Introducing the custom motorcycle that has been submitted to the Webike Community "MOTO HACK Custom Motorcycle Contest" campaign!
Meet the custom motorcycle of 'Sukusuku', who is riding on his TDM900!
Motorcycle and self-introduction
I have been riding motorcycles for about 30 years. I've ridden Yamaha Champ 50, Kawasaki AV50, Kawasaki Eliminator 400LX, Honda XL250 Degree, Yamaha TDM900, Yamaha TDM900.
I like motorcycles so much that I ride them for work. I started my career as a rider at Degree and have ridden over 600,000 km. A motorcycle is my tool for eating, having fun, and a reliable companion to help each other reach a higher level.
Customization of the particulars
[Direction to aim for]
This is an ideal machine for work, and I made it specially designed for riding around Tokyo on a rush job.
With 40kg of work tools in the cargo box, the center of gravity is high and unstable, but changing the rear suspension to Ohlins has improved this considerably. We also used booster plugs to raise the low and mid speed range, lightened the NAG internal pressure valve and clutch plate, and added a quick shifter and Scott oiler to reduce energy loss as much as possible, while aiming for a light ride even in an environment with a lot of stop and go traffic.
I was particularly particular about the electrical system. In order to reduce the risk of accidents on the way to the scene, I used the blinker position, blinker buzzer, fog lights, etc. to show my presence as a defense measure. There are a lot of electrical components on the motorcycle, but we had to think about how to keep them in good condition without causing contact failure, and how to reduce the burden on the battery.
As the number of electrical components increased, it became more and more difficult just to tie the wires together in the limited space, but maintaining the condition of the contacts for a long time was also a major theme.
It is often said that connectors are better than electrotaps, but since I constantly riding in vibration and high temperature and humidity, even connectors are not enough. After trying various terminals, connectors, and solder connections, the most stable method was bolting.
By replacing the tip of the wires with round terminals and tightening them with aluminum bolts and anti-loosening nuts, I was able to get both "removable" and "more durable.
I don't recommend this product to everyone because it is difficult to install, but it is worth considering for those who have the same problem.
The part we were most particular about was the wiring, and we faced the challenge of how to reduce the load on the battery. We have so many retrofitted electrical devices, but most of them are designed to light up after the engine is started.
Normally, the lights would come on when the key is turned on, but in this TDM, only the voltmeter and fuel gauge come on when the key is turned on. After the cell motor turns, the engine fires up and the generator starts to work, and then they all start at once, or in other words, you don't have to cut down on the electricity in the battery which is all concentrated on the cell motor.
In addition, as more and more electronic devices (such as the Scott Euler E system) require a constant power supply, we installed a sub-battery dedicated to constant power supply.
I think it doesn't become a big current consumption because I only let it maintain memory, but I am worried when I think about it for a long time, so I don't reduce the main battery of the main body. This one is also kept completely separate when stopped, and is connected after starting (after the generator turns).
Also, I installed a switch so that it can be temporarily connected (battery jump) when the main battery runs out of power. Another possibility of the sub-battery is that it is loaded with one freely available battery, so you can use it as much as you want, or even if you empty it, it will be recharged by performing. Although its use is limited, it may be an item that can be prepared for emergencies.
I went through a lot of trial and error to figure out how to turn on all these retrofitted electronic devices after startup, but I focused on the fact that the headlights come on after startup on Yamaha vehicles. As a result, I branched off from the headlight relay and used it as the power source for the relay (the positive wire that runs to the coil in the relay) that runs the retrofit electronics. The reason why I put the switch on the branch from the headlight relay is for the emergency stop switch that can turn off all the electrical components when it feels something abnormal.
By the way, if you are trying to run a retrofit electrical component, the ironclad rule is to pull the wiring directly from the battery (new installation) and insert the relay. If you are using it for the relay's power supply (the positive wire that flows to the coil), you can use it anywhere, but when you are taking out the power supply that runs the main body of the electrical components, the thickness of the wiring is very important. The original harness has a calculated thickness, so it's best not to interrupt it.
