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Tds Mk1 Rebuild Thread

Started by TonyDevil , Jan 15 2010 06:53 pm

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#1 TonyDevil

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Posted 15 January 2010 - 06:53 pm

finally got around to rebuilding Gs old mk1 as the GF has killed her bandit again and i want my TRX back....

anyway a few photos
started with an engine on my work bench and plonked the frame on top(note the rest of bike on a heap at the back of the garage)


frame paint "black smooth" hammerite by the GF


wiring loom, oil system and yokes fitted


old frame with swingarm still attatched (about to be removed and hammerited


raditor & water pipes and topped up with coolant (one of the pipes had a leak so had to replace em with a spare set)
lights and more electrics fitted, had to modify the clocks as they were KPH, had a dead set with mph so a bit of fiddling and they sorted =)


carbs & fuel system, new hoses all round. swingarm painted and shock fitted, forks serviced and fitted all parts cleaned and tidied up where needed

note the heater in the background, 2kw under £20 from B&Q....fantastic cool.gif

all bolts replaced with stainless, alu or Ti depending on need (and whats in my spares pot)


and now for first question....

"Never argue with an idiot. They just bring you down to their level and beat you with experience"
My TDM :
Black 1991 850 MK1, 160k+ miles(ish, best guess really, gave up trying to keep count after 3rd set of clocks and 3rd engine), PilotRoad2 tyres, custom stubby exhaust system, bluespot calipers & goodridge braided hoses with dunlopads, maxton forks, Ohlins shock, kedo handguards, stainless TDM grill, Scottoiler with lubetube & dual nozzle thingy, Givi Wingrack2 with E45 & 2xE36s, renntec crash bars, Autocom with blueteeth & PMR radio, TomTom Rider2, Optimate IIIsp, Bagster tank cover, anti-dazzle coating
to fit : led spotlights, heated grips, new braided lines and rear caliper that actually has bleed nipples
Silver-ish 2003 900, 70k miles, PilotRoad3 front tyre (new@65k) & PR2 rear(new at 69k), Renthal 755 bars with KTM handguards, oxford unheated grips, power commander 3usb, scorpion titanium exhausts, standard screen with vario winglet thingy, stainless grill, oem centre stand, bagster tank cover, givi monokey topplate mounted on grabrail with V46 topbox, Givi PL pannier rails with E21s, crash bungs, mirror extender thingys, Halfords Advanced Laser Blue brillance bulbs, 21w led spotlights, touring scottoiler with leehenty dual nozzle, Autocom with blueteeth & PMR radio, TomTom Rider3 Urban, winter style anti-dazzle coating
to fit : led brake light strip, replacement heated grips
current rides : TDM850 3vd/mk1=tourer&scratcher, TRX850=weekend twisty toy, 2003 TDM900=commuter, 2005 TDM900=unmolested.  Gone but not forgotton : XTZ750=overland touring toy, GS500e, GS125
If a strange looking truck driver honks at you & gives you the thumbs up, its could be me  :good:

#2 ChrisG

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Posted 15 January 2010 - 07:05 pm

Your garage is way too clean.

Liking the black swingarm, might be worth shoving some waxoil or similar inside it while it's all apart, or is there a risk of it getting out and on to the back wheel? Not so sure about the red bits on the chain guard but I'll reserve judgement on that until it's got the faring on.

Edited by ChrisG, 15 January 2010 - 07:06 pm.

1992 Mk1, 76k miles, Hagon springs, MTC exhaust, 4½ gears Gone now :(
2009 900 abs, 42k miles, Yamaha heated grips, double bubble screen, R&G crash bungs, scottoiler, Autocom, 1500 lumen LED spotlights.

post-1-1152402501.jpgpost-1-1150550726.gifpost-1-1150559830.gif

#3 TonyDevil

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Posted 15 January 2010 - 07:12 pm

the chainguard was red when i got it, think that was one of Gs modifications
the swingarm is getting black reflective tape down the sides with white carpe lettering etc, will do that in a bit once i've munched the veges i've just burnt dry.gif
will look into the waxoil thing in a bit

anyway...to the problem
bought an engine from a guy who had it in his XTZ750, although its a proper 850 3VD engine
on the right is the 3pin plug from the standard 3VD wiring loom, on the left is the 4ping plug (only 3 used) from the alternator cover

all the wires are white, which one goes where? or doesnt it matter?

