I now find I have a cracked frame no probs I got a good Welder
But I have to take the engine out for him to do the job so wot is
the minimum take off to get it out " like the carburettors - oil tank
shocker - battry box - " I am going to wire the harness to the frame
and so on and so on.
john
Wot Have I Got To Take Off
Started by
Blackpin
, Oct 02 2011 11:44 pm
43 replies to this topic
#1
Blackpin
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- Member
- 82 posts
really likes Carpe
- Location:Penistone
- TDM model: 1994
Posted 02 October 2011 - 11:44 pm
Ride the Round Britain Rally this Summer.
#2
dapleb
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- Root Admin(A)
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Monkey Boy
- Location:The home of morris dancin
- TDM model: 1990
Posted 03 October 2011 - 06:15 am
Oid gerra book and follow the destructions. Not a bad job at all.
Cracked on the vertical section some way above swingarm pivot and slightly to the inside? A few peeps have had a cwack there and probably a good few more who aint noticed. Would be interestin to see a pic.
Good luck with yer fix.
Cracked on the vertical section some way above swingarm pivot and slightly to the inside? A few peeps have had a cwack there and probably a good few more who aint noticed. Would be interestin to see a pic.
Good luck with yer fix.
"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.
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.
#3
Studley Ramrod
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Monkey Boys Monkey
- Location:HELLO ! I'm in the Library...Notts
- TDM model: 1993
Posted 03 October 2011 - 09:23 am
You can leave the shock on 
I think the carbs can stay on if you remove the throttle cables at the throttle end and disconnect the fuel supply
Here's my lickle list for wot to tek orf
Rider
Seat.
Cowling & side panels.
Tank.
Airbox.
Battery & box.
Radiator & Plumbing.
The vac pipes where they connect to the inlet stubs.
Exhaust system.
Front sprocket cover/s.
Rear brake lever, mechanism & switch.
Starter motor - possibly
Rear wheel - to get the chain slack enough to slip over the output shaft.
Clutch cable and choke pull mechanism and idle adjuster doohickymebob.
Engine brackets.
Oil tank - possibly.
Going off memory so please alow for middle-aged grey matter fuzzyness.
Basically, just keep undoin' stuff until you feel a heavy weight landing on your foot
Lemme know if ya need a hand as you aint far from me
I think the carbs can stay on if you remove the throttle cables at the throttle end and disconnect the fuel supply
Here's my lickle list for wot to tek orf
Rider
Seat.
Cowling & side panels.
Tank.
Airbox.
Battery & box.
Radiator & Plumbing.
The vac pipes where they connect to the inlet stubs.
Exhaust system.
Front sprocket cover/s.
Rear brake lever, mechanism & switch.
Starter motor - possibly
Rear wheel - to get the chain slack enough to slip over the output shaft.
Clutch cable and choke pull mechanism and idle adjuster doohickymebob.
Engine brackets.
Oil tank - possibly.
Going off memory so please alow for middle-aged grey matter fuzzyness.
Basically, just keep undoin' stuff until you feel a heavy weight landing on your foot
Lemme know if ya need a hand as you aint far from me
Edited by Studley Ramrod, 03 October 2011 - 09:26 am.
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
#4
TonyDevil
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- Supporting Member(thanks)
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- 9,336 posts
seagull squadron leader & founding member of GoatTracKrew
- Location:Saarfend-on-Sea, Essex
- TDM model: 1991
Posted 03 October 2011 - 12:30 pm
i'd remove everything and take the oppurtunity to have the frame and other parts powder coated.....
"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 
#5
3vd
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- Member
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PM Sent
- TDM model: no more
Posted 03 October 2011 - 03:39 pm
Anyone got a photo of this ere crack..... where should I look?
#6
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 03 October 2011 - 03:48 pm
Copied from JBX's site of tdm wonderment
The chassis has sometimes the tendency to crack on the inside, near the gearbox sprocket location. The main cause seems to be a too high mechanical constraints due to excessive use of the machine.
• Years : 1991-1995.
