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Rear Shock / Suspension Frame Bush Removal


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#1 Richardhuddleston

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Posted 30 November 2019 - 07:58 pm

2004 TDM900.

Sorry but I can't find anything on the forum about this except grinding it out.

Some guys reckon a plastic wall plug or Rawlbolt works, but what's the "official" way - with a bearing puller?  All the other mounts slipped out dead easy.

BTW the top shock mounting's easy enough from unedr the bike, given the right tools.


Edited by Richardhuddleston, 30 November 2019 - 07:59 pm.


#2 dablik

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Posted 30 November 2019 - 08:10 pm

Grinding out was only done in a few cases when the sleeve was siezed, mine being one of them, you wont get a puller in as the sleeve is right up against the blind hole end (albeit with a tiny hole there) so an appropriate sized rawl/anchor bolt or if it's free enough a plastic wall plug but if you have corrosion inside your gonna be grinding and i believe the sleeve is case hardened.... be careful wacking it from the blind side cos if it is siezed you may well end up breaking the aluminium..

 

Dunno what the official way is meant to be sorry..

 

Edit...you could fashion your own puller to maybe extract it out, into a larger size socket perhaps..


Edited by dablik, 30 November 2019 - 08:12 pm.

Bigred mk1 R1 Calipers- Braided lines- Givi wing rack-Crash bungs- Hi vis bullets-PR2's- and a hoot to ride.

Quad 900 Silver Laser duo tech pipes-Scott oiler-Engine crash bars- Radiator mounted see me ring LED's-Datatool system 3 alarm -Centre stand- Extender fender-Renthal bars-Handle bar risers-Mirror extenders-BMW GS Handgaurds-Acumen uprated horn & Nautilus-Stainless steel Radiator guard-Givi wing rack-OEM screen-Yammy touring screen-MRA Vario-MRA Double bubble cut down for fast as fk riding-Tiger screen-Tank protector-Stomp grip panels-Optimate lead

 

1991 MK1 in need of some TLC watch this space  :) Sorted and on the Road Mick :P :P it's the bike that Jack built ;)


#3 Richardhuddleston

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Posted 30 November 2019 - 08:15 pm

Does this mean the bush doesn't go all the way through, it stops short of the RH end of the mount, so you couldn't drift it out even if you wanted to?

(If so for God's sake why (need I ask!))?



#4 dablik

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Posted 30 November 2019 - 08:25 pm

Does this mean the bush doesn't go all the way through, it stops short of the RH end of the mount, so you couldn't drift it out even if you wanted to?

(If so for God's sake why (need I ask!))?

 

Yep that's correct, it butts right up on the RH side, i suppose once it's off you could sort that as it's a stupid design, your's being a 2004 it might be stuck inside if it was'nt done at least annually or you might be lucky, it's a pig of a job and luckily i had a helping hand with mine, once sorted it just needs an annual grease up, gotta be done though.

 

Edit,, you may be able to drift it out from the RH side through the bolt hole BUT it's chancey, worse case replace the whole linkage and service annually.

 

It's chancey to drift because the linkage is fixed to the swing arm and if that cracks you'll be looking to replace the whole swing arm then.


Edited by dablik, 30 November 2019 - 08:29 pm.

Bigred mk1 R1 Calipers- Braided lines- Givi wing rack-Crash bungs- Hi vis bullets-PR2's- and a hoot to ride.

Quad 900 Silver Laser duo tech pipes-Scott oiler-Engine crash bars- Radiator mounted see me ring LED's-Datatool system 3 alarm -Centre stand- Extender fender-Renthal bars-Handle bar risers-Mirror extenders-BMW GS Handgaurds-Acumen uprated horn & Nautilus-Stainless steel Radiator guard-Givi wing rack-OEM screen-Yammy touring screen-MRA Vario-MRA Double bubble cut down for fast as fk riding-Tiger screen-Tank protector-Stomp grip panels-Optimate lead

 

1991 MK1 in need of some TLC watch this space  :) Sorted and on the Road Mick :P :P it's the bike that Jack built ;)


#5 leehenty

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Posted 30 November 2019 - 08:32 pm

Having done this particular job more than once, a liberal coating of plus gas or any graphited easing oil and application of heat from a heat gun will help. You can grind it out with a dremel type tool but you only have to release the part in the lefthand eye viewed from rear of bike. Be very careful not to go outside the diameter of the bush into the alloy as you can't put metal back.

Take it out every year after replace it. Rawl bolt and a tube and washer often works.

Annoyingly, the bush is case hardened in the hole as well or the normal method would be to tap a thread in it to draw on. Why it's not just a longer bush through two holes the same size is beyond me.


Edited by leehenty, 01 December 2019 - 10:47 am.

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#6 Favs

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Posted 01 December 2019 - 12:00 am

M6 rawlbolt is your first action  :good:


Single-handedly reviving the Wave.

 

2008 reg. Black TDM 900 ABS

 

 

 


#7 Riggers

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Posted 01 December 2019 - 09:24 am

There's lots of bedtime  reading on this here....

 

http://www.carpe-tdm...showtopic=33859

 

Including some piccies wot I did.