"Never argue with an idiot. They just bring you down to their level and beat you with experience"
My TDM :
Black 1991 850 MK1, 160k+ miles(ish, best guess really, gave up trying to keep count after 3rd set of clocks and 3rd engine), PilotRoad2 tyres, custom stubby exhaust system, bluespot calipers & goodridge braided hoses with dunlopads, maxton forks, Ohlins shock, kedo handguards, stainless TDM grill, Scottoiler with lubetube & dual nozzle thingy, Givi Wingrack2 with E45 & 2xE36s, renntec crash bars, Autocom with blueteeth & PMR radio, TomTom Rider2, Optimate IIIsp, Bagster tank cover, anti-dazzle coating
to fit : led spotlights, heated grips, new braided lines and rear caliper that actually has bleed nipples
Silver-ish 2003 900, 70k miles, PilotRoad3 front tyre (new@65k) & PR2 rear(new at 69k), Renthal 755 bars with KTM handguards, oxford unheated grips, power commander 3usb, scorpion titanium exhausts, standard screen with vario winglet thingy, stainless grill, oem centre stand, bagster tank cover, givi monokey topplate mounted on grabrail with V46 topbox, Givi PL pannier rails with E21s, crash bungs, mirror extender thingys, Halfords Advanced Laser Blue brillance bulbs, 21w led spotlights, touring scottoiler with leehenty dual nozzle, Autocom with blueteeth & PMR radio, TomTom Rider3 Urban, winter style anti-dazzle coating
to fit : led brake light strip, replacement heated grips
current rides : TDM850 3vd/mk1=tourer&scratcher, TRX850=weekend twisty toy, 2003 TDM900=commuter, 2005 TDM900=unmolested.  Gone but not forgotton : XTZ750=overland touring toy, GS500e, GS125
If a strange looking truck driver honks at you & gives you the thumbs up, its could be me  :good:

#4 dapleb

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Posted 15 January 2010 - 07:38 pm

YEAH will be good to see the old badger bacon the road (even with G's dubious orange bits) laugh.gif

Sorry I am no help with wiring. The 4pin is a 3LD modification he made?
"Whats up", "Piston Broke", "Yeah me too...hic"

If you want to mark your location on the Carpe map: http://www.carpe-tdm...opic.php?t=5117

Doin valve clearances? Use dappers valve shim exchange program and the job will be carroty - Free (other than you postin me yer shims) for sporting members.

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#5 TonyDevil

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Posted 15 January 2010 - 07:40 pm

QUOTE(dapleb @ Fri 15th Jan 2010, 07:38 PM) <{POST_SNAPBACK}>
YEAH will be good to see the old badger bacon the road (even with G's dubious orange bits) laugh.gif
the orange headlamp thing has been replaced with a spare black one, the GF didnt like it laugh.gif

QUOTE(dapleb @ Fri 15th Jan 2010, 07:38 PM) <{POST_SNAPBACK}>
Sorry I am no help with wiring. The 4pin is a 3LD modification he made?

i ruhroh, sent him as message and asked on the XTZ forum to see if anyone knows
i dont really want to start pulling my XTZ apart to check as its a complete arse to get to and i already have 2 bikes in bits dry.gif

