Make sure you have a real good clean in the grooves where the seals sit and you won't go wrong.
Good luck with the bleeding.
Day Of Fettling
Started by
Moose
, Oct 17 2009 03:50 pm
188 replies to this topic
#162
Kaustic
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- Member
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- 204 posts
Carpe groupie
- Location:Cambridge, Cambridgeshire
- TDM model: 1999
Posted 13 November 2009 - 07:01 pm
Thanks for the advice
Three of the pistons on one caliper need replacing so i'll go for all four just to be sure. Cleanimg the grooves out is a bit awkward, so I'm going to try using my electric toothbrush.
It also looks as if the screws holding the brake reservoir lid are seized in plase, not surprising really cosidering there location. Given them a bit of the WD 40 and I'll have another look later. Ill also see if my old man has an impact driver but I'm warey of using one on an aluminium casting.
Does it sound feasable to tap a thread into the hole in the renthal handlebars to take the old bar ends ? The whole cost of this is really starting to add up & I don't want to splash out on anything more unless I really have to.
K
TDM Mk2a
Mods (so far) : Heavy duty chain & sprockets, Braided metal hose (front), DL650 handguards, Hyperpro progressive fork springs, Ohlins rear shock & Oxford Heated grips
Wish list : Home made panniers & frames, LED side light, crash bar, centre stand, oversize foot for sidestand.
Mods (so far) : Heavy duty chain & sprockets, Braided metal hose (front), DL650 handguards, Hyperpro progressive fork springs, Ohlins rear shock & Oxford Heated grips
Wish list : Home made panniers & frames, LED side light, crash bar, centre stand, oversize foot for sidestand.
#163
Moose
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- Supporting Member(thanks)
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- 3,312 posts
Master Cake Baker
- Location:Hartford, Huntingdon, Cambs
- TDM model: no more
Posted 13 November 2009 - 07:35 pm
QUOTE(Kaustic @ Fri 13th Nov 2009, 07:01 PM) <{POST_SNAPBACK}>
Thanks for the advice
Three of the pistons on one caliper need replacing so i'll go for all four just to be sure. Cleanimg the grooves out is a bit awkward, so I'm going to try using my electric toothbrush.
It also looks as if the screws holding the brake reservoir lid are seized in plase, not surprising really cosidering there location. Given them a bit of the WD 40 and I'll have another look later. Ill also see if my old man has an impact driver but I'm warey of using one on an aluminium casting.
Does it sound feasable to tap a thread into the hole in the renthal handlebars to take the old bar ends ? The whole cost of this is really starting to add up & I don't want to splash out on anything more unless I really have to.
K
Three of the pistons on one caliper need replacing so i'll go for all four just to be sure. Cleanimg the grooves out is a bit awkward, so I'm going to try using my electric toothbrush.
It also looks as if the screws holding the brake reservoir lid are seized in plase, not surprising really cosidering there location. Given them a bit of the WD 40 and I'll have another look later. Ill also see if my old man has an impact driver but I'm warey of using one on an aluminium casting.
Does it sound feasable to tap a thread into the hole in the renthal handlebars to take the old bar ends ? The whole cost of this is really starting to add up & I don't want to splash out on anything more unless I really have to.
K
I had that problem with mine a while ago fella, tried everything even cutting a new slot with a dremmel, then i got my Blue Spots and changer the M/C so never did get the little fooker out
I'm such a great help aint i
I'll eat some cake
Moose
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------
Carpe-TDM.net - A place where everyone can have their cake and eat it!!!!!
TDM900/A 2007 Black, DL650 XTZ1200 Super Ten Handguards, Oxford Heated Grips, Double Bubble Screen, Fenda Extenda, Pipe Werx Oval Black SL Zorsts, R+G Crash Bungs, Mirror Extenders, Wilbers Rear Shock with Remote Hydraulic Preload, Wilbers Progressive Fork Springs, Scottoiler Touring Kit, Clear LED Rear Light Unit, Clear Indicators, PUIG Bellypan, V46 + 2 x E41 Keyless Luggage, Black Renthal 755 Medium Road Bars with Brace, 3 x 12v Accessory Socket, Beowolf Rad Guard.
