Coolant Hoses - Removal And Installation - Yamaha TDM850 User Manual

3»8 Cooling system
8.11a Fit the O-ring into the groove in the
cover...
Installation
10 If removed, slide the shouldered side of the
pump drive gear into its bore in the crankcase
(see illustration 8.9). Install the front balancer
shaft (see Chapter 2).
11 Install the new cover O-ring into its groove in
the pump (see illustration). Fit the cover and
secure it with the two bolts (see illustration).
12 Fit the new pump body O-ring and joint pipe
O-ring (see illustration). Apply some grease to
the shim to stick it in place, then slide it onto the
pump shaft (see illustrations). Install the pump
into the crankcase, making sure it locates
correctly into the driven gear (see illustration).
Install the bolts and tighten them to the torque
setting specified at the beginning of the Chapter
(see illustration 8.6). Make sure the different
length bolts are in their correct locations.
13 Attach the coolant hose to the pump cover
and secure it with its clamp (see illustration
8.5).
14 On XTZ models, install the frame downtube
and tighten its bolts to the specified torque
setting (see Chapter 2).
8.12b ... then grease the shim ..
8.11b .. then fit the cover and its two
bolts
Also install the exhaust system (see Chapter 4).
15 Refill the cooling system (see Chapter 1).
9 Coolant hoses -
removal and installation
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Removal
1 Before removing a hose, drain the coolant
(see Chapter 1).
2 Use a screwdriver to slacken the larger-bore
hose clamps, then slide them back along the
hose and clear of the union spigot (see
illustrations 6.3, 7.3a and b). The smaller-bore
hoses are secured by spring clamps which can
be expanded by squeezing their ears together
with pliers (see illustration 7.3c).
Caution: The radiator unions are fragile. Do
not use excessive force when attempting to
remove the hoses.
3 If a hose proves stubborn, release it by
rotating it on its union before working it off. If
all else fails, cut the hose with a sharp knife
8.12c ... and slide it onto the shaft
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8.12a Fit a new O-ring onto the body...
then slit it at each union so that it can be peeled
off in two pieces. Whilst this means replacing the
hose, it is preferable to buying a new radiator.
4 The water pipe union on the front of the
cylinder block can be removed by unscrewing
the retaining bolts (see Chapter 2, Section 13).
If it is removed, the O-rings must be renewed.
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Installation
5 Slide the clamp onto the hose and then
work it on to its respective union.
If the hose is difficult to .
on its union, it can be jHlltIT! softened by
soaking it in
very hot water, or alternatively a
little soapy water can be used as a
lubricant.
6 Rotate the hose on its union to settle it in
position before sliding the clamp into place and
tightening it securely.
7 If the water pipe union on the engine has been
removed, fit new O-rings, then install the union
and tighten the mounting bolts to the specified
torque setting (see Chapter 2, Section 13).
8.12d Install the pump, making sure it
locates correctly into the drive gear
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