1991 Tdm 850 Mk1 Project By Margus

Posted 24 January 2012 - 09:04 pm

More and more parts are geting back to their original position:




I also finally got my front sprocket off useing a pneumatic tool:



Now I have to figure out how to rethread the shaft.

Work on my bike hasn't ended jet!

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Posted 25 January 2012 - 03:42 pm

HEY !! you´ve had the exactly the same problem as I have... Thank you for solving the first one for me (with the sprocket),,, I´ll guess I'll try the same with mine. I´m very interested in what you will do with the shaft. Keep on posting ! hehe this is like being in school

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Posted 25 January 2012 - 07:36 pm

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Posted 25 January 2012 - 08:37 pm

Work on my bike hasn't ended jet!

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Posted 25 January 2012 - 10:23 pm

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Posted 26 January 2012 - 08:18 am

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Posted 26 January 2012 - 08:23 am

QUOTE(haffi @ Wed 25th Jan 2012, 03:42 PM) <{POST_SNAPBACK}>

hehe this is like being in school

Quiet at the back.

QUOTE(Studley Ramrod @ Wed 25th Jan 2012, 07:36 PM) <{POST_SNAPBACK}>

If your changing the sprocket, don't use a JT sprocket. They don't fit the splines very well.

AFAM is very very close if snot the same as OEM. If you donut want to repeat this grind off then oid also suggest licktight 638hawaii'5'O

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Posted 26 January 2012 - 10:01 am

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Posted 26 January 2012 - 08:14 pm

Gear sensor is ready



How my TDM looks like right now:


Inside throttle housing:

Cleaned and lubed it
By the way, I have an homemade exhaust on it right now and I started my TDM today- oh thease mighy sounds
I hope to upload a video tonight.

Edited by Margus, 30 January 2012 - 06:23 pm.

Work on my bike hasn't ended jet!

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Posted 26 January 2012 - 09:29 pm

Sorry, can't upload the video tonight.

Work on my bike hasn't ended jet!

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Posted 26 January 2012 - 10:09 pm

Tere Margus

Cover your paint with automotive clear coat, usually just paint are soluble with petrol. Try it you see it...
Its not necessary to use heat resistant paint, engine will not heat more than 60-70c And almost any quality paint will withstand to that temperature
And its common then you tune your carbs removing a fuel tank or just drop your bike usually you will get fuel spills on engine and it will screw all your paintwork! I made that mistake did not checked before!
I like your gear gauge on rpm gauge.
And its pretty much impossible to re-thread correctly your output shaft on engine, not much space to work on. I would put new sprocket and weld sprocket nut back. You will forget about problem for 2-3 year at least. for that time I bet that you will buy newer TDM or overhaul your engine, then will be a time to work on your output shaft
And also forgot to tell that replace your output shaft seal then you will weld sprocket back, so you dont have to worry after, that oil will disappear from that place

Edited by eerik, 27 January 2012 - 08:21 am.

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Posted 26 January 2012 - 11:01 pm

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Posted 30 January 2012 - 06:22 pm

As I'm away from home in collage, my brother helped me a little bit with my TDM as fiting tyre on my freshly painted rear rim and attaching it to swingarm.


He couldn't fit front wheel because I've lost my wheel spindle Have to find it when I get back home.
Before I left I cleaned my front brake capipers and fited them to forks

Edited by Margus, 30 January 2012 - 06:22 pm.

Work on my bike hasn't ended jet!

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Posted 30 January 2012 - 08:32 pm

Loong waited video:
http://www.youtube.c...31cFAAAAAAAAAAA
Make sure to use good speakers to watch this video.
These "bangs" were made by using a kill switch
And if you are watching this video, press LIKE and leave a comment or add it to your favourites

Edited by Margus, 01 February 2012 - 08:11 pm.

Work on my bike hasn't ended jet!

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Posted 06 February 2012 - 11:19 am

I hoped more feedback on video, but OK
I got home for the weekend, but didn't had much time to spend on TDM. I looked for my front wheel spindle everywhere, but could'nt find it- looks like I have to use lathe to make a new one. I also practiced a bit TIG welding:


Internals on my new exhaust:

Wrapped bronse mesh around the stainless steel mesh:

Added rock wool and something more:

Sorry don't have more pics

Work on my bike hasn't ended jet!

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Posted 06 February 2012 - 01:34 pm

Engine sounds healthy and responsive Exhaust sounds great !

Tig welding looks neat and tidy

Still waiting to see how you refit the front sprocket

Thanks for posting up the piccys !

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Posted 06 February 2012 - 09:33 pm

Work on my bike hasn't ended jet!

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Posted 08 February 2012 - 01:52 pm

QUOTE(Margus @ Mon 6th Feb 2012, 11:33 PM) <{POST_SNAPBACK}>

I have an idea on how to "rethread" my output shaft. If I have time, I will use 3D program to show you guys my idea.

can´t wait

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Posted 10 February 2012 - 09:25 pm

I did some basic 3D moddeling to show you guys how I'm going to repair my output shaft.
Threaded part of the output shaft must be grinded down to about 15mm. I think I'm going to grind a bit more actually, so that the wall of the bushing could be thicker. To grind the end of the shaft, I will start the engin and put in the 5'th gear, raise the rpm to about 2500 and use pneumatic grinder to grind the shaft. This ensures that shaft will be eavenly grinded and won't become oval.
This bushing will be made useing lathe. It will have M20x1,5 threading on the outside. Inside diameter has to be exactly the same as output shaft's end's diameter. And the bushing will be welded to the shaft.




When I begin the work I will make a lot more pictures and maybe eaven a new thread, which hopefully will get to KnowledgeBase section.

Work on my bike hasn't ended jet!

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Posted 10 February 2012 - 09:27 pm

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