TDM has moved on, i now own a Black 2009 Honda VFR 800 VTEC
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Without cake, we are merely just people who ride bikes
#164
JollyGiant
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Crap Citizen
- Location:Jolly Giants World.
- TDM model: no more
Posted 13 November 2009 - 09:31 pm
QUOTE(Kaustic @ Fri 13th Nov 2009, 07:01 PM) <{POST_SNAPBACK}>
Thanks for the advice
Three of the pistons on one caliper need replacing so i'll go for all four just to be sure. Cleanimg the grooves out is a bit awkward, so I'm going to try using my electric toothbrush.
It also looks as if the screws holding the brake reservoir lid are seized in plase, not surprising really cosidering there location. Given them a bit of the WD 40 and I'll have another look later. Ill also see if my old man has an impact driver but I'm warey of using one on an aluminium casting.
Does it sound feasable to tap a thread into the hole in the renthal handlebars to take the old bar ends ? The whole cost of this is really starting to add up & I don't want to splash out on anything more unless I really have to.
K
Three of the pistons on one caliper need replacing so i'll go for all four just to be sure. Cleanimg the grooves out is a bit awkward, so I'm going to try using my electric toothbrush.
It also looks as if the screws holding the brake reservoir lid are seized in plase, not surprising really cosidering there location. Given them a bit of the WD 40 and I'll have another look later. Ill also see if my old man has an impact driver but I'm warey of using one on an aluminium casting.
Does it sound feasable to tap a thread into the hole in the renthal handlebars to take the old bar ends ? The whole cost of this is really starting to add up & I don't want to splash out on anything more unless I really have to.
K
When trying to undo the screw in the M/C cap try putting a screw driver onto screw and tapping quite hard down but not turn! If you do use the impact driver just small taps and turn and push down too but not too hard
And no you can't tap the Renthal out but just buy the Renthal bar ends. They do look nice and finish them off
My Super Modded TDM has gone to a new home 
I'm now a carbon whore!
#165
muddy
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- Supporting Member(thanks)
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full o shoite
- Location:North West
- TDM model: no more
Posted 13 November 2009 - 10:34 pm
QUOTE(Kaustic @ Wed 11th Nov 2009, 09:26 PM) <{POST_SNAPBACK}>
Well I pulled the pads and the pistons looked a bit of a state, so I've gone for an overhaul.
Eeeeeek. The thought of overhauling my brakes gives me shudders. It's a mole hill that i always seem to make into a mountain.
Blue 04 TDM,PR2 rear Roadsmart front, Yamaha topox, Givi E360 panniers, PL pannier holders, BMW handguards, Yamaha touring screen, Scottoiler, 12v ciggie socket, carbon core HT leads
Gorn 
#166
Guest_Catteeclan_*
Guest_Catteeclan_*
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- Guests
Posted 14 November 2009 - 11:12 am
QUOTE(Kaustic @ Fri 13th Nov 2009, 07:01 PM) <{POST_SNAPBACK}>
Cleanimg the grooves out is a bit awkward, so I'm going to try using my electric toothbrush.
The crap that builds up behing the seals is quite hard, I normally use a "L" shaped bit of wire and a small screwdriver to scratch it out.
#167
Kaustic
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- Member
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- 204 posts
Carpe groupie
- Location:Cambridge, Cambridgeshire
- TDM model: 1999
Posted 16 November 2009 - 04:37 pm
How clean does it have to be ?
I've been using Scotchbright polishing sheet (fine) borrowed from work. I can get it back to shiny again but it the devil's own job to get it all the way around due to being so fiddly. I have concentrated on the main seal groove rather than the grove for the dust seal . I reckon that I have now achieved a clean surface to at least 3/4 of the width all the way round for all the main seals. Is this enough or does it have to be completley spotless in the grooves
As to the M/C cover :
I couldn't get an impact driver off my father so might have to invest in one. I tried an old T handle driver I have had for years and the bit broke
It must have been real cheep crap.
Other than that I now have all the parts that I need (except bar ends but that can wait) that I need to start putting it all bake together again. I should be left with four sets of seals surplus to requirements as the new pistons came with seals.