"Never argue with an idiot. They just bring you down to their level and beat you with experience"
My TDM :
Black 1991 850 MK1, 160k+ miles(ish, best guess really, gave up trying to keep count after 3rd set of clocks and 3rd engine), PilotRoad2 tyres, custom stubby exhaust system, bluespot calipers & goodridge braided hoses with dunlopads, maxton forks, Ohlins shock, kedo handguards, stainless TDM grill, Scottoiler with lubetube & dual nozzle thingy, Givi Wingrack2 with E45 & 2xE36s, renntec crash bars, Autocom with blueteeth & PMR radio, TomTom Rider2, Optimate IIIsp, Bagster tank cover, anti-dazzle coating
to fit : led spotlights, heated grips, new braided lines and rear caliper that actually has bleed nipples
Silver-ish 2003 900, 70k miles, PilotRoad3 front tyre (new@65k) & PR2 rear(new at 69k), Renthal 755 bars with KTM handguards, oxford unheated grips, power commander 3usb, scorpion titanium exhausts, standard screen with vario winglet thingy, stainless grill, oem centre stand, bagster tank cover, givi monokey topplate mounted on grabrail with V46 topbox, Givi PL pannier rails with E21s, crash bungs, mirror extender thingys, Halfords Advanced Laser Blue brillance bulbs, 21w led spotlights, touring scottoiler with leehenty dual nozzle, Autocom with blueteeth & PMR radio, TomTom Rider3 Urban, winter style anti-dazzle coating
to fit : led brake light strip, replacement heated grips
current rides : TDM850 3vd/mk1=tourer&scratcher, TRX850=weekend twisty toy, 2003 TDM900=commuter, 2005 TDM900=unmolested.  Gone but not forgotton : XTZ750=overland touring toy, GS500e, GS125
If a strange looking truck driver honks at you & gives you the thumbs up, its could be me  :good:

#6 Guinness

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Posted 15 January 2010 - 08:27 pm

no, that's not a tear, i got somit in the eye ... bit of dust ... seriously
I'm an insomniac agnostic dyslexic. I lay awake at night and wonder if there really is a dog.

yamaha : xv535/92-92 | red TDM850/92-05 | silver TDM900A/05-
get them here

#7 Studley Ramrod

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Posted 15 January 2010 - 08:50 pm

QUOTE(TonyDevil @ Fri 15th Jan 2010, 07:12 PM) <{POST_SNAPBACK}>
the chainguard was red when i got it, think that was one of Gs modifications
the swingarm is getting black reflective tape down the sides with white carpe lettering etc, will do that in a bit once i've munched the veges i've just burnt dry.gif
will look into the waxoil thing in a bit

anyway...to the problem
bought an engine from a guy who had it in his XTZ750, although its a proper 850 3VD engine
on the right is the 3pin plug from the standard 3VD wiring loom, on the left is the 4ping plug (only 3 used) from the alternator cover

all the wires are white, which one goes where? or doesnt it matter?


It makes no difference Tony, any to any !

Edited by Studley Ramrod, 15 January 2010 - 08:50 pm.

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

#8 Guest_LDRider_*

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Posted 15 January 2010 - 08:55 pm

Far as I know, all three white stator wires effectively the same - any to any for those. Haven't tested that personally, but have that on good account.

#9 TDMTAM

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Posted 15 January 2010 - 08:55 pm

IIRC the 3 white wires are the AC voltage outputs from the generator that goto the reg rec to be changed to DC, so I dont think it matters.
TAM
2008 TDM 900 in BLACK, MRA Vario, DL handguards & more to come
1994 TDM 850 mkI Silver, with Blueflame end can, Gone to a new owner & I kinda miss her!

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#10 TonyDevil

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Posted 15 January 2010 - 09:54 pm

thanks guys, the xtz guy said the same cool.gif
all connected up now good.gif
wheels tomorrow then it can come off me bench and get an oil & filter and C&S, then hopefully fire up =)
QUOTE(Guinness @ Fri 15th Jan 2010, 08:27 PM) <{POST_SNAPBACK}>
no, that's not a tear, i got somit in the eye ... bit of dust ... seriously
i'm sure if you come to RTT10 IoM Kris will swap you for the 9er for the day wink.gif

