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


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#61 SteveK

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Posted 29 March 2011 - 03:31 pm

QUOTE(leehenty @ Tue 29th Mar 2011, 04:26 PM) <{POST_SNAPBACK}>
Sizes ... The bore of the banjo that fits over the nose that's what we need to know.


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.

Edited by SteveK, 29 March 2011 - 03:32 pm.

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#62 aircooled68

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Posted 29 March 2011 - 04:17 pm

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



Dave

202323336-M.jpgpost-1-1152402501.jpgpost-1-1150550726.gifpost-1-1150559830.gif


#63 SteveK

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Posted 29 March 2011 - 04:19 pm

QUOTE(aircooled68 @ Tue 29th Mar 2011, 05:17 PM) <{POST_SNAPBACK}>
Is that brass bit the end of a lokring???
Dave

Close. its the plain section of an Enots fitting.
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#64 fredtucker

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Posted 29 March 2011 - 07:11 pm

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.

#65 Catteeclan

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Posted 29 March 2011 - 07:23 pm

I was thinking of putting a gaiter over the end but that looks just the job. good.gif

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#66 wicklamulla

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Posted 29 March 2011 - 09:38 pm

looks a good mod.

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#67 dablik

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Posted 29 March 2011 - 10:32 pm

QUOTE(aircooled68 @ Tue 29th Mar 2011, 05:17 PM) <{POST_SNAPBACK}>
Is that brass bit the end of a lokring???
Dave


Dave you dont know how glad i am that your reading this fella laugh.gif

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#68 Nog

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Posted 30 March 2011 - 07:37 am

QUOTE(Catteeclan @ Tue 29th Mar 2011, 08:23 PM) <{POST_SNAPBACK}>
I was thinking of putting a gaiter over the end but that looks just the job. good.gif


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 good.gif

#69 SteveK

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Posted 30 March 2011 - 07:45 am

QUOTE(fruitcake @ Wed 30th Mar 2011, 08:37 AM) <{POST_SNAPBACK}>
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 good.gif


Something like this from a model power boat supplier,
http://www.prestwich...ellows4off1.jpg

Steve

Edited by SteveK, 30 March 2011 - 07:45 am.

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#70 Chris B

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Posted 30 March 2011 - 12:20 pm

Just twat it with a mallet when it sticks, it always free mine up tongue.gif

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#71 Catteeclan

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Posted 31 March 2011 - 08:46 am

QUOTE(SteveK @ Wed 30th Mar 2011, 08:45 AM) <{POST_SNAPBACK}>
Something like this from a model power boat supplier,
http://www.prestwich...ellows4off1.jpg

Steve


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.

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#72 leehenty

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Posted 05 April 2011 - 10:58 pm

found the right bellows for this.

http://www.prestwich...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.
2002 900 silver,oil pressure switch with brass 90 degree conversion, RG fork protectors. Wilburs custom made rear Shock with remote hydraulic preload and RG shocktube, Wilburs front springs. Scotoiler with a custom made swing arm delivery unit. Silicone radiator hoses.BMW 1150 handguards with Touratech extensions, Carbon Fibre yoke cover and fender extenda, MRA flip screen, Yamaha Engine bars, SW Motech Centre Stand, Kappa wingrack three box Luggage with E21's as option from the K960 boxes, Zumo 660 satnav on Touratech mount, Led Voltage monitor, Baglux tank cover, Clear LED Rear light, Aux LED brake light, BikeVis bullet LED's under front  nose,Stainless rear axle nut, stainless chain adjusters, stainless wheel spacers front and rear, Probolt Polished Stainless Flanged Hex engine screws, Polished stainless fairing screws, stainless disc bolts. Titanium brake pins front, Probolt Titanium Flanged Hex Front Caliper Bolts & Rear caliper slide pins Adventure Spec Tool tube under rear rack, left and right sides with custom alloy mounts.<p>Top Sellerie double gel pad seat. Carbon Fibre inner dash and side infill panels. Anodised black alloy swingarm pivot bolt covers and footpegs, Nano II Gear indicator.

#73 dmmsta

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Posted 06 April 2011 - 08:28 am

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.
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#74 leehenty

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Posted 06 April 2011 - 01:33 pm

QUOTE(dmmsta @ Wed 6th Apr 2011, 09:28 AM) <{POST_SNAPBACK}>
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.


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.

Edited by leehenty, 06 April 2011 - 01:38 pm.