(Also managed to pick up some ACF50 at the weekend, first time I have seen it for ssale other than by net)
K
I've been using Scotchbright polishing sheet (fine) borrowed from work. I can get it back to shiny again but it the devil's own job to get it all the way around due to being so fiddly. I have concentrated on the main seal groove rather than the grove for the dust seal . I reckon that I have now achieved a clean surface to at least 3/4 of the width all the way round for all the main seals. Is this enough or does it have to be completley spotless in the grooves
As to the M/C cover :
I couldn't get an impact driver off my father so might have to invest in one. I tried an old T handle driver I have had for years and the bit broke
It must have been real cheep crap.Other than that I now have all the parts that I need (except bar ends but that can wait) that I need to start putting it all bake together again. I should be left with four sets of seals surplus to requirements as the new pistons came with seals.
(Also managed to pick up some ACF50 at the weekend, first time I have seen it for ssale other than by net)
K
TDM Mk2a
Mods (so far) : Heavy duty chain & sprockets, Braided metal hose (front), DL650 handguards, Hyperpro progressive fork springs, Ohlins rear shock & Oxford Heated grips
Wish list : Home made panniers & frames, LED side light, crash bar, centre stand, oversize foot for sidestand.
Mods (so far) : Heavy duty chain & sprockets, Braided metal hose (front), DL650 handguards, Hyperpro progressive fork springs, Ohlins rear shock & Oxford Heated grips
Wish list : Home made panniers & frames, LED side light, crash bar, centre stand, oversize foot for sidestand.
#168
Moose
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- Supporting Member(thanks)
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- 3,312 posts
Master Cake Baker
- Location:Hartford, Huntingdon, Cambs
- TDM model: no more
Posted 16 November 2009 - 04:46 pm
QUOTE(Kaustic @ Mon 16th Nov 2009, 04:37 PM) <{POST_SNAPBACK}>
How clean does it have to be ?
I've been using Scotchbright polishing sheet (fine) borrowed from work. I can get it back to shiny again but it the devil's own job to get it all the way around due to being so fiddly. I have concentrated on the main seal groove rather than the grove for the dust seal . I reckon that I have now achieved a clean surface to at least 3/4 of the width all the way round for all the main seals. Is this enough or does it have to be completley spotless in the grooves
As to the M/C cover :
I couldn't get an impact driver off my father so might have to invest in one. I tried an old T handle driver I have had for years and the bit broke It must have been real cheep crap.
Other than that I now have all the parts that I need (except bar ends but that can wait) that I need to start putting it all bake together again. I should be left with four sets of seals surplus to requirements as the new pistons came with seals.
(Also managed to pick up some ACF50 at the weekend, first time I have seen it for ssale other than by net)
K
I've been using Scotchbright polishing sheet (fine) borrowed from work. I can get it back to shiny again but it the devil's own job to get it all the way around due to being so fiddly. I have concentrated on the main seal groove rather than the grove for the dust seal . I reckon that I have now achieved a clean surface to at least 3/4 of the width all the way round for all the main seals. Is this enough or does it have to be completley spotless in the grooves
As to the M/C cover :
I couldn't get an impact driver off my father so might have to invest in one. I tried an old T handle driver I have had for years and the bit broke
It must have been real cheep crap.Other than that I now have all the parts that I need (except bar ends but that can wait) that I need to start putting it all bake together again. I should be left with four sets of seals surplus to requirements as the new pistons came with seals.
(Also managed to pick up some ACF50 at the weekend, first time I have seen it for ssale other than by net)
K
You just cant stop thinking about it can ya
Moose
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------
Carpe-TDM.net - A place where everyone can have their cake and eat it!!!!!
TDM900/A 2007 Black, DL650 XTZ1200 Super Ten Handguards, Oxford Heated Grips, Double Bubble Screen, Fenda Extenda, Pipe Werx Oval Black SL Zorsts, R+G Crash Bungs, Mirror Extenders, Wilbers Rear Shock with Remote Hydraulic Preload, Wilbers Progressive Fork Springs, Scottoiler Touring Kit, Clear LED Rear Light Unit, Clear Indicators, PUIG Bellypan, V46 + 2 x E41 Keyless Luggage, Black Renthal 755 Medium Road Bars with Brace, 3 x 12v Accessory Socket, Beowolf Rad Guard.