 

Riggers.



#8 Richardhuddleston

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Posted 14 January 2020 - 06:41 pm

2004 TDM900.

Sorry but I can't find anything on the forum about this except grinding it out.

Some guys reckon a plastic wall plug or Rawlbolt works, but what's the "official" way - with a bearing puller?  All the other mounts slipped out dead easy.

BTW the top shock mounting's easy enough from unedr the bike, given the right tools.

 

Yes indeedy, one pig of a job, even by Jap bike standards.  Thanks for all suggestions.

The plastic Rawlplug method failed immediately, and the first couple of masonry plugs either pulled themselves back out or chewed themselves up when I tried the socket-as-a-puller method.  Seems the bush inner is so hard and smooth the Rawl can’t get a grip.

Eventually I found a good fit at Toolstation (97063, see photo) that did grip and after several separate attempts at the heat-Plusgas-tap method it eventually came out.  Tried the freeze spray but I’m not convinced that helped.  I did notice that it eventually freed when I put the blowtorch on the end of the Rawl rather than the alloy bracket – the opposite of what I’d expect.  Unless it was coincidence.  Obviously make sure you don’t set fire to the Plusgas or anything else (I’m not convinced a hot air gun would have worked).  I was surprised how little corrosion there was on the bush and hole when I eventually got it out.

Tips: it’s worth removing at least the RHS silencer to give room to swing the 3/4lb hammer.  I used a sawn-off M10 bolt as a drift.  I’ve filed a small notch in the RHS frame bracket to give access to a punch drift next time, it’s a very snug fit even with a brand new bush and cleaned-out hole.  Also bear in mind that the swinging arm bearings are not both the same, left is 2525Z right is 2515Z.

If anyone wants a Rawlbolt I’ve got some left, drop me a line.Attached File  Rawl.jpg   2.04MB   0 downloads



#9 dablik

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Posted 15 January 2020 - 10:31 am

Good job, mine was a barstard as well, luckily i had the master to help sort it out which involved a fair amount of grinding, an annual lube will keep it corrosion free now :good:


Bigred mk1 R1 Calipers- Braided lines- Givi wing rack-Crash bungs- Hi vis bullets-PR2's- and a hoot to ride.

Quad 900 Silver Laser duo tech pipes-Scott oiler-Engine crash bars- Radiator mounted see me ring LED's-Datatool system 3 alarm -Centre stand- Extender fender-Renthal bars-Handle bar risers-Mirror extenders-BMW GS Handgaurds-Acumen uprated horn & Nautilus-Stainless steel Radiator guard-Givi wing rack-OEM screen-Yammy touring screen-MRA Vario-MRA Double bubble cut down for fast as fk riding-Tiger screen-Tank protector-Stomp grip panels-Optimate lead

 

1991 MK1 in need of some TLC watch this space  :) Sorted and on the Road Mick :P :P it's the bike that Jack built ;)


#10 Favs

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Posted 15 January 2020 - 05:06 pm

It''s time to apply mine now............ ;)


Single-handedly reviving the Wave.

 

2008 reg. Black TDM 900 ABS

 

 

 


#11 wicklamulla

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Posted 16 January 2020 - 09:27 am

Good job, mine was a barstard as well, luckily i had the master to help sort it out which involved a fair amount of grinding, an annual lube will keep it corrosion free now :good:

 

It''s time to apply mine now............ ;)

 

 

OMG you two getta a room!


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 !

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#12 dablik

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Posted 16 January 2020 - 09:44 am

Ya just jealous Ken :P


Bigred mk1 R1 Calipers- Braided lines- Givi wing rack-Crash bungs- Hi vis bullets-PR2's- and a hoot to ride.

Quad 900 Silver Laser duo tech pipes-Scott oiler-Engine crash bars- Radiator mounted see me ring LED's-Datatool system 3 alarm -Centre stand- Extender fender-Renthal bars-Handle bar risers-Mirror extenders-BMW GS Handgaurds-Acumen uprated horn & Nautilus-Stainless steel Radiator guard-Givi wing rack-OEM screen-Yammy touring screen-MRA Vario-MRA Double bubble cut down for fast as fk riding-Tiger screen-Tank protector-Stomp grip panels-Optimate lead

 

1991 MK1 in need of some TLC watch this space  :) Sorted and on the Road Mick :P :P it's the bike that Jack built ;)


#13 wicklamulla

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Posted 16 January 2020 - 10:04 am

Ya just jealous Ken :P

 

 

menage a trois...?  I cud be bitched up by 2 9er pilots.


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

post-1-1150550733.gifpost-1-1150550726.gifpost-1-1150559830.gif


#14 Rallyist

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Posted 16 January 2020 - 04:29 pm

Blimey I am not going CAMPing anywhere with you lot :hide: :rotflmmfao:


For a challenging summer try the

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#15 AliG

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Posted 27 January 2020 - 02:56 pm

Started mine yesterday and picked up a plug from B&Q (their own brand Diall) and would you believe it? Damm thing is slightly too big to fit inside the collar. Be warned. Will have to go back to it when I get the Rawlbolt. Ali


2004 900 - Blue with lots of goodies

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