Jump to content


Photo
- - - - -

Tdm Skips Under Load


  • Please log in to reply
258 replies to this topic

#41 openroad

openroad

    Carpe fan

  • Member
  • Pip
  • 175 posts
  • Location:llandybie
  • TDM model: 1994

Posted 05 June 2012 - 06:36 am

sounds like we will have a similar winter job t do. oh the joys of biking


#42 Studley Ramrod

Studley Ramrod

    Monkey Boys Monkey

  • Root Admin(A)
  • PipPipPipPipPipPipPipPip
  • 19,202 posts
  • Location:HELLO ! I'm in the Library...Notts
  • TDM model: 1993

Posted 05 June 2012 - 10:50 am

QUOTE(alexk243 @ Tue 5th Jun 2012, 12:46 AM) <{POST_SNAPBACK}>
haha yea I have been just skipping 3rd for the most part. What parts do I need to fix this issue?


That's quite a loaded question there Alex. Apart from replacing the damaged 3rd gears, either with new or good used parts, the job involves stripping the engine down fully and splitting the crankcase halves.
Soooooo, you'd be looking at replacing all the gaskets and o rings and you'd also need a rotor puller and a clutch holding tool along with a few other items such as large diameter sockets.

Have a look at my mk2a bloggerydoodaah (link below) to get an idea of the job at hand as that's exactly what I did on my bike.

I would also do a top end refurb at the same time.

Another (easier) alternative would be to buy a good bottom end and swap it over and do a top end refurb.

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


#43 alexk243

alexk243

    Carpe groupie

  • Member
  • PipPip
  • 230 posts
  • Location:Northwest Suburbs, Illinois, USA
  • TDM model: 1992

Posted 26 August 2012 - 03:56 pm

Well I am having trouble finding any bottom ends or other parts for this bike. Also the bike is now popping out of 3rd and down to second... wasnt doing that before. I am just skipping from 2nd to 4th right now, but I would like to get it fixed this winter.

1992 Yamaha TDM 850
2006 BMW F650GS

 

My Website/Blog with Different Project Write Ups


#44 TYREDNGRUMPEE

TYREDNGRUMPEE

    has been here 4ever

  • Member
  • PipPipPipPipPipPipPipPip
  • 1,627 posts
  • TDM model: 1998

Posted 26 August 2012 - 09:50 pm

QUOTE(alexk243 @ Sun 26th Aug 2012, 16:56 PM) <{POST_SNAPBACK}>
Well I am having trouble finding any bottom ends or other parts for this bike. Also the bike is now popping out of 3rd and down to second...

This is what it should be doing when it goes wrong. It has just got a little worse. This is normal.
Keep changing thru 3rd to 4th before applying throttle.
Wait until a donor engine appears. You will be glad you did. 5 days of Summer remain and the rest of Autumn too.

How many miles has your bike done? smile.gif

Edited by TYREDNGRUMPEE, 26 August 2012 - 09:59 pm.


#45 Nick Apostolakis

Nick Apostolakis

    Carpe Regular

  • Member
  • Pip
  • 148 posts
  • Location:Crete, Greece
  • TDM model: 1999

Posted 27 August 2012 - 06:44 pm

QUOTE(alexk243 @ Fri 30th Mar 2012, 18:56 PM) <{POST_SNAPBACK}>
It does seem to happen in every gear, but not when its resting and if you accelerate easily it does not do it. Only under heavy load. The only thing it does at rest is backfire/caughs, and that is only at idle. This really only happens when driving and with a load. Which makes me think its something in the driveline as no matter how much you rev it at rest, it will not do it.

I like the idea of the clutch going out or slipping. That makes sense. How would I be able to check this or repair this?

The HT Lead/boots/plugs were just replaced as I thought that may have been an issue (it did it before the change as well) and the battery cause that was going bad as well.

I do not have to stick it back into gear so that must not be it. There is no way it can slip while in gear?


It reminds me suspiciously of my own bike tongue.gif

I am going to change my coils, as soon as I manage to set up a dust free area in my basement for dis-assembly.

Maybe you should put the coils too in your check list too.

--------------------------------------------------------------
Nick Apostolakis
e-mail: nickapos@oncrete.gr
Web Site: http://nick.oncrete.gr
--------------------------------------------------------------

#46 TYREDNGRUMPEE

TYREDNGRUMPEE

    has been here 4ever

  • Member
  • PipPipPipPipPipPipPipPip
  • 1,627 posts
  • TDM model: 1998

Posted 27 August 2012 - 09:54 pm

QUOTE(Nick Apostolakis @ Mon 27th Aug 2012, 19:44 PM) <{POST_SNAPBACK}>
It reminds me suspiciously of my own bike tongue.gif

You had better hope that it doesn't!