TDM has moved on, i now own a Black 2009 Honda VFR 800 VTEC
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------
Without cake, we are merely just people who ride bikes
#169
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Posted 16 November 2009 - 09:15 pm
Any crap left there will hold the seal out and push on the piston causing it to stick so the cleaner the better. You're never gonna get it sterile though.
#170
DazzerB
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Knight of Postsalot
- Location:Bristol
- TDM model: 2005
Posted 16 November 2009 - 09:46 pm
QUOTE(Jolly Giant @ Fri 13th Nov 2009, 11:31 PM) <{POST_SNAPBACK}>
And no you can't tap the Renthal out but just buy the Renthal bar ends. They do look nice and finish them off
I had no problem tapping a 16mm (fine) thread into a set of renthals bars, didn't even need to drill the hole any larger. Difficult bit is getting your hands on a set of 16mm fine taps !!.
Think it looks better with the original (larger diameter) bar ends or similar. The only bar ends i could find to fit renthals were only the diameter of the bars 7/8".
Daz
#171
Guest_trevini_*
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Posted 16 November 2009 - 10:33 pm
I uses these Motrax bar ends with my Renthals. Cost about a tenner and clamp on with a metal expanding bolt type fixing.
#172
Kaustic
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Carpe groupie
- Location:Cambridge, Cambridgeshire
- TDM model: 1999
Posted 18 November 2009 - 10:22 pm
Progress made today : Taped out the Renthal bars to take the original bar ends, and got a promise fromm a co-worker to bring in some Plus-gas to try on the M/C cap bolts.
Tommorrow ; Get some tubing for the brake bleeding and maybe buy an impact driver.
TDM Mk2a
Mods (so far) : Heavy duty chain & sprockets, Braided metal hose (front), DL650 handguards, Hyperpro progressive fork springs, Ohlins rear shock & Oxford Heated grips
Wish list : Home made panniers & frames, LED side light, crash bar, centre stand, oversize foot for sidestand.
Mods (so far) : Heavy duty chain & sprockets, Braided metal hose (front), DL650 handguards, Hyperpro progressive fork springs, Ohlins rear shock & Oxford Heated grips
Wish list : Home made panniers & frames, LED side light, crash bar, centre stand, oversize foot for sidestand.
#173
MCBodge
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- Member
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- 745 posts
Knight of Postsalot
- Location:NW
- TDM model: 1998
Posted 19 November 2009 - 09:38 am
QUOTE(Kaustic @ Thu 19th Nov 2009, 12:22 AM) <{POST_SNAPBACK}>
and maybe buy an impact driver.
One of these will do the trick.
You only need to drill the head off. You can get the stud out with a pair of pliers.
#174
JollyGiant
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- Member
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- 3,406 posts
Crap Citizen
- Location:Jolly Giants World.
- TDM model: no more
Posted 19 November 2009 - 02:39 pm
Or if that fails try this.........................
My Super Modded TDM has gone to a new home
I'm now a carbon whore!
#175
Studley Ramrod
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- Root Admin(A)
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Monkey Boys Monkey
- Location:HELLO ! I'm in the Library...Notts
- TDM model: 1993
Posted 19 November 2009 - 04:17 pm
Yo-Ho
Mk2a 2000 in Silver. Top end Refurb @ 41100 miles, Scottoiler, Renthal Road High Bars, Up & Back Bar Risers, Bellypan, DL650 Handguards, Capt. Picard Bar Ends, House of Henty SS Wheel spacers, New Seat Cover Fitted. 58 MPG !! Now owned by chrisbee ! Studley's mk2a Bloggerydoodaah ! Photos of my first MK1 Photos of my MK2a TPLQHCSRSFC No. 1 Fan
#176
Kaustic
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- Member
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- 204 posts
Carpe groupie
- Location:Cambridge, Cambridgeshire
- TDM model: 1999
Posted 21 November 2009 - 06:06 pm
Damn it. Just started to make progress at last only to find that the brake hose is for the wrong model of TDM. I checked the advice note but missed the label on the package.
The new bars are now fitted with just the M/C to put back on once the screws have been drilled out and replaced
Once I get the correct hose I'll just have to put it all back together, bleed the system & ill be running again
k
TDM Mk2a
Mods (so far) : Heavy duty chain & sprockets, Braided metal hose (front), DL650 handguards, Hyperpro progressive fork springs, Ohlins rear shock & Oxford Heated grips
Wish list : Home made panniers & frames, LED side light, crash bar, centre stand, oversize foot for sidestand.
