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What's Going On With My Mirrors And Levers?


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#1 Tor

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Posted 11 November 2021 - 09:47 am

With brake and clutch levers set the at the same angle, the mirror stems don't line up, by a lot. I'm thinking my brake lever bracket might have been replaced with something not TDM, also since the micro switch needs some braking force applied before it actuates, regardless of reach adjustment. And the fastening bolts are different. Can anyone see what the problem is?

 

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#2 fixitsan

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Posted 11 November 2021 - 08:27 pm

I think mine's the same


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#3 Tor

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Posted 12 November 2021 - 10:48 am

I think mine's the same

Hmm. Also the brake micro switch?



#4 steve27bha

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Posted 12 November 2021 - 11:51 am

On my 2008 model I have a similar effect with the levers.

 

pic #1 - My clutch lever and perch are turned down/forward more than yours, and more than my brake lever.

pic #2 - I measure the angle between mirror mount and clutch perch at 90° - similar to mine.

pic #3 - angle 100 - 105° - similar to mine.

So either the levers or mirrors have to be out of line, by 10 - 15°.

 

#4 & #6 - look like mine.

#5 - can't comment - I have handguards in the way.

 

My mirror stem bases are not parallel - the left leans forward more than the right. It doesn't bother me or even look noticeable since I have the controller for my Sena 10U intercom zip-tied around it.

Maybe mine is less obvious because I have black plastic plugs in the top of the mirror bases covering the shiny Allen bolt heads. OE AFAIK.

I have recently found my phone has an angle measuring function and would use it to report on the details but my handguards & controller get in the way.

 

My brake light microswitch clicks before the lever gets resistance, in other words before the brakes apply - as it should. This seems the only fault to me- and something you should investigate. Perhaps the switch is not fitted correctly?

 

HTH


Edited by steve27bha, 12 November 2021 - 12:01 pm.

TDM900A 2008/09 in use, with     gallery_179098_391_770.jpg sml_gallery_179098_391_1145.jpg  gallery_179098_391_1206.jpg gallery_179098_391_253.jpg gallery_179098_391_82.jpg gallery_179098_391_725.gif gallery_179098_391_797.jpg gallery_179098_391_1396.jpg gallery_179098_391_501.jpg gallery_179098_391_316.jpg  gallery_179098_391_1768.jpg gallery_179098_391_106.jpggallery_179098_391_2170.jpg gallery_179098_391_1373.jpg

 

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#5 fixitsan

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Posted 13 November 2021 - 12:33 pm

Hmm. Also the brake micro switch?

No not the switch, that should be a concern.

 

I'm currently wrestling (probably making it more difficult than needs to be) with a similar problem on my KTM620, where someone has mixed and matched the lever with a master cylinder from the wrong year, so I get full braking force with just a small movement of the lever before the brake light is actuated.

 

I took the lever off and noticed the master cyl plunger moved out quite a long way, making it difficult to refit the same lever. I remember some people who fitted cheap chinese 'shorty' levers to various bikes reported front brakes locking up, and it was all because the lever didn't let the plunger of the master cyl extend fully outwards, eventually after a few pulls on a ride the pads were held against the disk, overheating and then locking.

 

So although the lever looks standard has it been replaced by a poor quality copy which isn't machined to the same tolerances as the original ?

 

 

EDIT, Heres a GSXR owner reporting the issue https://www.gsxr.com...cking-up.92068/


Edited by fixitsan, 13 November 2021 - 12:36 pm.

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#6 PICARD

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Posted 14 November 2021 - 10:55 am

Yep same issue on the rear brake of a different bike. In my case the the piston was sticking in the master cylinder. The piston needs to fully return, to line up a "pressure relief" hole. If it doesn't for any reason, including the lever profile being incorrect, pressure will continue to be built up and applied to the pads. On positive note, I thought the rear disc looked great in cherry red!!
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#7 Tor

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Posted 15 November 2021 - 08:38 am

On my 2008 model I have a similar effect with the levers.

