BS to see this happen on a bike that's only a few years old. I'd be phoning up Yamaha first thing and demanding a new frame.
Suspension Woes Part 2
Started by
Guest_celticbiker_*
, Apr 24 2009 06:41 pm
58 replies to this topic
#22
dandywarhol
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Posted 26 April 2009 - 10:24 pm
And I think Yamaha will say piss off - you haven't checked the operation of the suspension linkage system every 6250 miles and strip and lubricate every 12500 miles as per the manual....................sory to be so blunt, but how many of us do it - hands up, I haven't 
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#23
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Posted 26 April 2009 - 10:36 pm
Actually Dandy, I give it a full check over every 6000 miles when I change the oil.
Thats why this was a bit of a shock cos I did it on Monday just gone and everything was fine.
Thats why this was a bit of a shock cos I did it on Monday just gone and everything was fine.
#24
JBX
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Posted 27 April 2009 - 12:10 am
QUOTE(celticbiker @ Mon 27th Apr 2009, 12:36 AM) <{POST_SNAPBACK}>
Actually Dandy, I give it a full check over every 6000 miles when I change the oil.
Thats why this was a bit of a shock cos I did it on Monday just gone and everything was fine.
Thats why this was a bit of a shock cos I did it on Monday just gone and everything was fine.
Glad you managed to stay on the bike after such a failure !
This is the first time I read about this kind of incident.
IMHO this was due to sized parts (corrosion), and too much stress applied on the rear suspension.
As someone quoted before, one side was already broken, apparently long before.
What do you mean by "full check" ?
Do you remove all suspension & linkage parts, clean, check, grease them, etc, or is it just a functioning check ?
It's not obvious when seeing the pics that a real full maintenance was done, but I may be wrong.
Some TDM850 MkI have had a problem with the frame : a crack on the left hand side, near the swing-arm axis.
Yamaha has never considered the problem, it was usualy solved by welding from the inside.
You may probably have your frame axis support fixed by a good mecanic.
QUOTE(dandywarhol @ Mon 27th Apr 2009, 12:24 AM) <{POST_SNAPBACK}>
And I think Yamaha will say piss off - you haven't checked the operation of the suspension linkage system every 6250 miles and strip and lubricate every 12500 miles as per the manual....................sory to be so blunt, but how many of us do it - hands up, I haven't
I did it at 40.000km :
#25
tdm850rider
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Posted 27 April 2009 - 01:10 am
QUOTE(JBX @ Sun 26th Apr 2009, 08:10 PM) <{POST_SNAPBACK}>
There is the problem... that chain looks way too loose!
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#26
munchkin
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Posted 27 April 2009 - 06:40 am
Man attacking a frame with a grinder. I like your style!
Bloody stupid we need to dismantle and grease a bike suspension in the 21st century just to make it last more than 20k miles tho.I remember doing that with Mini's etc in the seventies but you've never to touch them now so bikes might catch up, lol !
I really need some pics or summat on my posts or I'm in danger of seeming boring,would pic of me in Belstaff jacket and flatcap liven it up ?
Bloody stupid we need to dismantle and grease a bike suspension in the 21st century just to make it last more than 20k miles tho.I remember doing that with Mini's etc in the seventies but you've never to touch them now so bikes might catch up, lol !
I really need some pics or summat on my posts or I'm in danger of seeming boring,would pic of me in Belstaff jacket and flatcap liven it up ?
#27
cortez
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Posted 27 April 2009 - 06:59 am
I remember reading of a similar incident here in Oz some years ago (on Ulysses site?), bike was insured and was written off by the insurance company.
#28
wicklamulla
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Posted 27 April 2009 - 10:20 am
I very much doubt Yamaha will be interested as the bike is fairly old now. Ya gotta love MKI's & MKII's with no suspension linkage........pity the frames crack though !
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#29
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Posted 27 April 2009 - 10:59 pm
QUOTE(wicklamulla @ Mon 27th Apr 2009, 11:20 AM) <{POST_SNAPBACK}>
Ya gotta love MKI's & MKII's with no suspension linkage........pity the frames crack though !
