Yamaha TDM850 User Manual page 86

25.8 Remove the dowel (arrowed) if it is loose
7 Carefully lift the lower crankcase half off the
upper half, using a soft-faced hammer to tap
around the joint to initially separate the halves if
necessary (see illustration 25.15). Note: If the
halves do not separate easily, make sure all
fasteners have been removed. Do not try and
separate the halves by levering against the
crankcase mating surfaces as they are easily
scored and will leak oil. Tap around the joint
faces with a soft-faced mallet.
8 Remove the locating dowel from the crankcase
if it is loose (it could be in either crankcase half)
(see illustration).
9 Refer to Sections 26 to 32 for the removal and
installation of the components housed within the
crankcases.
Reassembly
10 Remove all traces of sealant from the
crankcase mating surfaces.
11 Ensure that all components and their
bearings are in place in the upper and lower
crankcase halves. If the transmission shafts have
not been removed, check the condition of the
output shaft oil seal on the left-hand
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25.14 Apply the sealant to the shaded areas
end of the shaft and renew it if it is damaged or
deteriorated (see illustration).
12 Generously lubricate the crankshaft and
transmission shafts, particularly around the
bearings, with clean engine oil, then use a rag
soaked in high flash-point solvent to wipe over
the mating surfaces of both crankcase halves to
remove all traces of oil.
13 If removed, install the locating dowel in the
upper crankcase half (see illustration 25.8).
14 Apply a small amount of suitable sealant
(such as Yamaha Bond 1215) to the outer mating
surface of one crankcase half (see illustration).
Caution: Do not apply an excessive amount
of sealant as it will ooze out when the case
halves are assembled and may obstruct oil
passages. Do not apply the sealant on or too
close (within 2 to 3 mm) to any of the bearing
inserts or surfaces.
15 Check again that all components are in
position, particularly that the bearing shells
are still correctly located
crankcase half. Carefully install the lower
crankcase half down onto the upper
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Engine, clutch and transmission 2*47
25.11 Use a new output shaft oil seal if required
crankcase half, making sure the dowel locates
correctly into the lower crankcase half (see
illustration).
16 Check that the lower crankcase half is
correctly seated. Note: The crankcase halves
should fit together without being forced. If the
casings are not correctly seated, remove the
lower crankcase half and investigate the problem.
Do not attempt to pull them together using the
crankcase bolts as the casing will crack and be
ruined.
17 Clean the threads of the 10 mm lower
crankcase
disulphide oil (a 50/50 mixture of molybdenum
disulphide grease and new engine oil) to their
threads. Insert them with their washers in their
original locations. Clean the threads of the 8 mm
and 6 mm lower crankcase bolts and apply new
engine oil to their threads. Insert them (with their
washers where fitted, and not forgetting the cable
guide) in their original locations. Secure all bolts
in the lower finger-tight at first, then tighten them evenly and
a little at a time in the correct numerical
sequence to the torque settings specified at the
beginning of the Chapter (see illustrations
25.4a or b).
25.15 Fit the lower half onto the upper half, making sure it locates
onto the dowel (arrowed)
bolts and apply molybdenum
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