Clutch Lever; Front Brake Lever; Forks - Removal And Installation - Yamaha TDM850 User Manual

5.8d Ensure that the flat (A) aligns with the cut-out (B)
aligns correctly with the corresponding cut-
out in the holder (see illustration). Tighten
the retaining bolts, positioning bolts and
clamp bolts to the torque settings specified at
the beginning of the Chapter. Tighten the
positioning bolt before the clamp bolt.
d) Refer to the relevant Chapters as directed for
the installation of the handlebar mounted
assemblies
e) Do not forget to reconnect the front brake
light switch and clutch switch wiring
connectors.

Clutch lever

9 On XTZ models, remove the hand guard
(see illustration).
10 Slacken the clutch cable adjuster lockring
and thread the adjuster fully into the bracket
to provide maximum freeplay in the cable (see
illustration). Unscrew the lever pivot bolt
locknut, then withdraw the pivot bolt and
remove the lever, detaching the cable nipple
via the slots in the adjuster and lockring. On
TRX models, note the collar for the pivot bolt.
1 Pivot bolt
2 Collar
3 Nut
4 Cap
5 E-clip
6 Nut
7 Spring
8 Plate
5.13 Brake lever components - TDM models
11 Installation is the reverse of removal.
Apply grease to the pivot bolt shaft, or on TRX
models to the collar, and the contact areas
between the lever and its bracket, and to the
clutch cable nipple. Adjust the clutch cable
freeplay (see Chapter 1).

Front brake lever

12 On XTZ models, remove the hand guard
(see illustration 5.9).
13 On TDM models, remove the cap from the
end of the master cylinder pushrod in the lever,
then remove the E-clip, the nut, the spring and
the plate (see illustration).
14 Unscrew the lever pivot bolt locknut, then
withdraw the pivot bolt and remove the lever (see
illustration).
15 Installation is the reverse of removal. Apply
grease to the pivot bolt shaft and the contact
areas between the lever and its bracket. On TDM
models, locate the master cylinder pushrod
through the pivot in the lever, and install the
plate, the spring, the nut, the E-clip and the cap.
Frame, suspension and final drive 6*7
5.9 Handguard retaining screw -
XTZ models
5.10 Slacken the lockring (A) and turn the
adjuster (B) fully in, then unscrew the nut
(C) and withdraw the pivot bolt (D) to free
the lever
Forks -
removal and installation
Removal
Caution: Although not strictly necessary,
before removing the forks it is recommended
that the fairing panels and/or fairing are
removed (see Chapter 8). This will prevent
accidental damage to the paintwork.
1 Remove the front wheel (see Chapter 7).
2 Remove the front mudguard (see Chapter 8).
5.14 Unscrew the nut (A) and withdraw the
bolt (B)
I
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