Another part that I was particular about was the 50A relay that connects the sub battery to the main battery. With this much capacity, I think it will be able to withstand emergency jump starting (using the sub battery to make up for the lack of the main battery). If I didn't care about the ammeter, I wouldn't need a shunt resistor, so the wiring would be much simpler, but I wanted to be able to check all the capacities in a timely manner, so this is the wiring diagram.
I also wanted to be able to check the voltage and CCA of each of the two batteries individually, and to be able to charge them, so I was able to achieve my goal with a single switch. This is a point where I worked very hard, or rather, where I had to use all my ingenuity.
[Points that I think are cool]
Pannier cases are cool, but I've always wanted to make a custom side case out of a commercial tool case. So I was very happy when my wish came true. I like the effect of having more choices of cases, but I also like the overall design of the tool case. Also, I like the DIY chain cover. Originally, I made it just for practicality, but now that it's finished, I'm starting to think that it's not bad in terms of design. I'm starting to think so.
Just because it's a unique custom makes it feel more special and cool. Homemade side cases are a minority, but I think homemade chain covers are even more of a minority.
By the way, if you put the chain cover on, it won't run out of oil even in the rain. I originally made it myself to prevent the Scott oiler from spattering, but it was a nice byproduct that resulted in an all-weather slippery chain. Longer lubrication means more power, better fuel economy, and a longer life for the chain and sprockets, so there are a lot of benefits.
[Points of change in performance]
There are many points that have been changed from the bare state, but the first one is the ability to select modes. I made my own ON/ON switch for the booster plug that I'll explain later, and I also added a cancel switch for the TDM900's own variable intake duct, so together we can now enjoy 4 levels of ride quality.
I think it benefits greatly from the internal pressure valve, aluminum clutch plate and Scott oiler that were introduced to extend the good parts of the original TDM. Most of the drivetrain crud (resistance and friction) has disappeared from the engine, and the motorcycle is now easy to ride with a distinctly silky heartbeat.
Custom Points
1. Brand: DAYTONA
Item Name: MOTO GPS RADAR LCD 3.0
2. Brand: TOURATECH
Item Name: Scottoiler E System
It is a device that automatically lubricates the chain oil, but it is possible to set the lubrication timing and other details. Because the amount of oil remaining, the temperature, and time, etc. are displayed, it is a multifunctional monitor casually.
3. Brand: PROTEC
Item Name: Dual Gas Trip Meter 12V Precision Fuel System for FI Vehicles
4. Brand: KOSO
Item Name: KOSO Mini3 Digital [Current Voltmeter]
It is difficult to install because of the shunt resistor. If you are considering to install it, I recommend you to cut and solder it directly in advance because the connector part will be corroded.
5. Brand: unknown
Product name: elfin203 waterproof mini digital voltmeter blue 3.50V~30.0V
Buy at Amazon.com
I installed it because I wanted a voltmeter that was small and had no extra features. The function is enough.
6. Brand: unknown
Product name: TPMS Tire Pressure Monitoring System for two-wheeled motorcycles
Buy at Amazon.com
7. Brand: unknown
Product name: M6 Motorcycle Drive Recorders Motorcycle Car Camera Drive Recorder
Buy at Amazon.com
This is a Chinese driving recorder with simultaneous front and rear recording. The back monitor is not waterproof, so I put it in the screen to keep it out of the rain. With the mirror, you can see the people in the motorcycle behind you, but with the rear view monitor, you can avoid such a bad situation.
8. Brand: unknown
Product name: Universal Blind Spot Monitor BSM Radar
Buy on ebay
I used the BSM for my motorcycle. In Tokyo, there are a lot of bicycles that rush from behind when you turn left, so it's a relief to have this. I put the sensor in the side case and waterproofed the base.
All electrical components are not directly affected by the rain from the front. Even though the motorcycle is waterproof, it's not good to keep water pressure on it for years, so we hid everything inside the screen and cowl. This is a unique feature of the old motorcycles and is difficult to achieve with today's clean gauges.
