Bodywork - Yamaha TDM850 User Manual

Chapter 8

Bodywork

Contents
Engine bashplate - removal and installation .................................. 7
Fairing - removal and installation ................................................ 5
Fairing side panels - removal and installation ................................. 4
Front mudguard - removal and installation .................................... 6
Degrees of difficulty
Easy, suitable for Fairly easy, suitable
novice with little for beginner with
expenence some expenence
This Chapter covers the procedures
necessary to remove and install the body
parts. Since many service and repair
operations on these motorcycles require the
removal of the body parts, the procedures are
grouped here and referred to from other
Chapters.
In the case of damage to the body parts, it
is usually necessary to remove the broken
component and renew it (or replace it with a
used one from a breaker). Note that there are
however some companies that specialise in
'plastic welding' and there are a number of
bodywork repair kits now available for
motorcycles.
When attempting to remove any body
panel, first study it closely, noting any
General information ...................................................................... 1
Seat - removal and installation ...................................................... 2
Side covers - removal and installation ........................................... 3
Fairly difficult, fk
suitable for competent
DIY mechanic
fasteners and associated fittings, to be sure of
returning everything to its correct place on
installation. In some cases the aid of an
assistant will be required when removing
panels, to help avoid the risk of damage to
paintwork. Once the evident fasteners have
been removed, try to withdraw the panel as
described but DO NOT FORCE IT - if it will not
release, check that all fasteners have been
removed and try again. Where a panel
engages another by means of tabs, be careful
not to break the tab or its mating slot or to
damage the paintwork. Remember that a few
moments of patience at this stage will save
you a lot of money in renewing broken fairing
panels!
When installing a body panel, first study it
closely, noting any fasteners and associated
fittings removed with it, to be sure of returning
everything to its correct place. Check that all
fasteners are in good condition, including all
trim nuts or clips and damping/rubber mounts;
Difficult, suitable for
experienced DIY
^
J
iiS mechanic
any of these must be renewed if faulty before
the panel is reassembled. Check also that all
mounting brackets are straight and repair or
renew them if necessary before attempting to
install the panel. Where assistance was
required to remove a panel, make sure your
assistant is on hand to install it.
Tighten the fasteners securely, but be
careful not to overtighten any of them or the
panel may break (not always immediately) due
to the uneven stress. Where quick-release
fasteners are fitted, turn them 90° anti-
clockwise to release them, and 90° clockwise
to secure them.
Note ,hat a sma
BERTHS
BhjIMSI lubricant (liquid soap or
similar) applied to mounting
rubber grommets will assist
pegs to engage without the need for
undue pressure.
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8*1
15
Very difficult,
suitable for expert DIY «J
or professional ^
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8
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