• Check / Repair : check the inside of the frame, left hand side, near the axis of the swingarm. A crack at this location needs a repair by welding with no delay.
• Difficulty : rather difficult, the engine needs to be removed.
I dunt av any crack pics
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
#7
TonyDevil
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- Supporting Member(thanks)
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- 9,336 posts
seagull squadron leader & founding member of GoatTracKrew
- Location:Saarfend-on-Sea, Essex
- TDM model: 1991
Posted 03 October 2011 - 03:57 pm
me neither, i've checked mine each time i've done an engine swap and its been fine 
"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
#8
Studley Ramrod
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- Root Admin(A)
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- 19,334 posts
Monkey Boys Monkey
- Location:HELLO ! I'm in the Library...Notts
- TDM model: 1993
Posted 03 October 2011 - 04:05 pm
The frame certainly gets rusty on the inner parts and along the seams
Gonna get mine painted this winter.........probably.
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
#9
sidestand
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- Member
-
- 3,456 posts
Carpe Citizen
- Location:Lincolnshire
- TDM model: 1996
Posted 03 October 2011 - 09:18 pm
QUOTE(TonyDevil @ Mon 3rd Oct 2011, 04:57 PM) <{POST_SNAPBACK}>
me neither, i've checked mine each time i've done an engine swap and its been fine
Every other service then ?
The older I get, the better I was96 MkII in yellow & silver with bluespots, braided lines, Remus 2 into 1, Hagon rear shock & fork springs, bashplate, heated grips,Motech pannier racks, Road Attacks, Jockoiler, Baglux tank cover & bag. Gone to a far better place - hasn't it Remo?
Another 96 Mk2 in yellow & silver - absolutely standard & pristine ( apart from a butchered rear mudguard - but I'm looking for a new one
'76 Suzuki GT500 Stroker in need of a rebuild
'80 Yamaha XT250 mudplugger
another '81 XT250
'91 BMW R80GS - this one really will do a RTW trip
'05 BMW K1200S - inline four with a shaft
'10 BMW R1200GSA Anniversary Edition
'02 Fazer 1000 - 4 carbs are better than 2 ! - water pump rebuilt by Mr Ramrod Engineering
'00 Triumph Adventurer - Cruiser with a difference - British & a tripleGary's Bathtub - '99 BMW K1200RS in luvverly pillarbox red . Now been Waspycycled to Nuneaton
And the Latest Addition - a nice BMW G650 XCountry greenlaner - on long term loan to Boy Wonder
1996 Kawasaki KH125 Stroker
2000 TDM Mk2A - nicely Studleyfied - Modified by Masterbrewer, but we've fixed that now !
BMW K1300R
2004 TDM 900 in Silver/Blue - heated grips, MRA vary screen, Wilbers rear shock & engine bars to fit
BMW S1000XR in white
#10
3vd
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- Member
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- 2,665 posts
PM Sent
- TDM model: no more
Posted 03 October 2011 - 09:35 pm
Cheers, I'll have a look in the morning.
#11
wtfover
-
- Member
- 32 posts
sticking around
- Location:Ventura, California USA
- TDM model: 1992
Posted 04 October 2011 - 03:23 am
When I bought my bike, there was a crack starting at the swingarm pivot (left side) and went to the 10 O'clock position for maybe 20mm long. After I pulled the engine I found another crack on the inside of the frame. That also started at the pivot hole but went for at least 100mm. I also pulled the oil tank off and MIG welded it all up before the motor rebuild was done. Did it all while the frame was upright, but I should have layed it on it's side. That would have been easier than vertical welding.
I'm guessing the last owner shouldn't have ridden the bike off road with his wife on the back......
I'm guessing the last owner shouldn't have ridden the bike off road with his wife on the back......
#12
masterbrewer
-
- Member
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- 1,553 posts
has been here 4ever
- Location:Adelaide, South Australia
- TDM model: 1991
Posted 04 October 2011 - 06:54 am
Did someone mention "off road"
Are there any photos of what to look for?
Yeah ..................... I know it's a crack
........ but?