Even though it looks like a ding dong shop, it's all hidden inside the cowl, so you can't notice it from a distance.
Sometimes people say, "There are so many meters, it must be confusing", but it doesn't matter how many meters you have, because you only look at the information you need when you need it. Just like no one keeps looking at the meter while driving, you only look at it for a moment depending on the situation that comes up. It's like looking at the ammeter when the grip heater is on, or changing the timing of the chain oil lubrication when entering the highway.
Brand: unknown
Product Name: Ammeter Digital Clamp DROK 0.56" DC 100A 0-99.9A
Buy at Amazon.com
I installed it in order to see the current of only retrofit electric components. Because it is not waterproof specification, I filled the gap between the case and the board with caulking, or cut out the connector and soldered it directly. Basically, it is better to solder the connector from the beginning because it will cause contact failure.
As for the merit, it becomes a guide to control oneself not to use a large amount of electricity at a time. For example, if you turn on the grip heater and fog lamp at the same time, which consume a lot of current, the value will rise at once, so you can adjust it by using them separately.
I don't think anyone wants to know how much electricity is flowing through their motorcycle, but it's interesting to learn a lot when it's there.
Brand: Daytona
Item Name.: Battery tester 75505 *Sold out
It is a tester that can measure CCA value as well as battery voltage.
It is a group of switches. The upper left is the booster plug ON/ON switch, the lower left is the variable intake duct cancel switch ON/OFF switch, the upper right is the emergency switch that can turn off the electrical components at once, and the lower right is the switch that can see the motorcycle navigation system even with the key OFF.
Brand: NKK Switches (Nippon Switchgear Co., Ltd.)
Item Name: Waterproof Toggle Switch M Series Function Operation ON-OFF, Circuit Single-pole Single-throw, M-2011 *From outside brand site
It is a type of ON/OFF. The cancellation switch of the variable intake duct was used here.
Brand: NKK Switches (Nippon Switchgear Co., Ltd.)
Item Name: Waterproof Toggle Switch M Series Function Operation ON-ON, Circuit Single pole twin throw, M-2012I *From outside brand site
This is the ON/ON type. I used this switch for the booster plug.
Brand: NKK Switches (Nippon Switchgear Co., Ltd.)
Item Name: Waterproof Cap (for Ultra-small Toggle Switch) *From outside brand site
The toggle switch above does not come with a waterproof cap and must be purchased separately.
It is a waterproof switch, but it is preferable to install it in a place where it is not directly exposed to water. I fixed the switch and wiring with solder. If it is a small amount of current, the switch alone is OK, but it is best to use the relay for the lights and the grip heater.
Brand: DAYTONA
Item Name: Exclusive Power Supply 2.1A for Motorcycle
It has a waterproof lid, but when you're plugging in the cable, it doesn't matter how waterproof it is. Therefore, I installed it at the far end of the screen. It seems to be able to endure the rain from the front and the top unless it rains too hard.
Brand: unknown
Product name: Extremely simple ashtray for motorcycle (substitute as accessory case)
Purchased at Autobacs
I built it in as a highway ticket holder 15 years before I still had ETC. I just hollowed out the cowl with a soldering iron and put the ashtray in and fixed the backside. Because there is a gap in some places, I put urethane around the circumference and waterproofed it. Because the plastic board is pasted on the ashtray, it becomes waterproof even if the cover is opened. The things to put in it have changed from the old days, but it is convenient for something if there is a little small container at hand.
Brand: DAYTONA
Item Name: Hot Grip Heavy Duty Built-In 4Sn
I was shopping in a hurry and only checked the thickness and popped it in, but unfortunately, the length was insufficient. I cut a PVC pipe to fill the missing gap.
The appearance is a little disappointing, but the warty shape of the grip is excellent, and I am satisfied that it is not slippery even if the glove is dull. The new one is the justice for such an electric appliance, and it is becoming power-saving and high-efficiency every time the model is changed (it is understood well when the ammeter is attached).
