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Help! Rear Suspension Linkage

Started by Commando , Nov 15 2009 09:31 pm

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#1 Commando

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Posted 15 November 2009 - 09:31 pm

I am trying to lube the rear suspension linkage as per service interval on my 2003 900. Can anyone tell me how does the front pin come out of the lower suspension pivot? all the other ones have come out OK but this one seems to have the sleeve pushed in from the nearside.

Also there is about 25 thou of side to side in the swingarm with the linkage disconnected. can this be removed by tightening up the spindle nut?

help appreciated

thanks in advance
Mark
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Posted 15 November 2009 - 10:23 pm

The best and safest way is to use yamahas special removal tool or make one.

Edited by celticbiker, 15 November 2009 - 10:23 pm.

#3 Commando

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Posted 15 November 2009 - 10:30 pm

QUOTE(celticbiker @ Mon 16th Nov 2009, 12:23 AM) <{POST_SNAPBACK}>
The best and safest way is to use yamahas special removal tool or make one.



thanks for the reply. what does it look like, or where can I get one?
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Posted 15 November 2009 - 11:34 pm

Hmmm, can't seem to find the number for the tool but if you contact Yam UK they will tell you what you need and how much it costs,

#5 JBX

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Posted 15 November 2009 - 11:47 pm

QUOTE(Commando @ Sun 15th Nov 2009, 10:31 PM) <{POST_SNAPBACK}>
I am trying to lube the rear suspension linkage as per service interval on my 2003 900. Can anyone tell me how does the front pin come out of the lower suspension pivot? all the other ones have come out OK but this one seems to have the sleeve pushed in from the nearside.

Also there is about 25 thou of side to side in the swingarm with the linkage disconnected. can this be removed by tightening up the spindle nut?

help appreciated

thanks in advance
Mark


Do not use brut force as the lower pivot may break !
Use an extractor if it doesn't come loose easily.
Check the page on my site, I've faced the same problem.

Yep, that's what it's made for !



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#6 Commando

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Posted 16 November 2009 - 06:21 pm

Thanks for the replies. It seems the side play in the swingarm is correct. Anyone know where I can get an extractor for the front lower suspension bearing pin

thanks
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#7 wicklamulla

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Posted 17 November 2009 - 08:17 pm

QUOTE(Commando @ Mon 16th Nov 2009, 06:21 PM) <{POST_SNAPBACK}>
Thanks for the replies. It seems the side play in the swingarm is correct. Anyone know where I can get an extractor for the front lower suspension bearing pin

thanks

why don't ya ask a yamaha dealer what ya need and how mush etc ?? waiting.gif

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#8 Commando

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Posted 20 November 2009 - 09:12 pm

Got the bugger!!!!!

emaild a few Yamaha dealers as there's none local for a special tool. None replied (perhaps they leave this one when they do the service)

got a 2" long M5 countersing screw. Wrapped some stainless wire and a few split washers on it so it slid into the pin snug. Tightened a nut down on the screw to compress the wire and grip the inside of the pin. Gentle heat on the lug with a paint stripping gun on lowest setting for a few mins to get the alloy lug up to temp (no more than you can leave your finger on) wiggle and pull....Bingo. Glad I did as the bearings were quite dry and a few more miles the bearings may have been shot.

Thanks for all the advice (especially the "Don't hit it") because breaking that frame lug would be a mega catastrophe!!
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Posted 20 November 2009 - 09:29 pm

QUOTE(Commando @ Fri 20th Nov 2009, 09:12 PM) <{POST_SNAPBACK}>
Got the bugger!!!!!

emaild a few Yamaha dealers as there's none local for a special tool. None replied (perhaps they leave this one when they do the service)

got a 2" long M5 countersing screw. Wrapped some stainless wire and a few split washers on it so it slid into the pin snug. Tightened a nut down on the screw to compress the wire and grip the inside of the pin. Gentle heat on the lug with a paint stripping gun on lowest setting for a few mins to get the alloy lug up to temp (no more than you can leave your finger on) wiggle and pull....Bingo. Glad I did as the bearings were quite dry and a few more miles the bearings may have been shot.

Thanks for all the advice (especially the "Don't hit it") because breaking that frame lug would be a mega catastrophe!!

You aint kidding mine snapped off a little while ago(both of them) and about 3 months ago someone else had the same problem.
I think you're right though I reckon dealers tend not to bother with that part of the service.

#10 dapleb

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Posted 20 November 2009 - 09:30 pm

Nice wan Commando.....yo realise you are now the 9'er lower suspension expert?


