Fuel Tank - Trx Models; Fuel Tank - Xtz Models; Fuel Tap(S) - Yamaha TDM850 User Manual

4»4 Fuel and exhaust systems
2.9a Detach the fuel hose (A), the vacuum
hose (B)...
models, carefully lift the tank off the frame and
remove it, bringing the remote fuel tap and hoses
with it (where still attached), making sure the tap
does not get snagged. On 1999 models, carefully
lift the tank up to access the fuel level sender
wiring; disconnect the wiring and remove the
tank, making sure the tap does not get snagged.
6 Inspect the tank mounting rubbers for signs
of damage or deterioration and renew them if
necessary.
Installation
7 Installation is the reverse of removal, noting
the following:
a) Make sure the hoses are properly attached
and secured by their clamps.
bj On 1996 to 1998 models, if the tap on the
fuel outlet from the tank was turned OFF, do
not forget to turn it back ON.
c) Don't forget to reconnect the fuel level
sender wiring on 1999 TDM models.
d) Start the engine and check that there is no
sign of fuel leakage, then shut if off.

Fuel tank - TRX models

Removal
8 Make sure the fuel filler cap is secure and the
fuel tap is in the ON or RES position. Remove
the seat (see Chapter 8).
9 Release the clamps securing the fuel hose to
the fuel pump and the vacuum hose to the fuel
tap and detach the hoses (see illustration). Also
release the clamp securing
2.10b ... and the front mounting bolt
(arrowed) on each side
2.9b ... and the breather hose (arrowed)
the breather hose to its union and detach the
hose (see illustration).
10 Unscrew the nut and withdraw bolt securing
the rear of the tank, then unscrew the bolt on
each side at the front (see illustrations).
11 Carefully lift the tank off the frame and
remove it.
12 Inspect the tank mounting rubbers for signs
of damage or deterioration and renew them if
necessary.
Installation
13 Installation is the reverse of removal,
noting the following:
a) Make sure the hoses are properly attached
and secured by their clamps.
b) Start the engine and check that there is no
sign of fuel leakage, then shut if off.

Fuel tank - XTZ models

Removal
14 Make sure the fuel filler cap is secure and
both fuel taps are in the OFF position. Remove
the seat and the fairing side panels (see Chapter
8).
15 Release the clamp securing the fuel hose to
each fuel tap and detach the hoses.
16 Unscrew the bolts securing the rear of the
tank, then unscrew the bolt on each side at the
front, and the top bracket-to-frame bolt (see
illustrations).
17 Carefully lift the tank off the frame and
remove it.
2.16a Remove the rear mounting bolts
(arrowed)...
2.10a Remove the rear mounting bolt
(arrowed)...
18 Inspect the tank mounting rubbers for
signs of damage or deterioration and renew
them if necessary.
Installation
19 Installation is the reverse of removal,
noting the following:
a) Make sure the hoses are properly attached
and secured by their damps.
b) Start the engine and check that there is no
sign of fuel leakage, then shut if off.

Fuel tap(s)

Removal
Note: The tap should not be removed
unnecessarily from the tank to prevent the
possibility of damaging the O-ring or the filter.
20 Remove the fuel tank as described above.
21 On 1991 to 1995 TDM models, connect a
drain hose to the fuel outlet union on the remote
tap and insert its end in a container suitable and
large enough for storing the petrol. Turn the fuel
tap to the RES position and allow the tank to
drain. When the tank has drained, turn the tap to
the OFF position.
22 On 1996 to 1998 TDM models, if the remote
tap is still attached, connect a drain hose to the
fuel outlet union on the remote tap and insert its
end in a container suitable and large enough for
storing the petrol. Turn the fuel tap to the RES
position and allow the tank to drain. If the remote
tap was left in situ, connect a drain hose to each
union on the fuel outlet on the tank and insert
their ends in a container suitable and
2.16b ... and the front mounting bolt
(arrowed) on each side
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