Mind you, this thread has proven that it is possible to make anything sound like anything.

Suggest reading the thread.
rolleyes.gif


#47 Nick Apostolakis

Nick Apostolakis

    Carpe Regular

  • Member
  • Pip
  • 148 posts
  • Location:Crete, Greece
  • TDM model: 1999

Posted 29 August 2012 - 04:14 am

QUOTE(TYREDNGRUMPEE @ Tue 28th Aug 2012, 00:54 AM) <{POST_SNAPBACK}>
You had better hope that it doesn't!

Mind you, this thread has proven that it is possible to make anything sound like anything.

Suggest reading the thread.
rolleyes.gif


Yes, I see that you have managed to isolate the problem on the 3rd gear, so it seems that your problem lies with the gearbox.
It seems that our problems are not the same after all.
Good luck (and results) with your repairs....
--------------------------------------------------------------
Nick Apostolakis
e-mail: nickapos@oncrete.gr
Web Site: http://nick.oncrete.gr
--------------------------------------------------------------

#48 alexk243

alexk243

    Carpe groupie

  • Member
  • PipPip
  • 230 posts
  • Location:Northwest Suburbs, Illinois, USA
  • TDM model: 1992

Posted 04 September 2012 - 07:41 pm

Best I can remember I think it is around 40k on the bike. So somewhat higher for a motorcycle. Seems about the right time for 3rd to go out lol

1992 Yamaha TDM 850
2006 BMW F650GS

 

My Website/Blog with Different Project Write Ups


#49 alexk243

alexk243

    Carpe groupie

  • Member
  • PipPip
  • 230 posts
  • Location:Northwest Suburbs, Illinois, USA
  • TDM model: 1992

Posted 09 November 2012 - 12:49 am

So its been a while and I cannot locate an engine. Any idea what it would cost for me to do the rebuild on my engine myself?

Figured this is what I need (but cannot locate):

-3rd gear for trans
-Gaskets/O-Rings for engine

What parts does a top end refurb require?

1992 Yamaha TDM 850
2006 BMW F650GS

 

My Website/Blog with Different Project Write Ups


#50 Studley Ramrod

Studley Ramrod

    Monkey Boys Monkey

  • Root Admin(A)
  • PipPipPipPipPipPipPipPip
  • 19,202 posts
  • Location:HELLO ! I'm in the Library...Notts
  • TDM model: 1993

Posted 09 November 2012 - 08:14 am

Parts for a top end refurb would depend on the condition of the barrels and valves. If they are good then you'd probably need new piston rings, new valve stem seals, some valve shims, camchain tensioner gasket, cylinder base gasket, cylinder head gasket & possibly a rocker cover gasket. In addition you'd need to get the cylinder bores honed and the valves/valve seats lapped in and the head cleaned.
If the barrels show signs of wear then you may need a rebore and new pistons and new rings.

Hard to say what it'd cost to rebuild the engine/gearbox. Basically it'd be all new engine and cover gaskets and o rings, some liquid gasket, some specialist tools like a clutch holder and a rotor puller and whatever is needed for the gearbox.

I dunno, maybe $500-$800 ? :unsure2:

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


#51 alexk243

alexk243

    Carpe groupie

  • Member
  • PipPip
  • 230 posts
  • Location:Northwest Suburbs, Illinois, USA
  • TDM model: 1992

Posted 09 January 2013 - 02:52 am

So I started doing the rebuild on the trans and I got stuck at the flywheel and the huge 10mm allen keys that have to go through the cam shaft. Gonna borrow some tools from a friend and then get back to it tomorrow or so.

Here is the video of me stripping the engine out of the bike (time-lapse):

1992 Yamaha TDM Engine Removal

If you guys have any advice for pulling the flywheel or things I need to know when I pull the engine apart (thats different from other motorcycle engines). Please let me know. I am already half-way into it.

Edited by alexk243, 09 January 2013 - 02:54 am.

1992 Yamaha TDM 850
2006 BMW F650GS

 

My Website/Blog with Different Project Write Ups


#52 Studley Ramrod

Studley Ramrod

    Monkey Boys Monkey

  • Root Admin(A)
  • PipPipPipPipPipPipPipPip
  • 19,202 posts
  • Location:HELLO ! I'm in the Library...Notts
  • TDM model: 1993

Posted 09 January 2013 - 10:17 am

Easier to remove the camshafts to get at the cylinder head bolts & nuts. Keep an eye on the washers under the head nuts as they tend to stick in the recess.
You'll need a decent puller, I made my own, make sure it's lined up correctly and use some heat on the rotor to help removal.

