Neutral Switch - Check, Removal And Installation; Chock - Yamaha TDM850 User Manual

9*16 Electrical system
21.2a Neutral switch wiring connector (A),
sidestand switch wiring connector (B) -
TDM models
21 Neutral switch - check,
removal and installation

Chock

1 Before checking the electrical circuit, check
the bulb (see Section 16) and fuse (see Section
5).
2 The switch is located in the left-hand side of
the transmission casing above the front sprocket.
To access the wiring connector, on TDM models
remove the seat, on TRX models remove the
side covers, and on XTZ models remove the left-
hand side cover (see Chapter 8). Trace the
single light blue wire from the top of the
alternator cover and disconnect it at
21.8 Unscrew the bolts (arrowed) and
remove the plate
21.9 Detach the wiring grommet and
remove the screws (arrowed)...
21.2b Neutral switch wiring connector (A),
sidestand switch wiring connector (B) -
TRX models
the connector (see illustrations). Make sure the
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transmission is in neutral.
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3 With the connector disconnected and the
ignition switched ON, the neutral light should be
out. If not, the wire between the connector and
instrument cluster must be earthed at some point.
4 Check for continuity between the wire terminal
on the switch side of the wiring connector and the
crankcase. With the transmission in neutral, there
should be continuity. With the transmission in
gear, there should be no continuity. If the tests
prove otherwise, then the switch is faulty.
5 If the continuity tests prove the switch is good,
check for voltage at the terminal on the wiring
loom side of the wiring connector using a test
light with the ignition ON. If there's no voltage
present, check the wire between the connector,
the instrument cluster and fusebox (see the
wiring diagrams at the end of this Chapter). Turn
the ignition OFF.
Removal
6 Make sure the transmission is in neutral. The
switch is located in the left-hand side of the
transmission casing above the front sprocket.
To access the wiring connector, on TDM models
remove the seat, on TRX models remove the
side covers, and on XTZ models remove the left-
hand side cover (see Chapter 8). Trace the
single light blue wire from the top of the
alternator cover and disconnect it at the
connector (see illustrations 21.2a, b and c).
21.10 ... and remove the switch
21.2c Neutral switch wiring connector
(arrowed) - XTZ models
7 Remove the alternator cover (see Section 32).
8 Unscrew the bolts securing the transmission
output shaft retainer plate to the left-hand side of
the crankcase and remove the plate (see
illustration).
9 Pull the wiring grommet from its cutout in the
crankcase (see illustration).
10 Remove the screws securing the switch
and detach it from the casing
illustration). Discard the O-ring as a new one
must be used.
Installation
11 Fit a new O-ring onto the switch (see
illustration), then install the switch and tighten
its screws securely (see illustration 21.9).
12 Press the wiring grommet into its cutout in
the crankcase (see illustration 21.9).
13 Install the transmission output shaft retainer
plate onto the left-hand side of the crankcase
(see illustration 21.8). Apply a suitable non-
permanent thread locking compound to the
threads of the bolts and tighten them to the
specified torque setting.
14 Connect the wiring connector
illustrations 21.2a, b and c). Check the
operation of the neutral light.
15 Install the alternator cover (see Section 8).
16 On TDM models install the seat, on TRX
models install the side covers, and on XTZ
models install the left-hand side cover (see
Chapter 8).
21.11 Fit a new O-ring onto the switch
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