mechanism

CSM

injection choke

tdm900 choke

enrichment plunger (snort)

cold starting difficulty

high revving

high tickover

low tickover when cold

the more yamaha have overthought the plumbing the more that goes wrong

when rubber makes sense

 

 

If you have searched for any of these terms and you find this post then this is the thread you are looking for - if your tdm 900 either:


Ticks over very low when cold, yet is normal when warm OR ticks over normally when cold and ticks over very fast when warm OR could be that the tickover is never quite right hot or cold then go pack to first post and note that the later posts include some excellent mods that are well worth knowing about before you perform post 1 and don't know what leehentys rubber boot is all about.

[Rallyist]

Mine has the bellows fitted however the slide mechanism on the throttle bodies got stuck, my own fault obviously never lubed it properly, all ok now.

[Robk321]

Did this job over the weekend, went quite well undid the screws with mole grips and freed and greased everything.

Trouble is I have the problem where the slide bar does not return. It does move easy enough with my fingers but I think it may be the spring is corroded and not effective. Anyone got a link or part numcer for a replacement spring?

Dissapointed as it took me ages and still doesnt work properly. Cant see me stripping down the slide mech as well so will just have to live with it but would like to try a new return spring.

Love this bike, but it does have some serious design faults. Greased the rear rocker last time and that is an unbelievable piece of shite engineering!

[Studley Ramrod]

Did you check out JBX's page on the CSM ?

 

https://www.tdm-yamaha.heliohost.org/?page=CS1

 

If you can get the spring out a replacement should be easy to come by ?

[Robk321]

Hi yes, it all went really well the pin is now free but the slide mech doesnt return to the cold position which is a bugger.

Think I have found a site to get the spring for the slide 👍

[Nig]

Would you believe it - a couple of weeks ago when it was still warm my bike was revving ridiculously high to the point of fan cut in by the time i got to work - it is one of the only times i have ever heard the fan come on. I thought the fan was cabbaged actually. but was perplexed with the high tick over. 

 

It was fine since - until last night.

 

Came out of work at 02:00hrs and it had been raining and was reasonably nippy. Bike started but no idle up - just bog standard low rev tick over, it was a bit of a job to get it up to temperature without stalling it.  

 

I would venture that i have a similar concern with "plunger stickage" 

 

If you go down the tappy tap route on the side of the plunger assembly, how hard to do need to batter it?

[dablik]

Not hard at all, increments of hard    should move fairly easy.