I recommend replacing the whole thing rather than using the old one while fixing it, because it will be better in all directions.
Brand: SEIKOU Technology
Item Name: THETA II *From outside brand site
The good thing about the Theta Alarm is that it is harmless to the battery. It consumes zero current even when the security is on. The mechanism is that there is a ball in a small box, and when the ball moves, the alarm sounds.
For example, when the motorcycle is parked at an angle on the side stand and you raise it horizontally, the ball inside rolls and the alarm sounds. It is released when the key is turned on, but it is difficult to handle it during maintenance if it is left hanging, so it is necessary to make the switch by oneself, but I think that it is the best security for the person who doesn't want to put the burden on the battery. It's a security system that pursues a very good point, with an optional system to report to a remote location.
Brand: YAMAHA Europe
Item Name: LED Turn Signals
The edge of the tip makes the whole motorcycle look more refined, so for example, just making the blinkers pointed makes the whole thing look a little younger.
Brand: POSH Faith
Item Name: Blinker extension bracket
If you have an older motorcycle with newer blinkers and you think the blinkers are cool but they don't fit your motorcycle, try extending them with a stay. Even if it is only a few mm, it will look completely different. The point is to make it the same size as stock. It's just like clothes, the first is the size and the second is the design, if the two are reversed, the motorcycle will look disappointing.
Brand: Device Sales Techno (Panasonic alternative)
Item Name: Electronic buzzer holo holo DSEB2132I *From outside brand site
When the indicator is on, it will beep and beep. It has the merit of appealing to children and deaf people, and preventing them from forgetting to turn it off, but there are many situations where you don't want it to sound, so I retrofitted a switch at hand.
Brand: SEIKOU Technology
Item Name: Blinker Position Kit *From other brand site.
It is a loss if you do not make the position because you have taken the trouble to LED blinkers. Because you can show a large (to appeal to the presence) even from a distance, there is an effect that you can reduce the risk of being forced to turn right from the oncoming vehicle (right turn accident), or suddenly U-turn.
Brand: TrailTech
Product Name: A182-SS Equinox Black 35mm LED Dual Light Kit
Buy at US Amazon
This is a 10W fog lamp. When I first bought it, it flooded from the gap between the lens and the case, but it stopped after I put silicon grease on the back mating surface and assembled it. This is the 10th year. Grease is very effective for waterproof.
Brand: MRA
Item Name: Vario Touring
A long screen will be essential for TDM. It provides a good windbreak on the highway and reduces fatigue considerably.
Brand: TANAX NAPOLEON
Item Name: Shark Mirror 4
I prefer the design of the Shark Mirror 3, but for some reason the paint peeled off (maybe the glass coating wasn't good). I replaced it with the 4 in a hurry and the glare reduction mirror gives me good visibility.
Brand: YUPITERU
Item Name: Motorcycle Drive Recorder BDR-2 WiFiI *From outside brand
When I first bought it, there were not many kinds, so I bought this one, but now there are many cheap drrorecorders, so it is not like "this is definitely recommended". By the way, it is attached with three in total because I have also attached the Chinese drum recorder besides this.
Brand: Pyramid Plastics
Item Name: Enduro Fender
It can reduce the splash of water on the front wheel, so the motorcycle will stay clean longer.
Brand: NAG racing service NAG racing service
Item Name: Internal pressure control valve Internal pressure controller for circuit "Superb Force R Race & Street (NAG valve) NAG01-012SFR
This is the only one of the many internal pressure valves that is emulsion proof and maintenance-free. A negative pressure hose is attached to the moving part of the one-way valve, and it is designed to suck out the residue such as mist of blow-by gas.
I installed it with the expectation that it would reduce the dirt of the throttle valve which is the weak point of TDM.