"Never argue with an idiot. They just bring you down to their level and beat you with experience"
My TDM :
Black 1991 850 MK1, 160k+ miles(ish, best guess really, gave up trying to keep count after 3rd set of clocks and 3rd engine), PilotRoad2 tyres, custom stubby exhaust system, bluespot calipers & goodridge braided hoses with dunlopads, maxton forks, Ohlins shock, kedo handguards, stainless TDM grill, Scottoiler with lubetube & dual nozzle thingy, Givi Wingrack2 with E45 & 2xE36s, renntec crash bars, Autocom with blueteeth & PMR radio, TomTom Rider2, Optimate IIIsp, Bagster tank cover, anti-dazzle coating
to fit : led spotlights, heated grips, new braided lines and rear caliper that actually has bleed nipples
Silver-ish 2003 900, 70k miles, PilotRoad3 front tyre (new@65k) & PR2 rear(new at 69k), Renthal 755 bars with KTM handguards, oxford unheated grips, power commander 3usb, scorpion titanium exhausts, standard screen with vario winglet thingy, stainless grill, oem centre stand, bagster tank cover, givi monokey topplate mounted on grabrail with V46 topbox, Givi PL pannier rails with E21s, crash bungs, mirror extender thingys, Halfords Advanced Laser Blue brillance bulbs, 21w led spotlights, touring scottoiler with leehenty dual nozzle, Autocom with blueteeth & PMR radio, TomTom Rider3 Urban, winter style anti-dazzle coating
to fit : led brake light strip, replacement heated grips
current rides : TDM850 3vd/mk1=tourer&scratcher, TRX850=weekend twisty toy, 2003 TDM900=commuter, 2005 TDM900=unmolested.  Gone but not forgotton : XTZ750=overland touring toy, GS500e, GS125
If a strange looking truck driver honks at you & gives you the thumbs up, its could be me  :good:

#11 TonyDevil

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Posted 16 January 2010 - 12:33 am

reflective black tape (sticky paper) on swingarm with no flash


....and with flash


and same stuff on handguards and mirrors, no flash


and with flash and in the dark


hmmm....may remove the big patch from the mirrors

i loike this stuff, canne see it against a shiney/metalic black paint except when light shines on it

and now run out of stuff i can do until wheels are sorted tomorrow....

"Never argue with an idiot. They just bring you down to their level and beat you with experience"
My TDM :
Black 1991 850 MK1, 160k+ miles(ish, best guess really, gave up trying to keep count after 3rd set of clocks and 3rd engine), PilotRoad2 tyres, custom stubby exhaust system, bluespot calipers & goodridge braided hoses with dunlopads, maxton forks, Ohlins shock, kedo handguards, stainless TDM grill, Scottoiler with lubetube & dual nozzle thingy, Givi Wingrack2 with E45 & 2xE36s, renntec crash bars, Autocom with blueteeth & PMR radio, TomTom Rider2, Optimate IIIsp, Bagster tank cover, anti-dazzle coating
to fit : led spotlights, heated grips, new braided lines and rear caliper that actually has bleed nipples
Silver-ish 2003 900, 70k miles, PilotRoad3 front tyre (new@65k) & PR2 rear(new at 69k), Renthal 755 bars with KTM handguards, oxford unheated grips, power commander 3usb, scorpion titanium exhausts, standard screen with vario winglet thingy, stainless grill, oem centre stand, bagster tank cover, givi monokey topplate mounted on grabrail with V46 topbox, Givi PL pannier rails with E21s, crash bungs, mirror extender thingys, Halfords Advanced Laser Blue brillance bulbs, 21w led spotlights, touring scottoiler with leehenty dual nozzle, Autocom with blueteeth & PMR radio, TomTom Rider3 Urban, winter style anti-dazzle coating
to fit : led brake light strip, replacement heated grips
current rides : TDM850 3vd/mk1=tourer&scratcher, TRX850=weekend twisty toy, 2003 TDM900=commuter, 2005 TDM900=unmolested.  Gone but not forgotton : XTZ750=overland touring toy, GS500e, GS125
If a strange looking truck driver honks at you & gives you the thumbs up, its could be me  :good:

#12 aircooled68

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Posted 16 January 2010 - 12:54 am

keep the pic's coming



Dave

Edited by aircooled68, 16 January 2010 - 12:54 am.

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

#13 TonyDevil

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Posted 16 January 2010 - 01:59 am

QUOTE(aircooled68 @ Sat 16th Jan 2010, 12:54 AM) <{POST_SNAPBACK}>
keep the pic's coming
Dave

good.gif

giv/kappa rack installed (just need the pillion peg mounts but the GF wants to paint them tomorrow rolleyes.gif)

quiz time : how many TDM engines are there in this photo? (not inc the one in the bike i'm working on)