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#11 Commando

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Posted 20 November 2009 - 09:41 pm

QUOTE(celticbiker @ Fri 20th Nov 2009, 11:29 PM) <{POST_SNAPBACK}>
You aint kidding mine snapped off a little while ago(both of them) and about 3 months ago someone else had the same problem.
I think you're right though I reckon dealers tend not to bother with that part of the service.


what did you do celt? is there a repair for that or is it a new frame job?
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#12 robelst

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Posted 20 November 2009 - 09:57 pm

Am I so old that I can remember that bikes use to have grease-nipples for linkages like that rolleyes.gif

Actually, I fitted one myself to a Honda Pro-Link that had seized and took me 3 days to take apart dry.gif
That was not a banana, Dougal

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Posted 20 November 2009 - 10:25 pm

You can read the whole sorry saga here including the fix.

#14 Commando

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Posted 21 November 2009 - 08:23 am

QUOTE(celticbiker @ Sat 21st Nov 2009, 12:25 AM) <{POST_SNAPBACK}>
You can read the whole sorry saga here including the fix.


Fantastic CB. Unfortunately I don't have that sort of equipment or the skills to use it. Best I keep mine clean and well greased. forget every 6000 miles I'm going for every 3000

thanks for the info
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#15 sidestand

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Posted 21 November 2009 - 10:14 am

seeing that lot, I think the arse end of my niner is going to get dismantled & greased this winter....

Just got to get that fazer put back together & off the ramp first dry.gif

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Posted 23 March 2010 - 11:54 pm

QUOTE(Commando @ Fri 20th Nov 2009, 11:12 PM) <{POST_SNAPBACK}>
Got the bugger!!!!!

emaild a few Yamaha dealers as there's none local for a special tool. None replied (perhaps they leave this one when they do the service)

got a 2" long M5 countersing screw. Wrapped some stainless wire and a few split washers on it so it slid into the pin snug. Tightened a nut down on the screw to compress the wire and grip the inside of the pin. Gentle heat on the lug with a paint stripping gun on lowest setting for a few mins to get the alloy lug up to temp (no more than you can leave your finger on) wiggle and pull....Bingo. Glad I did as the bearings were quite dry and a few more miles the bearings may have been shot.

Thanks for all the advice (especially the "Don't hit it") because breaking that frame lug would be a mega catastrophe!!


Sorry for digging out this old topic, but I'm currently facing the same problem. I've tried and managed to grip a rubber-coated screw inside that collar which I intend to extract, but with all the pulling and "careful enough" hammering from the other side, it still wouldn't go out.

Somebody more experienced than me on these matters suggested inserting a 10 or 12 mm tap inside the collar and start "threading" it. That way it should start to rotate at some point and brake loose; if it it doesn't, I should get the tap stuck in there and try to hammer it out from the other side. What do you think about this, do you think is a risky operation? Could that hammering be so dangerous... I mean using a hammer with some decency, not a sledgehammer or something like that.

I know many of you may think that a Yamaha service should be the right route to follow but at least here where I live, I really don't trust them at all. I may not have the tools or the experience, but I care... smile.gif

@Commando: Do you have by any chance some photos of your improvised tool? Thanks.

#17 dapleb

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Posted 24 March 2010 - 07:47 am

More info and a wee pic here: http://www.carpe-tdm...o...inkage&st=0
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If you want to mark your location on the Carpe map: http://www.carpe-tdm...opic.php?t=5117

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#18 silver

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Posted 24 March 2010 - 08:45 am

QUOTE(robelst @ Fri 20th Nov 2009, 11:57 PM) <{POST_SNAPBACK}>
Am I so old that I can remember that bikes use to have grease-nipples for linkages like that rolleyes.gif

Actually, I fitted one myself to a Honda Pro-Link that had seized and took me 3 days to take apart dry.gif


I must be as old as you then cos i had a honda with prolink, an XR200 which i used to ride enduro.
Dave

Edited by silver, 24 March 2010 - 08:47 am.

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Posted 24 March 2010 - 11:17 am

QUOTE(dapleb @ Wed 24th Mar 2010, 09:47 AM) <{POST_SNAPBACK}>
More info and a wee pic here: http://www.carpe-tdm...o...inkage&st=0

Thank you. I hope it will work without the heat gun.

#20 Commando

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Posted 24 March 2010 - 09:16 pm

DO NOT HIT IT from the other side. It is cast alloy and not designed to take sideways load. If it breaks it's end of game!!

Gentle and prolonged heat should free it. It takes a while as there is a lot of alloy to warm up. I got mine to a temperature that I could just still leave my finger on (aboyt 60 degrees C I think) and it just twisted and pulled out easily. I tried the tap method but the steel was too hard and the tap would not bite. After getting mine out, I read somwhere that a 10mm comression type wall fixing was used. This could be pulled out using a nut and socket without putting any stress on the alloy lug.

No heat was needed to reassemble it, it is a close tolerence fit and slides in nice with a bit of grease

PS I'm not convinced a Yamaha service tool exists as none of the dealers I spoke to seemed to have any idea what I was talking about

good luck
Mark
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