My TDM is 9 years old, I have it 2 years and clocked up 40,000klms since I got it (Over 90K on the clock now). The most I have ever done is a visual inspection of the linkage from the outside.
So inspired by some info on Carpe TDM, I decided to tackle the linkage today.
I go stuck into a full service, oil, plugs, filters, cleaning calipers and eventually after much procrastination I got started on the linkage.
One of the main points, you need a centre stand or some kind of a bike lift, you can't use a rear paddock stand as you have to take the weight off the back suspension.
Tools needed: sizes 14 and 17 sockets and spanners.
A puller (You will see my bodge later)
Some good cleaner (I used Kerosene)
Grease
Gloves (It's a very dirty job)
Toothbrush and rags
(If you can, I would suggest power'washing the linkage befor starting, I didn't )
So, bike on centre stand.
Support the back wheel
Undo the three nuts seen in this photo and the one at the top of the dogbones in the next photo. The ones on the top and bottom of the dogbones are size 17, the others are size 14. You may need to put a spanner on the back of then if the bolts start turning.
All four bolts should pull out from the right hand side easily. Dogbones will come off and the linkage will be hanging from the two lugs on the frame, even though the bolt is out.
Here's the thing, the holes in the lugs are fifferent sizes. One is the size of the bolt, the other is larger, cos there is a sleeve that pushes in through the larger side and this can get stuck.
So the key to getting the sleeve out is not a lump hammer, you could break off the lugs on the frame and you are in big trouble then.
To get them out you need a puller. After a quick chat with a looney mate. I nipped to the hardware and got an M6 rawl bolt and some different sized washers. I used this to pull the sleeve out the right hand side of the bike. The reason for the different sized washers are to leave enough space for the sleeve to pull out through the holes in the big washers.
You can see the "puller", washers and sleeve in this photo
So here is everything cleaned up externally and ready to clean the bearings. Clean externally with a paintbrush and Kerosene, while the bearing sleeves are still in place to keep crud from getting into the bearings.
Then remove the three sleeves and clean and inspect the bearings. To clean them, I used a clean rag wrapped around the head of a toothbrush and dampened slightly with Kerosene. All bearings looked in good condition and sleeves turned smoothly. Then cleaned and dried again with a dry part of the cloth and packed all of the bearings with clean grease. (I used Maxol EP2 grease)
Not forgetting to do the same with the bearings on the swingarm
Then re-assemble everything
Jobs a good-un
Edited by FrDougal, 03 March 2012 - 06:24 pm.