The bottom of the shock shears too! I had it happen to the original shock. Got it repaired at college (full access to bike workshop on account of me doing City & Guilds Motorcycle Maintenance course). It broke again some time and many miles later. Replaced with a low mileage example (approx. 11000) - still going strong.
I only knew the shock had broken the first time because we were doing practice MOTs on our bikes, and I'd lifted the back of the bike up...the rear wheel stayed put
The second time was after riding home from work - I got the feeling after going over a pothole that something wasn't right, nothing drastic, but one of those gut feelings you get.I love the Mk1 - it didn't try to kill me!...twice!
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#30
ChrisG
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Posted 28 April 2009 - 09:50 pm
The 850 shock shearing is due to the bottom bush seizing. Block the hole in the swing arm to stop it getting covered in crap and take the bush out and grease it every so often. I believe a couple of people on here have even drilled the shock and fitted a grease nipple.
1992 Mk1, 76k miles, Hagon springs, MTC exhaust, 4½ gears Gone now 
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#31
JBX
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Posted 29 April 2009 - 12:02 am
QUOTE(ChrisG @ Tue 28th Apr 2009, 11:50 PM) <{POST_SNAPBACK}>
The 850 shock shearing is due to the bottom bush seizing. Block the hole in the swing arm to stop it getting covered in crap and take the bush out and grease it every so often. I believe a couple of people on here have even drilled the shock and fitted a grease nipple.
That reminds me that Yamaha fitted grease nipples everywhere on the XTZ750 rear suspension, plus a rubber protection.
Shame that they didn't keep it on the TDM.
On the other hand, it's not that common to own a grease pump at home, with the right nipple adapter - there are different ones...
(sounds funny)
Edited by JBX, 29 April 2009 - 12:04 am.
#32
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Posted 13 June 2009 - 10:10 pm
Right folks here's an update.
Yamaha basically said 'Thanx for the information, we have passed it on to our technical department who will contact you in due course'.
Now for the interesting stuff.
Seeing as how I live in Wales and work in Bristol I didn't want and couldn't really afford to be without my bike for too long. So I gave it 3 weeks and a lot of thought and came up with this solution.
For those of you who have a centre stand on their 9er you will be aware that it is mounted on a 10mm thick plate that is bolted to the underside of the frame, I decided to utilise this to make my own suspension mounts.
First I took some measurements and then removed the remains of the two lugs from the frame with an angle grinder.
And after taking some more measurements I programmed (using Lantek expert) and laser cut the parts I needed.
Then tacked and welded it all together
And checked the range of movement. At full extension the linkage normally sits just below the horizontal, so I made sure I had a range from this
To this
If you can't picture it yet, this is how it will sit in the bike with the bolts going up from underneath into the frame.
A quick coat of a zinc based primer an onto the bike
450 miles (2 up) later and tested on some pretty rough roads and fast (90mph) chicken strip removing corners and all is working well and holding together OK
So folks, tell me am I winning in the 'who can bodge a 9er the best' competition yet?
Yamaha basically said 'Thanx for the information, we have passed it on to our technical department who will contact you in due course'.
Now for the interesting stuff.
Seeing as how I live in Wales and work in Bristol I didn't want and couldn't really afford to be without my bike for too long. So I gave it 3 weeks and a lot of thought and came up with this solution.
For those of you who have a centre stand on their 9er you will be aware that it is mounted on a 10mm thick plate that is bolted to the underside of the frame, I decided to utilise this to make my own suspension mounts.
First I took some measurements and then removed the remains of the two lugs from the frame with an angle grinder.
And after taking some more measurements I programmed (using Lantek expert) and laser cut the parts I needed.
Then tacked and welded it all together
And checked the range of movement. At full extension the linkage normally sits just below the horizontal, so I made sure I had a range from this
To this
If you can't picture it yet, this is how it will sit in the bike with the bolts going up from underneath into the frame.
A quick coat of a zinc based primer an onto the bike
450 miles (2 up) later and tested on some pretty rough roads and fast (90mph) chicken strip removing corners and all is working well and holding together OK
So folks, tell me am I winning in the 'who can bodge a 9er the best' competition yet?
#33
ChrisG
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Posted 14 June 2009 - 07:50 am
QUOTE(celticbiker @ Sat 13th Jun 2009, 11:10 PM) <{POST_SNAPBACK}>
So folks, tell me am I winning in the 'who can bodge a 9er the best' competition yet?
