Having seen various YouTube clips on replacing the timing chain etc. and the brilliant resource database that is the JBX site, I've done enough spannering to undertake most of this myself but, you know, two little nippers and a Norwegian carport in January represent a strong NAY vote. So I'll have to pay to make it go away.
Downshifting Issue In The Cold
Started by
Tor
, Jan 12 2022 11:17 am
48 replies to this topic
#42
leehenty
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Backstreet Mechanikin'
- Location:Rushden Northamptonshire.
- TDM model: 2002
Posted 17 January 2022 - 11:53 am
Just remember the inlet camshaft will compress valves as its put in. Therefore the cap tightening sequence is critical. The tiny dot on the shaft near the sprockets must be uppermost. You will need access to a 9.48 shim kit.
2002 900 silver,oil pressure switch with brass 90 degree conversion, RG fork protectors. Wilburs custom made rear Shock with remote hydraulic preload and RG shocktube, Wilburs front springs. Scotoiler with a custom made swing arm delivery unit. Silicone radiator hoses.BMW 1150 handguards with Touratech extensions, Carbon Fibre yoke cover and fender extenda, MRA flip screen, Yamaha Engine bars, SW Motech Centre Stand, Kappa wingrack three box Luggage with E21's as option from the K960 boxes, Zumo 660 satnav on Touratech mount, Led Voltage monitor, Baglux tank cover, Clear LED Rear light, Aux LED brake light, BikeVis bullet LED's under front nose,Stainless rear axle nut, stainless chain adjusters, stainless wheel spacers front and rear, Probolt Polished Stainless Flanged Hex engine screws, Polished stainless fairing screws, stainless disc bolts. Titanium brake pins front, Probolt Titanium Flanged Hex Front Caliper Bolts & Rear caliper slide pins Adventure Spec Tool tube under rear rack, left and right sides with custom alloy mounts.<p>Top Sellerie double gel pad seat. Carbon Fibre inner dash and side infill panels. Anodised black alloy swingarm pivot bolt covers and footpegs, Nano II Gear indicator.
#43
MipeTDM
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really likes Carpe
- TDM model: 1997
Posted 31 January 2022 - 03:32 pm
Just remember the inlet camshaft will compress valves as its put in. Therefore the cap tightening sequence is critical. The tiny dot on the shaft near the sprockets must be uppermost.
Actually I found when performing a valve adjustment on my 97' TDM850, that it is possible to mount the camshaft with the dot off-center (but as close as possible) and no valves being compressed when tightening the caps. And next rotate the camshaft manually (with some effort) towards the position with the dot on top as a second step (compressing the valves).
#44
Tor
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seems to like Carpe
- TDM model: 2003
Posted 26 February 2022 - 06:11 pm
So, I solved the downshift stickiness. It was indeed the lever pivot, where the grease had caked up and there wasn’t a lot of it anyway. It didn’t snap back fully until warm, fooling me as long as it still felt nice and springy. So, some alcohol and wire brushing, fresh lithium grease plus lubing up of the connecting rod ball joints and the gear shifts are lickety slick again. I tend to forget the bike is almost 18 years old, low miles doesn’t mean new 
I’m keeping this in mind for the next job, which will be cleaning and lubing the trailing arm and suspension linkage. Thanks for all your feedback gents.
#45
Studley Ramrod
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Monkey Boys Monkey
- Location:HELLO ! I'm in the Library...Notts
- TDM model: 1993
Posted 27 February 2022 - 03:01 pm
Result 
Mk2a 2000 in Silver. Top end Refurb @ 41100 miles, Scottoiler, Renthal Road High Bars, Up & Back Bar Risers, Bellypan, DL650 Handguards, Capt. Picard Bar Ends, House of Henty SS Wheel spacers, New Seat Cover Fitted. 58 MPG !! Now owned by chrisbee ! Studley's mk2a Bloggerydoodaah ! Photos of my first MK1 Photos of my MK2a TPLQHCSRSFC No. 1 Fan
#46
fixitsan
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Carpe Citizen
- Location:West Lothian
- TDM model: 2003
Posted 27 February 2022 - 08:51 pm
So, I solved the downshift stickiness. It was indeed the lever pivot, where the grease had caked up and there wasn’t a lot of it anyway. It didn’t snap back fully until warm, fooling me as long as it still felt nice and springy. So, some alcohol and wire brushing, fresh lithium grease plus lubing up of the connecting rod ball joints and the gear shifts are lickety slick again. I tend to forget the bike is almost 18 years old, low miles doesn’t mean new
Mine used to do it, and because of the very high mileage (110,000miles) the gear lever hole had been worn wider by the steel pivot, you would think the loose-ness would help too but, the bigger gap just attracts bigger pieces of dirt !
I used very thin stainless steel shim tape, 0.03mm thick, to make a 'temporary' sleeve for the pivot bolt, and 2 years later and with an annual greasing it is just as smooth as ever.
I suppose I really ought to change that lever one day. 
Edited by fixitsan, 27 February 2022 - 09:16 pm.
900 with better bits. Owes me nothing, Makes me smile
#47
leehenty
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- Supporting Member(thanks)
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Backstreet Mechanikin'
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- TDM model: 2002
Posted 28 February 2022 - 10:36 am
My lever wore slightly and became slightly sloppy so I made a brass bush with a stainless screw slightly oversized to take up the gap.
2002 900 silver,oil pressure switch with brass 90 degree conversion, RG fork protectors. Wilburs custom made rear Shock with remote hydraulic preload and RG shocktube, Wilburs front springs. Scotoiler with a custom made swing arm delivery unit. Silicone radiator hoses.BMW 1150 handguards with Touratech extensions, Carbon Fibre yoke cover and fender extenda, MRA flip screen, Yamaha Engine bars, SW Motech Centre Stand, Kappa wingrack three box Luggage with E21's as option from the K960 boxes, Zumo 660 satnav on Touratech mount, Led Voltage monitor, Baglux tank cover, Clear LED Rear light, Aux LED brake light, BikeVis bullet LED's under front nose,Stainless rear axle nut, stainless chain adjusters, stainless wheel spacers front and rear, Probolt Polished Stainless Flanged Hex engine screws, Polished stainless fairing screws, stainless disc bolts. Titanium brake pins front, Probolt Titanium Flanged Hex Front Caliper Bolts & Rear caliper slide pins Adventure Spec Tool tube under rear rack, left and right sides with custom alloy mounts.<p>Top Sellerie double gel pad seat. Carbon Fibre inner dash and side infill panels. Anodised black alloy swingarm pivot bolt covers and footpegs, Nano II Gear indicator.
#48
Tor
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seems to like Carpe
- TDM model: 2003
Posted 28 February 2022 - 11:18 am
Yeah, I can see how this can become an issue in the long run but I'm aware of this now and will keep it greased up. I've got some bits of super-fine brass sheet for this and similar uses.
Riding to work this morning in the (continuing, eternal, sack-aching) cold I had sweet shifting action all the way. Yay.
#49
Snowbird
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Just won't go.
- Location:Often on another planet, but mostly south Cambs. (St.Neots)
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Posted 28 February 2022 - 11:43 am
A cheap fix is the best fix, nice one.
Current toys: '99 XT600E, 2000 4TX, '82 Princess 30DS (where the username comes from), No longer a '03 Fazer thou.
Save the planet, it's the only one with beer!
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