Cheers dudes
"Beauty is in the eye of the beer holder"
* to see the latest masterbrewer "TDM Adventure Ride Reports" click "HERE"
click here to read: "Adventure Riding Assumption of Risk"
"Beauty is in the eye of the beer holder"
* to see the latest masterbrewer "TDM Adventure Ride Reports" click "HERE"click here to read: "Adventure Riding Assumption of Risk"
#13
Rallyist
-
- Supporting Member(thanks)
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- 3,266 posts
Gettin to be an 'Old Bugger'
- Location:Usually in a Hospital somewhere in the Birmingham area
- TDM model: 1993
Posted 04 October 2011 - 05:58 pm
QUOTE(maximuspetrolhead @ Mon 3rd Oct 2011, 04:39 PM) <{POST_SNAPBACK}>
Anyone got a photo of this ere crack..... where should I look?
Picture of my crack oooeerr
when stripped will post pictures as it gets stripped and rebuilt, I think it is down to resonance of the frame in that area all Mk1's I have ridden have vibration peaks at/around 3500 & 4500 rpm felt more prominently through the left hand footrest so with this in mind will be strengthening the frame in this area with a shaped piece of square section steel curved to follow the shape of the frame, will decide action when stripped.
For a challenging summer try the
Round Britain Rally.....
1993 TDM 850 Mk1 ..... 2008 TDM 900 .... 1975, 1979, 1982, 1992 Goldwings, Scott, AJS, Triumph 5TA
#14
3vd
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- Member
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- 2,665 posts
PM Sent
- TDM model: no more
Posted 04 October 2011 - 08:13 pm
Definitely no cracks like that on my mkI 
Thanks for posting the photo
Thanks for posting the photo
#15
masterbrewer
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- Member
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- 1,553 posts
has been here 4ever
- Location:Adelaide, South Australia
- TDM model: 1991
Posted 04 October 2011 - 09:20 pm
Me neither
Thanks for the photo.
Re resonance, I used to have a 250cc single cylinder superKart and all those models were renown for cracking frames, welds & undoing lock nuts. Bit of a worry when you're racing down the track @ 100mph
Cheers dudes
"Beauty is in the eye of the beer holder"
* to see the latest masterbrewer "TDM Adventure Ride Reports" click "HERE"
click here to read: "Adventure Riding Assumption of Risk"
"Beauty is in the eye of the beer holder"
* to see the latest masterbrewer "TDM Adventure Ride Reports" click "HERE"click here to read: "Adventure Riding Assumption of Risk"
#16
dapleb
-
- Root Admin(A)
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- 18,279 posts
Monkey Boy
- Location:The home of morris dancin
- TDM model: 1990
Posted 04 October 2011 - 09:24 pm
The ones I have seen run up the inside of the frame by the seam, in the same rough location.
"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.
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.
#17
wicklamulla
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- Supporting Member(thanks)
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- 12,211 posts
is it Jizzy Rascal time yet.....?
- Location:Parish of Cruwys (pronounced 'Cruise' just loike Tom) Morchard, Mid Devon.
- TDM model: 1999
Posted 04 October 2011 - 09:35 pm
too many wheelies could account fer frame cracks too me tinks.
spyball alarm/immob, bluespot brake calipers and Stainless hoses, Fournales air adjustable shock with Remote Resevoir, forks raised 10mm thru yokes, racetech linear fork springs in 15 wt oil, Kappa wingrack/luggage, heated grips, Kedo handguards, dual heat controller to power heated jacket liner and or pants!!, Stebel 136DB horn, K&N air filter, colour matched Baglux tank cover (magnetic tank bag modified to fit cover), osram +50% headloight bulbs, headlight protector,"NitramSpecial" parking loight, tail light indicators all running on LED's & incorporate "Lite Buddies", MK7 Scottoiler fitted, taller screen, 2-2 stainless steel CCC's, Devil stainless down pipes. MKI Renntec engine crash bars & sump guard.
engine changed july 2007 on a dyno run it made 79.1BHP / Torque 59.9Had a brief flirtation with a 1999 MKIIa but it blew an exaust valve on the M5 so was sold on to be repaired.