...

My brake light microswitch clicks before the lever gets resistance, in other words before the brakes apply - as it should. This seems the only fault to me- and something you should investigate. Perhaps the switch is not fitted correctly?

Thanks for this considered response! Yeah, I need to get new covers for the stem adjusters to make it less of an annoyance (I can't deal with missing stuff). I'm curious why Yam let this alignment thing pass, unless it's intended for improved near-field visibility on the RHS but ... what about LHD versus RHD? And the different fasteners? Feels like an afterthought, oversight or whatever. Anyway.

 

So I'll investigate the micro switch, and whether the pads are binding at all, plus check the state of the fluid. The bike will be maneuvered indoors to have some goodies fitted, hopefully this week. Or whenever my Beowulf cans arrive...



#8 fixitsan

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Posted 15 November 2021 - 11:22 am

Thanks for this considered response! Yeah, I need to get new covers for the stem adjusters to make it less of an annoyance (I can't deal with missing stuff). I'm curious why Yam let this alignment thing pass, unless it's intended for improved near-field visibility on the RHS but ... what about LHD versus RHD? And the different fasteners? Feels like an afterthought, oversight or whatever. Anyway.

 

So I'll investigate the micro switch, and whether the pads are binding at all, plus check the state of the fluid. The bike will be maneuvered indoors to have some goodies fitted, hopefully this week. Or whenever my Beowulf cans arrive...

It's possible it was a parts bin issue, where they already had one clutch perch or throttle side perch for a different bike and it was a close enough match ?


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#9 Tor

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Posted 15 November 2021 - 11:47 am

It's possible it was a parts bin issue, where they already had one clutch perch or throttle side perch for a different bike and it was a close enough match ?

Would make sense for the final production run, but in 2004?

Anyhow, it seems it is what it is, so I'll just live with it. Ordered some perch caps locally now, so the bike will be complete  :)


Edited by Tor, 15 November 2021 - 11:53 am.


#10 fixitsan

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Posted 15 November 2021 - 03:13 pm

Would make sense for the final production run, but in 2004?

Anyhow, it seems it is what it is, so I'll just live with it. Ordered some perch caps locally now, so the bike will be complete  :)

Mine's a 2004 reg, but built in 2002, and is similar to yours.

We'd have to a do a parts search with Fowlers or a Yamaha dealer to see if it's a match for another bike too


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#11 steve27bha

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Posted 15 November 2021 - 05:55 pm

....And the different fasteners?....

I'm grateful the LHS perch is secured by a normal hex-head bolt, not a recessed Allen head, so I can mount my HotGrips controller under it:-

 

http://www.carpe-tdm...lery&image=1614


Edited by steve27bha, 15 November 2021 - 05:57 pm.

TDM900A 2008/09 in use, with     gallery_179098_391_770.jpg sml_gallery_179098_391_1145.jpg  gallery_179098_391_1206.jpg gallery_179098_391_253.jpg gallery_179098_391_82.jpg gallery_179098_391_725.gif gallery_179098_391_797.jpg gallery_179098_391_1396.jpg gallery_179098_391_501.jpg gallery_179098_391_316.jpg  gallery_179098_391_1768.jpg gallery_179098_391_106.jpggallery_179098_391_2170.jpg gallery_179098_391_1373.jpg

 

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#12 Tor

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Posted 16 November 2021 - 02:49 pm

I'm grateful the LHS perch is secured by a normal hex-head bolt, not a recessed Allen head, so I can mount my HotGrips controller under it:-

 

http://www.carpe-tdm...lery&image=1614

Yeah, I've got a set to go on as well so that's a point.



#13 TKH

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Posted 22 November 2021 - 03:28 pm

I'm grateful the LHS perch is secured by a normal hex-head bolt, not a recessed Allen head, so I can mount my HotGrips controller under it:-

 

http://www.carpe-tdm...lery&image=1614

 

My right hand side is also hex bolts. Don't know what year they were changed.




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