Disassembly
On this page you will find the complete process of dissassembling every part of my TDM 850. It is probably not done in the perfect order or for that matter in a right way, but this is how I did it. Like I said before, enter at your own risk :) So of course I forgot to take pictures before I started... I had already removed the fairings of the motorcycle before I remembered the camera. Anyways,,, here on the right is a picture of the bike with the fairings come off. |
Removing the Fuel Tank
Removing the Air Filter
Removing the Battery
Removing the Engine Protector
Removing Engine Oil
Removing the Electrical Cable
Removing the Speedometer
Removing Front Lights and Stay
Removing Rear Fender and Foot rest
Removing Brakes, and Horn
Removing Stuff on the Steer and Front Fender
Removing the Carburetor
Removing the Engine
Some Engine Pictures
Removing the Starter
Trouble with the Water Pipe
Removing the Timing Plug and the Straight Plug
Measuring Valve Clearence
Removing the Camshaft
Removing the Valves
Removing Engine Bracket
Trying to remove Chain Tensioner
Removing Cylinder
Removing Pistons
Cleaning Pistons
Cylinder Head
Removing Crankcase Cover (top)
Removing Crankcase Cover (left)
Removing Clutch Cover
Removing Clutch Plates and Oil Pump Cover
Removing Clutch Housing
Removing the Rotor Bolt
What seem´s to be easy is often very difficult with the wrong tools. You need to hold the rotor while unscrewing the bolt. The manual say´s that the bolt is fastend to 130 nm but in my case it was much more. I tried some sheave holder, that didn´t work so...
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here is my homemade tool nr. 2. The sheave holder. I found this idea here!
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Wood is softer than steel, but I put some rags between. Work with out a problem. The bolt was really stuck, and I had to get a helping hand, just to keep the engine and the sheave holder tool still.
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Removing the Rotor
First of all, how stuck can a rotor be... ok maybe just a little bit naive with the MDF wood. Tightened it as much as I could and left it like this over night. Nothing happened except a little crack in the MDF.
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So an upgrade! Tightened it as much as I could again, and left it over night. Nothing happened. Tapped lightly on the rotor with a hammer and a wood between. Still nothing.
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So,,, time to go on-line to learn! Interesting discussion here and here about the rotor problem. Seems it needs some heavy duty tools, and when it goes, it goes out with a bang!
::Mental note, if this is the first time the rotor goes of,,, it´s not easy, take it serious. |