3vd Engine Rebuild

Posted 03 June 2010 - 12:04 pm

what is the size of conrod and crankshaft shells

I can't find the size anywhere, in service manual and parts catalog there are only colors but no sizes

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Posted 03 June 2010 - 12:41 pm

You won't. There are only the colours used to represent sizes. And the list of which colours to jump to in order to jump up/down a size. Obviously when they left the factory they were issued with the correct colour dependent on clearance, so wan enjun will vary from the next. This is all great fun after many thousand miles of use and being colour blind....stunningly dumb idea. Though you can also calculate size if the colour is not clear on the shell. You subtract the number on the conrod from some other number (printed on the case) and it gives you the numberical code for the colour...simple really.

Do you plan on plastiguaging the shells or just using the orig colours?

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Posted 03 June 2010 - 01:31 pm

I am planing to send crankshaft to machining company so they will fix it if it is possible, otherwise new crank is the only way

the problem is that it is almost impossible to find second hand crank in good condition.

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Posted 07 June 2010 - 07:06 am

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Posted 07 June 2010 - 10:34 am

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Posted 07 June 2010 - 10:42 am

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Posted 07 June 2010 - 04:14 pm

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Posted 07 June 2010 - 05:28 pm

Got your pm - I'll get my wife to translate it later

It's the 4.5mm shorter stroke I question, you'll loose compression as well as capacity. But perhaps considering the quality of the fuel here...

I wouldn't think there'd be any problem with the balance shaft as you're using the same pistons.

By the way my brother is coming by car to Croatia from the UK at the end of next month and he'll already be loaded with TDM parts...

Edited by steveearwig, 07 June 2010 - 07:29 pm.

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Posted 08 June 2010 - 06:50 am

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Posted 08 June 2010 - 04:04 pm

It's all in the stroke (piston travels a greater distance on the TDM)

Kužim skoro sve ali samo trebam jednu rijeć i onda pizdarija.... Anyway, I thought you were an expat like me as your written English is so good

My brother organising anything to do with a motorbike? I'd like to see that! It would be better to talk to my father (in my avatar). I'll start filling in some forms, sending some emails, see what we can come up with & report back here if I get any joy.

Shame your bike isn't a little later, there's someone breaking a 4TX on ebay.

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Posted 09 June 2010 - 09:10 am

nop, I'm native Bosnian but I studied english in university and worked as interpreter for some years

anyway I can't get magnet of, i managed to brake 3 pullers but bloody thing wont move a bit.

even tried to heat it with heat gun but no movement at all

i really don't know what to do next.


any idea any one

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Posted 09 June 2010 - 12:33 pm

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Posted 09 June 2010 - 01:10 pm

I think it was my CX needed a bolt screwed into the rotor, (hold rotor, tighten bolt, hit with hammer - bang!) I have no TDM Haynes here but does the TDM need anything similar?

Something like this:

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Posted 09 June 2010 - 01:35 pm

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Posted 09 June 2010 - 01:57 pm

according to Haynes, it needs something like this


and I also build something like brian but with handlebar for better grip

Edited by danbara, 09 June 2010 - 01:59 pm.

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Posted 11 June 2010 - 06:57 am

Did you have any success with the rotor yet? Perhaps you should take it to an engineering shop, although you'll probably have to point out it's not for a tractor...

I've had zero response to my enquiries so far

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Posted 11 June 2010 - 07:30 am

managed to take the magnet off.

it went of with a big bang ,

had to put a bigger bolt ( i made puller with M12 central pusher but they had tendency on snapping like a branch so i put M16 bolt ) ann applied some heat to the magnet.
and yesterday was a 32 deg C in shadow so the day was like perfect to work with a torch

anyway it's of now but (there is always but) now i have trouble with balancer security plate and the screws that holds them.

i don't know if I can tap them with a hammer or apply some heat?

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Posted 11 June 2010 - 11:04 am

QUOTE(danbara @ Fri 11th Jun 2010, 08:30 AM) <{POST_SNAPBACK}>

i don't know if I can tap them with a hammer or apply some heat?

Well done on the alteenator.

Did we forget to mention the balancer shaft end plates?

Think there is an o-ring in there somewhere so be careful if you use heat and dont wanna replace oring! The screws are made from the special Yamaha Marshmallow.

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Posted 11 June 2010 - 12:49 pm

damn those things are soft.

I'll try a bigger screwdriver and make a gently knock with 1/2 kilo hammer

hope that will talk them into getting out hehe

if don't then I am out of idea. maybe a drill is good one

Edited by danbara, 11 June 2010 - 12:51 pm.

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Posted 11 June 2010 - 01:02 pm

Your getting the idea........ if the first wan doesn't work.........use a bigger wan !

I commend you on your perseverence....and perspiration !

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