We'll have to make you an honary Mk1 rider if you keep this up
Good bit of work. I'd love to have access to the facilities to do that kind of stuff.
1992 Mk1, 76k miles, Hagon springs, MTC exhaust, 4½ gears Gone now
2009 900 abs, 42k miles, Yamaha heated grips, double bubble screen, R&G crash bungs, scottoiler, Autocom, 1500 lumen LED spotlights.
#34
TDMick
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Posted 14 June 2009 - 08:08 am
Thats that sorted then 
Probly worth sticking in the KB
Mick
Probly worth sticking in the KB
Mick
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#35
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Posted 14 June 2009 - 05:42 pm
QUOTE(ChrisG @ Sun 14th Jun 2009, 08:50 AM) <{POST_SNAPBACK}>
We'll have to make you an honary Mk1 rider if you keep this up
I appreciate the sentiment Chris but unfortunately all the bits on my bike belong to me, so I don't qualify
Good bit of work. I'd love to have access to the facilities to do that kind of stuff.
Your bike would never be on the road if you had that kind of equipment
I appreciate the sentiment Chris but unfortunately all the bits on my bike belong to me, so I don't qualify
Good bit of work. I'd love to have access to the facilities to do that kind of stuff.
Your bike would never be on the road if you had that kind of equipment
This is my playground and some of my toys Chris.
SNC00043.JPG 185.64KB
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59 downloadsQUOTE(TDMick @ Sun 14th Jun 2009, 09:08 AM) <{POST_SNAPBACK}>
Thats that sorted then
Probly worth sticking in the KB
Mick
Thanx Mick but I doubt it will happen to anyone else, just me and my luck or lack thereof
Probly worth sticking in the KB
Mick
Thanx Mick but I doubt it will happen to anyone else, just me and my luck or lack thereof
#36
Daveb
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Posted 14 June 2009 - 05:51 pm
Nice toys CB, 
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#37
dapleb
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Posted 14 June 2009 - 05:51 pm
QUOTE(ChrisG @ Sun 14th Jun 2009, 08:50 AM) <{POST_SNAPBACK}>
I'd love to have access to the facilities to do that kind of stuff.
I'd love to have those welding skills.
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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.
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#38
ChrisG
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Posted 14 June 2009 - 05:57 pm
QUOTE(celticbiker @ Sun 14th Jun 2009, 06:42 PM) <{POST_SNAPBACK}>
all the bits on my bike belong to me, so I don't qualify
Ooooo, harsh...
...but fair
QUOTE(dapleb @ Sun 14th Jun 2009, 06:51 PM) <{POST_SNAPBACK}>
I'd love to have those welding skills.
Yeah, that too. Mate of mine did a nightschool welding course recently and reckoned it was a pretty good, though he's still not bought a welder yet.
1992 Mk1, 76k miles, Hagon springs, MTC exhaust, 4½ gears Gone now
2009 900 abs, 42k miles, Yamaha heated grips, double bubble screen, R&G crash bungs, scottoiler, Autocom, 1500 lumen LED spotlights.
#39
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Posted 14 June 2009 - 06:36 pm
CB - If I was you I'd patent it pretty quick, then you can get royalties off Yam for every one sold when every other 900 frame cracks
I take it, its made from Al?
I'd keep on eye on it for stress failures
Might be better to make it out of steel.
You don't know what kind of stress is acting on it, and Al can be funny stuff
Otherwise good job, and I would not consider it a bodge, but 'adapt and overcome' your previous situation.
I see you have a Amada machine tools - they're UK HQ is in Kidderminster, just down the road from me, not that you need to know that
I take it, its made from Al?
I'd keep on eye on it for stress failures
Might be better to make it out of steel.
You don't know what kind of stress is acting on it, and Al can be funny stuff
Otherwise good job, and I would not consider it a bodge, but 'adapt and overcome' your previous situation.
I see you have a Amada machine tools - they're UK HQ is in Kidderminster, just down the road from me, not that you need to know that
Edited by GuyGraham, 14 June 2009 - 06:39 pm.
#40
dandywarhol
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