Output Shaft Disassembly; Output Shaft Inspection; Output Shaft Reassembly - Yamaha TDM850 User Manual

2*56 Engine, clutch and transmission
31.18b ... and set the distance as specified
the 1st gear pinion (which is integral with the
shaft) is 116.6 mm to 116.8
illustration).
19 Check that all components have been
correctly installed (see illustration).

Output shaft disassembly

1991 to 1994 TDM models and all XTZ
models
20 Remove the caged ball bearing from the
right-hand end of the shaft (see illustration
31.41).
21 Slide the 1st gear pinion and the 4th gear
pinion off the right-hand end of the shaft (see
illustrations 34.40b and a).
22 Remove the circlip securing the 3rd gear
pinion, then slide the splined washer, the 3rd
gear pinion and its splined bush, followed by the
5th gear pinion off the shaft (see illustrations
31.39d, c, b and a, and 31.37).
23 This leaves the 2nd gear pinion, its bush and
the bearing on the left-hand end of the shaft;
these components are not available individually -
refer to a Yamaha dealer if they need renewing.
1995-on TDM models and all TRX
models
24 Remove the caged ball bearing from the
right-hand end of the shaft (see illustration
31.41).
25 Slide the thrust washer, the 1st gear pinion
and the 4th gear pinion off the right-hand end of
the shaft (see illustrations 31.40c, b and a).
26 Remove the circlip securing the 3rd gear
pinion, then slide the splined washer, the 3rd
gear pinion and its splined bush off the shaft (see
illustrations 31.39d, c, b and a)
27 Slide the lockwasher and the splined washer
off the shaft, noting how they fit together, then
slide the 5th gear pinion off the shaft (see
illustrations 31.38c, b and a, and 31.37).
28 This leaves the 2nd gear pinion, its bush and
the bearing on the left-hand end of the shaft;
these components are not available
individually - refer to a Yamaha dealer if they
mm (see
need renewing.

Output shaft inspection

29 Refer to Steps 7 to 13 above.

Output shaft reassembly

1991 to 1994 TDM models and XTZ models
30 During reassembly, apply engine oil to the
mating surfaces of the shaft, pinions and bushes.
When installing the circlips, do not expand their
ends any further than is necessary. Install the
stamped circlips so that their chamfered side
faces the pinion it secures and the sharp edged
sides faces the direction of thrust load (see
'correct fitting of a stamped circlip illustration' in
Tools and Workshop Tips in the Reference
section).
31 Slide the 5th gear pinion onto the right-hand
end of the shaft, with its dogs facing the 2nd gear
pinion (integral with the shaft) (see illustration
31.37).
32 Slide the 3rd gear pinion splined bush onto
the shaft, followed by the 3rd gear pinion, and the
splined washer, and secure them with the circlip,
making sure it locates correctly in its groove in
the shaft (see illustrations 31.39a, b, c and d).
31.37 Slide the 5th gear pinion onto the
shaft, making sure it is the correct way
round
31.19 The assembled input shaft should be as shown
33 Slide the 4th gear pinion onto the shaft, with
its selector fork groove facing the 3rd gear pinion,
followed by the 1st gear pinion (see illustrations
31.40a and b).
34 Fit the caged ball bearing onto the right-hand
end of the shaft (see illustration 31.41).
35 Check that all components have been
correctly installed.
1995-on TDM models and TRX models
36 During reassembly, apply engine oil to the
mating surfaces of the shaft, pinions and bushes.
When installing the circlips, do not expand their
ends any further than is necessary. Install the
stamped circlips so that their chamfered side
faces the pinion it secures and the sharp edged
sides faces the direction of thrust load (see
'correct fitting of a stamped circlip illustration' in
Tools and Workshop Tips in the Reference
section).
37 Slide the 5th gear pinion onto the right-hand
end of the shaft, with its dogs facing the 2nd gear
pinion (integral with the shaft) (see illustration).
38 Slide the slotted splined washer onto the
shaft and locate it in its groove, then turn it in the
groove so that the splines on the washer locate
between the splines of the shaft and secure the
washer in the groove (see illustrations). Slide
the lockwasher onto the
31.38a Slide the slotted splined washer on
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