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


#53 TYREDNGRUMPEE

TYREDNGRUMPEE

    has been here 4ever

  • Member
  • PipPipPipPipPipPipPipPip
  • 1,627 posts
  • TDM model: 1998

Posted 09 January 2013 - 06:04 pm

You'll need a decent puller, I made my own, make sure it's lined up correctly and use some heat on the rotor to help removal.

Where's the LINK to all them photos?

#54 Studley Ramrod

Studley Ramrod

    Monkey Boys Monkey

  • Root Admin(A)
  • PipPipPipPipPipPipPipPip
  • 19,202 posts
  • Location:HELLO ! I'm in the Library...Notts
  • TDM model: 1993

Posted 09 January 2013 - 06:13 pm

http://www.carpe-tdm...=19504&hl=rotor

http://www.carpe-tdm...6&showentry=104

:)

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


#55 tdm850rider

tdm850rider

    Carpe Citizen

  • Member
  • PipPipPipPipPipPipPipPip
  • 6,103 posts
  • Location:Pittsburgh, Pennsylvania USA
  • TDM model: 1992

Posted 09 January 2013 - 06:21 pm

Your bike skips? Is it a 900? :lol:
Posted Image

Always tell the truth, it will gratify some of the people and astonish the rest. (Mark Twain)
£

Stebel Nautilus air-horn, Corbin seat, MRA Touring screen, single Delkevic silencer.
"I see by your outfit that you are a spaceman"(MkI (3VD) TDM Review)
Hints for using Carpe-TDM. (photo's, links, etc).

#56 TYREDNGRUMPEE

TYREDNGRUMPEE

    has been here 4ever

  • Member
  • PipPipPipPipPipPipPipPip
  • 1,627 posts
  • TDM model: 1998

Posted 09 January 2013 - 08:32 pm

http://www.carpe-tdm...=19504&hl=rotor

http://www.carpe-tdm...6&showentry=104

:)

Thanks Studders. Those links will serve as inspiration. Check them out alex, spesh the second one.

#57 alexk243

alexk243

    Carpe groupie

  • Member
  • PipPip
  • 230 posts
  • Location:Northwest Suburbs, Illinois, USA
  • TDM model: 1992

Posted 10 January 2013 - 07:01 am

Ill post this on the other one, but I got to the trans today... no signs of broken teeth or damage... oddly disappointing...

1992 Yamaha TDM 850
2006 BMW F650GS

 

My Website/Blog with Different Project Write Ups


#58 alexk243

alexk243

    Carpe groupie

  • Member
  • PipPip
  • 230 posts
  • Location:Northwest Suburbs, Illinois, USA
  • TDM model: 1992

Posted 10 January 2013 - 07:03 am

Thanks for the pictures and info. Used a traditional "harmonic balancer" puller and with some heat, a hammer (on the puller), and a breaker bar I was able to get the flywheel off and completed the steps on splitting the case and to my disappointment... there was nothing visible wrong with the gears...

I guess I was expecting to see broken teeth, should I be looking for something else? Ill try and upload some pic/vids of the trans...

1992 Yamaha TDM 850
2006 BMW F650GS

 

My Website/Blog with Different Project Write Ups


#59 Studley Ramrod

Studley Ramrod

    Monkey Boys Monkey

  • Root Admin(A)
  • PipPipPipPipPipPipPipPip
  • 19,202 posts
  • Location:HELLO ! I'm in the Library...Notts
  • TDM model: 1993

Posted 10 January 2013 - 09:08 am

Yeah, you should be looking at the dogs n cogs. :)

Gearsbox1.jpg

The arrows point at the cogs and the holes they slide into are the dogs.


http://www.carpe-tdm...c=26613&hl=dogs

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


#60 TYREDNGRUMPEE

TYREDNGRUMPEE

    has been here 4ever

  • Member
  • PipPipPipPipPipPipPipPip
  • 1,627 posts
  • TDM model: 1998

Posted 10 January 2013 - 10:06 am

Yeah, you should be looking at the dogs n cogs. :)

You should look at everything really, as wear and bad behaviour in one area often leads to wear in another.
Check selector barrel, the channels that guides the selector forks. The selector forks. etc.


0 user(s) are reading this topic

0 members, 0 guests, 0 anonymous users