2002 900 silver,oil pressure switch with brass 90 degree conversion, RG fork protectors. Wilburs custom made rear Shock with remote hydraulic preload and RG shocktube, Wilburs front springs. Scotoiler with a custom made swing arm delivery unit. Silicone radiator hoses.BMW 1150 handguards with Touratech extensions, Carbon Fibre yoke cover and fender extenda, MRA flip screen, Yamaha Engine bars, SW Motech Centre Stand, Kappa wingrack three box Luggage with E21's as option from the K960 boxes, Zumo 660 satnav on Touratech mount, Led Voltage monitor, Baglux tank cover, Clear LED Rear light, Aux LED brake light, BikeVis bullet LED's under front  nose,Stainless rear axle nut, stainless chain adjusters, stainless wheel spacers front and rear, Probolt Polished Stainless Flanged Hex engine screws, Polished stainless fairing screws, stainless disc bolts. Titanium brake pins front, Probolt Titanium Flanged Hex Front Caliper Bolts & Rear caliper slide pins Adventure Spec Tool tube under rear rack, left and right sides with custom alloy mounts.<p>Top Sellerie double gel pad seat. Carbon Fibre inner dash and side infill panels. Anodised black alloy swingarm pivot bolt covers and footpegs, Nano II Gear indicator.

#75 dmmsta

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Posted 06 April 2011 - 02:41 pm

QUOTE(leehenty @ Wed 6th Apr 2011, 02:33 PM) <{POST_SNAPBACK}>
I do hold all these sizes in stock of course.


Kinda thought you probably would, but didn't want to take the michael so to speak... blush.gif

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

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

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Posted 06 April 2011 - 06:37 pm

QUOTE(leehenty @ Tue 5th Apr 2011, 11:58 PM) <{POST_SNAPBACK}>
found the right bellows for this.

http://www.prestwich...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.


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
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#77 Catteeclan

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Posted 06 April 2011 - 07:49 pm

QUOTE(leehenty @ Tue 5th Apr 2011, 11:58 PM) <{POST_SNAPBACK}>
found the right bellows for this.

http://www.prestwich...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.

clapping.gif

Good find, now ordering.

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#78 leehenty

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Posted 09 April 2011 - 06:02 pm

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.



Edited by leehenty, 09 April 2011 - 07:22 pm.

2002 900 silver,oil pressure switch with brass 90 degree conversion, RG fork protectors. Wilburs custom made rear Shock with remote hydraulic preload and RG shocktube, Wilburs front springs. Scotoiler with a custom made swing arm delivery unit. Silicone radiator hoses.BMW 1150 handguards with Touratech extensions, Carbon Fibre yoke cover and fender extenda, MRA flip screen, Yamaha Engine bars, SW Motech Centre Stand, Kappa wingrack three box Luggage with E21's as option from the K960 boxes, Zumo 660 satnav on Touratech mount, Led Voltage monitor, Baglux tank cover, Clear LED Rear light, Aux LED brake light, BikeVis bullet LED's under front  nose,Stainless rear axle nut, stainless chain adjusters, stainless wheel spacers front and rear, Probolt Polished Stainless Flanged Hex engine screws, Polished stainless fairing screws, stainless disc bolts. Titanium brake pins front, Probolt Titanium Flanged Hex Front Caliper Bolts & Rear caliper slide pins Adventure Spec Tool tube under rear rack, left and right sides with custom alloy mounts.<p>Top Sellerie double gel pad seat. Carbon Fibre inner dash and side infill panels. Anodised black alloy swingarm pivot bolt covers and footpegs, Nano II Gear indicator.

#79 TonyDevil

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Posted 09 April 2011 - 06:05 pm

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

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to fit : led spotlights, heated grips, new braided lines and rear caliper that actually has bleed nipples
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to fit : led brake light strip, replacement heated grips

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#80 dmmsta

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Posted 11 April 2011 - 06:47 am

QUOTE(TonyDevil @ Sat 9th Apr 2011, 07:05 PM) <{POST_SNAPBACK}>
anyone think this worthy of be moved to the knowledge base?


With all the problems us 9ers have with the CSM I give that idea the good.gif
MY06 TDM 900 Blue over Silver 354906_45.png
-----
Fuel Pipes
Givi Top Box
Renthal 758's
Grip Puppies
MRA Bubble
Dip & Hi HIDs

To-Do:
LED DRLs
Loobman
Powercoat Wheels
Hand Guards

-----
MY04 TDM 900 Blue over Silver Parts Bin
MY02 TDM 900 Yellow over Black RIP
post-1-1150550733.gif...post-1-1150559830.gif...copilot_zpsgezqc0xz.jpg...hids.jpg...


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