and sorry G sorry.gif

"Never argue with an idiot. They just bring you down to their level and beat you with experience"
My TDM :
Black 1991 850 MK1, 160k+ miles(ish, best guess really, gave up trying to keep count after 3rd set of clocks and 3rd engine), PilotRoad2 tyres, custom stubby exhaust system, bluespot calipers & goodridge braided hoses with dunlopads, maxton forks, Ohlins shock, kedo handguards, stainless TDM grill, Scottoiler with lubetube & dual nozzle thingy, Givi Wingrack2 with E45 & 2xE36s, renntec crash bars, Autocom with blueteeth & PMR radio, TomTom Rider2, Optimate IIIsp, Bagster tank cover, anti-dazzle coating
to fit : led spotlights, heated grips, new braided lines and rear caliper that actually has bleed nipples
Silver-ish 2003 900, 70k miles, PilotRoad3 front tyre (new@65k) & PR2 rear(new at 69k), Renthal 755 bars with KTM handguards, oxford unheated grips, power commander 3usb, scorpion titanium exhausts, standard screen with vario winglet thingy, stainless grill, oem centre stand, bagster tank cover, givi monokey topplate mounted on grabrail with V46 topbox, Givi PL pannier rails with E21s, crash bungs, mirror extender thingys, Halfords Advanced Laser Blue brillance bulbs, 21w led spotlights, touring scottoiler with leehenty dual nozzle, Autocom with blueteeth & PMR radio, TomTom Rider3 Urban, winter style anti-dazzle coating
to fit : led brake light strip, replacement heated grips
current rides : TDM850 3vd/mk1=tourer&scratcher, TRX850=weekend twisty toy, 2003 TDM900=commuter, 2005 TDM900=unmolested.  Gone but not forgotton : XTZ750=overland touring toy, GS500e, GS125
If a strange looking truck driver honks at you & gives you the thumbs up, its could be me  :good:

#14 dapleb

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Posted 16 January 2010 - 02:09 am

Lolz, at least tree.
"Whats up", "Piston Broke", "Yeah me too...hic"

If you want to mark your location on the Carpe map: http://www.carpe-tdm...opic.php?t=5117

Doin valve clearances? Use dappers valve shim exchange program and the job will be carroty - Free (other than you postin me yer shims) for sporting members.

Active member of TPLQHCSRSFC and TSRMCMAS (even though a year off) and avid fan of PM not sent.

#15 JollyGiant

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Posted 16 January 2010 - 07:06 am

phoar....phwee

My daughter has that stereo and what a posh garage you have with a computer but what the hell are you looking at on it??

My Super Modded TDM has gone to a new home :(

 

I'm now a carbon whore!

#16 ChrisG

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Posted 16 January 2010 - 08:47 am

You blagged a Hagon for it?

1992 Mk1, 76k miles, Hagon springs, MTC exhaust, 4½ gears Gone now :(
2009 900 abs, 42k miles, Yamaha heated grips, double bubble screen, R&G crash bungs, scottoiler, Autocom, 1500 lumen LED spotlights.

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#17 catsbum

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Posted 16 January 2010 - 09:33 am

A visit I think. You in this pm Tony?

#18 TonyDevil

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Posted 16 January 2010 - 01:48 pm

QUOTE(Jolly Giant @ Sat 16th Jan 2010, 07:06 AM) <{POST_SNAPBACK}>
phoar....phwee

My daughter has that stereo and what a posh garage you have with a computer but what the hell are you looking at on it??

WMP by looks of it

this garage is nice
double glazing
2kw heater
docking station for me laptop
surround sound 250w
running water - need a mini kettle

only thing i need to do is seal and paint the floor.....easier said than done dry.gif

apologies for quality of pics, they are from mobile phone

cats, about to pop down to Reading to get C&S and tyres sorted (still aint found a decent bike shop in Oxf dry.gif )
will ring ya in a bit