I loike tay and hang sangwiches !
www.kenhogantreeservices.co.uk
http://s33.photobuck...77/wickla/?sc=6
http://reg.imageshack.us/v_images.php
#18
Blackpin
-
- Member
- 82 posts
really likes Carpe
- Location:Penistone
- TDM model: 1994
Posted 04 October 2011 - 11:28 pm
My crack is in the same place as Ralyist crack but going more up wards, will
get my photo up tomorrow,and a follow up with how the work went on.
My crack was hard to see after finding it I cleaned it back to the steel then I
put 5 coats primmer on it did 50 miles on the bike and you could see it very clear then.
Thanks for the offer studlel i thing i could be needing a the help on the rebuild.
Sorry for being a bit slow in replying to all this help off the site its very nice of you all, as
I just had to make a trip to Levant in Cornwall then stop off in Bridgnorth on the way back
that trip went very well on a bit boring roads .
jd
get my photo up tomorrow,and a follow up with how the work went on.
My crack was hard to see after finding it I cleaned it back to the steel then I
put 5 coats primmer on it did 50 miles on the bike and you could see it very clear then.
Thanks for the offer studlel i thing i could be needing a the help on the rebuild.
Sorry for being a bit slow in replying to all this help off the site its very nice of you all, as
I just had to make a trip to Levant in Cornwall then stop off in Bridgnorth on the way back
that trip went very well on a bit boring roads .
jd
Ride the Round Britain Rally this Summer.
#19
wtfover
-
- Member
- 32 posts
sticking around
- Location:Ventura, California USA
- TDM model: 1992
Posted 05 October 2011 - 04:08 am
QUOTE(Rallyist @ Tue 4th Oct 2011, 10:58 AM) <{POST_SNAPBACK}>
Picture of my crack oooeerr
Actually, that's right where mine started and not down by the pivot bolt area. Then it went around the front edge to the back side and upwards. Repair is holding up well after 10K (road) miles.
QUOTE(masterbrewer @ Mon 3rd Oct 2011, 11:54 PM) <{POST_SNAPBACK}>
Did someone mention "off road"
Are there any photos of what to look for?
I've seen plenty of your ride reports on ADVrider. Why your frame isn't cracked yet......
Just kidding. But you might want to simply use a flashlight and look your entire frame over just as a precaution.
Edited by wtfover, 05 October 2011 - 04:18 am.
#20
Studley Ramrod
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- Root Admin(A)
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- 19,334 posts
Monkey Boys Monkey
- Location:HELLO ! I'm in the Library...Notts
- TDM model: 1993
Posted 05 October 2011 - 09:42 am
QUOTE(Blackpin @ Wed 5th Oct 2011, 12:28 AM) <{POST_SNAPBACK}>
My crack is in the same place as Ralyist crack but going more up wards, will
get my photo up tomorrow,and a follow up with how the work went on.
My crack was hard to see after finding it I cleaned it back to the steel then I
put 5 coats primmer on it did 50 miles on the bike and you could see it very clear then.
Thanks for the offer studlel i thing i could be needing a the help on the rebuild.
Sorry for being a bit slow in replying to all this help off the site its very nice of you all, as
I just had to make a trip to Levant in Cornwall then stop off in Bridgnorth on the way back
that trip went very well on a bit boring roads .
jd
get my photo up tomorrow,and a follow up with how the work went on.
My crack was hard to see after finding it I cleaned it back to the steel then I
put 5 coats primmer on it did 50 miles on the bike and you could see it very clear then.
Thanks for the offer studlel i thing i could be needing a the help on the rebuild.
Sorry for being a bit slow in replying to all this help off the site its very nice of you all, as
I just had to make a trip to Levant in Cornwall then stop off in Bridgnorth on the way back
that trip went very well on a bit boring roads .
jd
Not a problem bod
So long as it's before December when my transport will once again be in many, many pieces.
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
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