Brand: CMP
Item Name: Clutch plate CP-14510021-01 *From outside brand
The CMP aluminum clutch plate is 1/3 of the stock weight. The lighter the clutch is, the less power the crank has to transfer to the power side, which leads to better launch and acceleration. Also, the holes are partially drilled so that the clutch can be sharper and easier to operate.
By the way, I replaced the stock clutch plate at 130,000km, but it was not reduced as much as I thought. The clutch was worn out very much in the previous TDM because of a lot of short distance travel. It is rare for ordinary people to drive more than 100,000km, so I think you don't need to change the clutch permanently.
Brand: BoosterPlug *From outside brand.
Product name: YAMAHA-B391
The booster plug is designed to compensate for the intake air temperature sensor and make the fuel mixture +6% thicker. By the way, the TDM was set at -22 degrees C. Since the TDM can adjust the CO in the meter, it can be changed freely without the booster plug, but I bought it to be able to change it easily while driving. If you refer to the wiring diagram, you'll see that with some ingenuity, you can get the switch in without damaging the stock harness, so it's like modern mode selection on an old motorcycle.
Brand: HEALTECH ELECTRONICS
Item Name: Quickshifter Easy
You can change gears from 3rd to 6th gear without using the clutch (within a comfortable range). The price is quite expensive, so it will be an expensive part for people who do not ride frequently, but it is nice to be able to shift up without any drop in acceleration.
You can install it without damaging the stock wiring at all, and you can fine-tune the timing of the ignition cut with the smartphone app, so you can pin down the setting of your choice.
Brand: OHLINS
Item Name: Rear suspension Sold out
The good thing about Ohlins is that you can benefit a lot even if you just drive on normal roads. Compared to the stock suspension, the Ohlins reduces unnecessary vibration. On the other hand, the disadvantage of Ohlins is that it makes you feel slower than you actually are.
Brand: DIRTSKIN
Item Name: Rear shock cover
I installed this to protect the suspension shaft and seals. Motorcycles don't have dust boots like motorcycles, so they get scratched easily, but this is no matter stock or Ohlins. I recommend this item for those who want to keep good condition for a long time.
Brand: SKF
Item Name: Fork Seal Kit
SKF seals lighten the friction and reduce the slight vibration compared to the stock seals. It is very useful because it reduces the fatigue from arm to shoulder and upper body. The SKF seals are not suitable for motorcycles that have been ridden a certain distance because they may cause oil leaks if the inner tube is not worn well.
Brand: kriega
Item Name: Fork Seal Covers Fork Seal
I installed it for the purpose of extending the fork oil change cycle, and it turned out to be a good decision. The more maintenance you can't do easily, the more you can extend the maintenance cycle with a little effort.
Customization that I want to do in the future
Before writing this article, I was thinking "I have something to write about, but it's kind of depressing", but after writing it, I understood better. It's simply too long. I was depressed because my body knew it would be a very long story.
That's because I've been riding the TDM900 alone for almost 20 years, so all of the above is 20 years of customization. I was excited to put in Ohlins as a reward for my hard work this year, or a quickshifter as a goal for next year, but 20 years had passed...
I've spent the last few years with no desire for customization, but now that I've looked back, it's become clear to me that I've evolved to the point where I no longer even have the desire to tinker with the motorcycle, or so the title says.
Although many of the customizations are not common, I thought it would be a shame to let them remain buried in my personal life if I put so much energy into them, and I thought it would be meaningful to introduce such customizations. I thought it would be worthwhile to introduce this kind of customization.
If I were to do it in the future, I would like to add a non-seal chain. I'm thinking of using a combination of Scott Euler and a chain cover. I'd like to experience what awaits me after reducing friction to the utmost.
Thank you, Sukesuke, for participating in our custom motorcycle contest! You will receive 500 points to use at Webike!
See Accessories of DAYTONA
See Accessories of KOSO
See Accessories of TANAX
See Accessories of POSH
See Accessories of MRA
See Accessories of PROTEC
See YAMAHA Moto Index Page
See Accessories for YAMAHA TDM900
