32 replies to this topic

[Geordie Guy]

Started Sunday morning 11.00 till 12.00 midnight, then again today.

Fook me what a job !

On the new bike I noticed that on start up the bike struggled to maintain 1,000 RPM and then slowly rise to 1,250 RPM on big red it would go up to 1,800 and then drop to 1,250.

Looking on JBX Minty had posted his solution for the cold start solutions, First I tried the option 1 but the plunger was solid.

So I had to take it off. JBX page link

Tried to unscrew it, too tight to get anything in , spent ages cutting tools down fecking every thing I tried failed. By that time I had chewd up the screw slots , so there was no point in taking the radiator off, plus i did not have a foot long screwdrive.

Decided to demil two slots in to use a flat screwdriver. Got one out but the other just collapsed, those screw heads are seriously tight and there is no way to stop it slipping.

so late last night I bit the bullet abd Dremil the whole head off.

Even the two side screws tore up, they are just the wrong fixting.

Today just went and got some M5 allen key fixings and replaced the lot.







once the head is off it just springs apart, the plunger was solid and took an age to free and polish up so it moved freely.

Replacing is easy.









Why Yamaha did not use these fixings in the first place , I do not know.



I had to use this mini ratchet and the back has been cut down to fit, that is how tight it is.

Started it up and SORTED !

What a bloody job, its a bastard to get to and the odd thing is the position is open to all the crap that would get drawn through radiator.

Moral of the story,

LUBE your PLUNGER.


I'm off for a Johnny Walkers Black, I have earned it.

Cheers, Ivan

[leehenty]

I had this nasty little problem, so did Moose and several others. my solution was similar to yours, use allen bolts and a small bellows seal off a model boat supplier.
I didn't want to keep going in there and cleaning it. Should have had a seal on in the first place.
Yamaha san make the engine off the bike and it just has to last long enough to get out of warranty.
The right tool to do this job (Bahco 2058S26 Ratchet Socket Bit Set 26-Piece) is here below, just be sure to use a tight fitting philips bit, not a common pozi bit, the angles inside the cross are different. Still a pig of a job though.

http://www.amazon.co...c...841&sr=1-11

Bellows came from here Part GA18, snip off small end at bottom of third bump. four cost £2.95.plus post.

http://www.prestwich...uk/hdwraccs.htm

Edited by leehenty, 24 April 2012 - 05:02 pm.

[Pantboy]

I had this nasty little problem, so did Moose and several others. my solution was similar to yours, use allen bolts and a small bellows seal off a model boat supplier.
http://www.prestwich...uk/hdwraccs.htm

not been to prestwich models for many years, but then again i gave up model boating years ago too

[Studley Ramrod]

Well done Ivan ! Warra ball-ache eh !

[ChrisG]

I like that bellows seal idea. I was lucky when I did mine and manage to get the screws out easily with a screwdriver bit held in a pair of mole grips. SagaLout always reckons to squird some WD40 in the area every time he washes the bike, but as that's only once or twice a year for me I think I'll be going for the stainless hex bolts and bellows option next time it causes me any grief.

[Matlock]

Perseverance (and a Dremmel) pays off Well done Ivan. Touching wood, I've never had this problem, I wonder if it's because mine gets used most days, all year, so the plunger is moving regularly and keeping itself free? If you get stuck with anything like this again, feel free to give me a ring if you want a hand. I've no more idea than you, but I've got a well appointed garage, full of tools, and a fine collection of hammers!

Edited by Matlock, 24 April 2012 - 10:03 am.

[dmmsta]

I had that grief about 6 months after I got my 9er.

Stripped it down and gave it a good clean and all way gravy. I did have problems subsequent to that, and thought it was the same thing, however I borked the same screws you mentioned trying to remove it, so ended up applying a liberal amount of WD, and leaving it as is.

This does mean that once I have a weekend to do all the bits outstanding, I'll be swearing loudly at the bikes mid-rif in a vain attempt to get the taffy screws out.

(Oh and of course the usual PM to Mr Henty for the stainless bits prior to the work starting!)

Edited by dmmsta, 24 April 2012 - 11:05 am.

[Chris B]

I just get something solid long and thing (not jokes) like a 1/2 extension bar then go to the LHS of the bike find it line up the extension and twat it with a mallet. No the most delicate of fixes but mine has been trouble free for 20k all weather miles.

[JBX]

I like the Dremel and allen bolts solution !

Didn't have the idle plunger problem on my bike, although it's a 2002 model & I've never lubed this part !

[leehenty]

The Henty house of stainless does actually make a little kit up for this job.

£4.85 delivered in UK. Choice of hex head or allen head M5 screws. (8mm AF head)

Sometimes the 30mm hex head screws are easier to get in and out.

Comprises of
2 off M5 x 30mm screws
2 off M5 x 16mm screws
4 off M5 spring washers
1 off rubber seal boot.

Edited by leehenty, 23 April 2013 - 09:30 am.

[dmmsta]

The Henty house of stainless does actually make a little kit up for this job.

£4.50 delivered in UK. Choice of hex head or allen head M5 screws. (8mm AF head)

Sometimes the 30mm hex head screws are easier to get in and out.

Comprises of
2 off M5 x 30mm screws
2 off M5 x 16mm screws
4 off M5 spring washers
1 off rubber seal boot.

I'll be in touch next week (post payday )

[dandywarhol]

I was lucky - used a 1/4 drive crosshead/extension/ratchet and cracked back the screws, stripping the unit in place. Good shout on the rubber bitty

[Stratman]

I have just noticed that on cold start up the revs aren't high as they were before. However, she starts and runs no problem so the questions are:- is this likelt to be the fast idle plunger (I guess that will be a yes) but if she starts and runs OK, is there any point in fiddling about with it?

[TKH]

When I had the problem, the revs increase when the bike warmed up. Revving it they would drop and then raise again. If you're going anywhere near for airfilter, etc. it may well be worth giving it a good lube. Mr Henty did a really good kit (don't know if he still does) it replaced the bolts and provided a rubber cover for the mechanism. I think it's covered above on how to diy. Something Yamaha should have done as stock imho.

[leehenty]

 Mr Henty keeps kits in stock. This will be an ongoing problem for the niners, even new ones still leave it open to the elements. Spray the internal pin with ACF50, fit boot kit, forget it.

Edited by leehenty, 20 March 2013 - 01:12 am.

[Stratman]

I am grateful milud. I will have a fiddle in due course when it warms up enough for my fingers not to freeze to the bike. I might try some plus gas around the plunger and the whack with the long bar first though - a lot less kerfuffle!

[TKH]

I am grateful milud. I will have a fiddle in due course when it warms up enough for my fingers not to freeze to the bike. I might try some plus gas around the plunger and the whack with the long bar first though - a lot less kerfuffle!

Mine needed persuading to get it free - after removal. TBH once you have the kit on it covers it up, fit and forget.

[Ronnie]

The Henty house of stainless does actually make a little kit up for this job.

£4.50 delivered in UK. Choice of hex head or allen head M5 screws. (8mm AF head)

Sometimes the 30mm hex head screws are easier to get in and out.

Comprises of
2 off M5 x 30mm screws
2 off M5 x 16mm screws
4 off M5 spring washers
1 off rubber seal boot.

Any chance you could help me source this rather natty bit of kit as I too have this problem.

[leehenty]

no problem, just pm your addy and all that, I'll get one sent out asap.

[Borderraider]

Thanks for the write up, I'll attempt to repair mine tomorrow.
Bikes been garaged since October, fitted battery & eventually got it fired up to find revs wont drop below 2k.

17 years of GS's and not had any such issues ;-)