Mods (so far) : Heavy duty chain & sprockets, Braided metal hose (front), DL650 handguards, Hyperpro progressive fork springs, Ohlins rear shock & Oxford Heated grips
Wish list : Home made panniers & frames, LED side light, crash bar, centre stand, oversize foot for sidestand.
#177
Kaustic
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- Member
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- 204 posts
Carpe groupie
- Location:Cambridge, Cambridgeshire
- TDM model: 1999
Posted 23 November 2009 - 09:54 am
Hey Jolly Giant
I'm not sure that my PM are being sent. Can you confrim that you have recieved any about the brake hose ?
K
I'm not sure that my PM are being sent. Can you confrim that you have recieved any about the brake hose ?
K
TDM Mk2a
Mods (so far) : Heavy duty chain & sprockets, Braided metal hose (front), DL650 handguards, Hyperpro progressive fork springs, Ohlins rear shock & Oxford Heated grips
Wish list : Home made panniers & frames, LED side light, crash bar, centre stand, oversize foot for sidestand.
Mods (so far) : Heavy duty chain & sprockets, Braided metal hose (front), DL650 handguards, Hyperpro progressive fork springs, Ohlins rear shock & Oxford Heated grips
Wish list : Home made panniers & frames, LED side light, crash bar, centre stand, oversize foot for sidestand.
#178
JollyGiant
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- Member
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- 3,406 posts
Crap Citizen
- Location:Jolly Giants World.
- TDM model: no more
Posted 23 November 2009 - 10:36 am
QUOTE(Kaustic @ Mon 23rd Nov 2009, 09:54 AM) <{POST_SNAPBACK}>
Hey Jolly Giant
I'm not sure that my PM are being sent. Can you confrim that you have recieved any about the brake hose ?
K
I'm not sure that my PM are being sent. Can you confrim that you have recieved any about the brake hose ?
K
Yes and replied
My Super Modded TDM has gone to a new home
I'm now a carbon whore!
#179
Kaustic
-
- Member
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- 204 posts
Carpe groupie
- Location:Cambridge, Cambridgeshire
- TDM model: 1999
Posted 24 November 2009 - 09:18 am
The latest update
WEMOTO came back with an E-Mail to apoligise that apparentley HEL can not supply a brake hose kit for a '99 due to T-BOlts etc. On the web site they list as alternatives a double line racing type setup or a loop over the mudguard. Anyone with experience of these ?
K
PS Mangaged to get the MC cover off at last using a drill, ill have to replace the cover now but at least its off.
WEMOTO came back with an E-Mail to apoligise that apparentley HEL can not supply a brake hose kit for a '99 due to T-BOlts etc. On the web site they list as alternatives a double line racing type setup or a loop over the mudguard. Anyone with experience of these ?
K
PS Mangaged to get the MC cover off at last using a drill, ill have to replace the cover now but at least its off.
TDM Mk2a
Mods (so far) : Heavy duty chain & sprockets, Braided metal hose (front), DL650 handguards, Hyperpro progressive fork springs, Ohlins rear shock & Oxford Heated grips
Wish list : Home made panniers & frames, LED side light, crash bar, centre stand, oversize foot for sidestand.
Mods (so far) : Heavy duty chain & sprockets, Braided metal hose (front), DL650 handguards, Hyperpro progressive fork springs, Ohlins rear shock & Oxford Heated grips
Wish list : Home made panniers & frames, LED side light, crash bar, centre stand, oversize foot for sidestand.
#180
OldGreyWizard
-
- Member
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- 258 posts
Carpe groupie
- Location:Flitwick, Bedfordshire
- TDM model: 2005
Posted 24 November 2009 - 01:38 pm
QUOTE(Kaustic @ Tue 24th Nov 2009, 09:18 AM) <{POST_SNAPBACK}>
On the web site they list as alternatives a double line racing type setup or a loop over the mudguard. Anyone with experience of these ?
I've always had double lines fitted to all of my sport bikes. I've never had any trouble with this. I personally wouldn't go the loop over the mudguard route.
The TDM 900 is the one bike that I have had that I felt just doesn't need braided hoses. The brakes are so good.
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