"Never argue with an idiot. They just bring you down to their level and beat you with experience"
My TDM :
Black 1991 850 MK1, 160k+ miles(ish, best guess really, gave up trying to keep count after 3rd set of clocks and 3rd engine), PilotRoad2 tyres, custom stubby exhaust system, bluespot calipers & goodridge braided hoses with dunlopads, maxton forks, Ohlins shock, kedo handguards, stainless TDM grill, Scottoiler with lubetube & dual nozzle thingy, Givi Wingrack2 with E45 & 2xE36s, renntec crash bars, Autocom with blueteeth & PMR radio, TomTom Rider2, Optimate IIIsp, Bagster tank cover, anti-dazzle coating
to fit : led spotlights, heated grips, new braided lines and rear caliper that actually has bleed nipples
Silver-ish 2003 900, 70k miles, PilotRoad3 front tyre (new@65k) & PR2 rear(new at 69k), Renthal 755 bars with KTM handguards, oxford unheated grips, power commander 3usb, scorpion titanium exhausts, standard screen with vario winglet thingy, stainless grill, oem centre stand, bagster tank cover, givi monokey topplate mounted on grabrail with V46 topbox, Givi PL pannier rails with E21s, crash bungs, mirror extender thingys, Halfords Advanced Laser Blue brillance bulbs, 21w led spotlights, touring scottoiler with leehenty dual nozzle, Autocom with blueteeth & PMR radio, TomTom Rider3 Urban, winter style anti-dazzle coating
to fit : led brake light strip, replacement heated grips
current rides : TDM850 3vd/mk1=tourer&scratcher, TRX850=weekend twisty toy, 2003 TDM900=commuter, 2005 TDM900=unmolested.  Gone but not forgotton : XTZ750=overland touring toy, GS500e, GS125
If a strange looking truck driver honks at you & gives you the thumbs up, its could be me  :good:

#19 TDMick

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Posted 16 January 2010 - 02:15 pm

Where did you get the black reflective tape from Tony.
I like the look of that stuff.

Growing old is compulsory, growing up is optional
Who dies with the most toys wins!
 
 
2010 'stealth' grey 900. '14 plate. engine bars, Centre stand, datatool alarm, datatag, E22s, Cree DRLs, Barkbuster handguards, Carpe sticker. Led running lights
 

 

#20 TonyDevil

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Posted 16 January 2010 - 02:31 pm

QUOTE(TDMick @ Sat 16th Jan 2010, 02:15 PM) <{POST_SNAPBACK}>
Where did you get the black reflective tape from Tony.
I like the look of that stuff.

ebay months ago (if not years)
its made by 3M

http://cgi.ebay.co.u...em=290365846096

IIRC i bought about a quarter of a roll that the guy had left
originally wanted it to go around the middle of givi panniers but couldnt get the old stuff off and kinda forgot about it

you can buy it in bigger sheets too, but its fecking expensive stuff in big chunks

"Never argue with an idiot. They just bring you down to their level and beat you with experience"
My TDM :
Black 1991 850 MK1, 160k+ miles(ish, best guess really, gave up trying to keep count after 3rd set of clocks and 3rd engine), PilotRoad2 tyres, custom stubby exhaust system, bluespot calipers & goodridge braided hoses with dunlopads, maxton forks, Ohlins shock, kedo handguards, stainless TDM grill, Scottoiler with lubetube & dual nozzle thingy, Givi Wingrack2 with E45 & 2xE36s, renntec crash bars, Autocom with blueteeth & PMR radio, TomTom Rider2, Optimate IIIsp, Bagster tank cover, anti-dazzle coating
to fit : led spotlights, heated grips, new braided lines and rear caliper that actually has bleed nipples
Silver-ish 2003 900, 70k miles, PilotRoad3 front tyre (new@65k) & PR2 rear(new at 69k), Renthal 755 bars with KTM handguards, oxford unheated grips, power commander 3usb, scorpion titanium exhausts, standard screen with vario winglet thingy, stainless grill, oem centre stand, bagster tank cover, givi monokey topplate mounted on grabrail with V46 topbox, Givi PL pannier rails with E21s, crash bungs, mirror extender thingys, Halfords Advanced Laser Blue brillance bulbs, 21w led spotlights, touring scottoiler with leehenty dual nozzle, Autocom with blueteeth & PMR radio, TomTom Rider3 Urban, winter style anti-dazzle coating
to fit : led brake light strip, replacement heated grips
current rides : TDM850 3vd/mk1=tourer&scratcher, TRX850=weekend twisty toy, 2003 TDM900=commuter, 2005 TDM900=unmolested.  Gone but not forgotton : XTZ750=overland touring toy, GS500e, GS125
If a strange looking truck driver honks at you & gives you the thumbs up, its could be me  :good:

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