Engine, Clutch And Transmission; Degrees Of Difficulty - Yamaha TDM850 User Manual

Chapter 2

Engine, clutch and transmission

Contents
Alternator rotor and stator - removal and installation .. .see Chapter 9
Balancer shafts - removal, inspection and installation ............................. 23
Cam chain and guides - removal, inspection and installation .................24
Cam chain tensioner- removal, inspection and installation ....................... 9
Camshafts and followers - removal, inspection and installation ... 8
Clutch cable - removal and installation ..................................................17
Clutch - check ........................................................................ see Chapter 1
Clutch - removal, inspection and installation.............................................16
Connecting rods - removal, inspection and installation .............................28
Crankcase halves - inspection and servicing ............................................26
Crankcase halves - separation and reassembly .......................................25
Crankshaft and main bearings - removal, inspection
and installation .................................................................................. 29
Cylinder block - removal, inspection and installation ................................13
Cylinder head - removal and installation ................................................10
Cylinder head and valves - disassembly, inspection
and reassembly ................................................................................... 12
Engine - compression check.................................................. see Chapter 1
Engine - removal and installation ...........................................................
Engine disassembly and reassembly - general information .....................
Gearchange mechanism external components -
removal, inspection and installation ................................................... 19
General information .................................................................................
Idle speed - check and adjustment ........................................ see Chapter 1
Initial start-up after overhaul .................................................................... 33
Main and connecting rod bearings - general note.................................... 27

Degrees of difficulty

Easy, suitable for Jk
Fairly easy, suitable Jk for
novice with little is?
In beginner
experience ^
experience
Specifications
General
Type ...............................................................................................................
Capacity
TDM and TRX models ...............................................................................
XTZ models ...............................................................................................
Bore
TDM and TRX models ...............................................................................
XTZ models ...............................................................................................
Stroke
TDM and TRX models ...............................................................................
XTZ models ...............................................................................................
Compression ratio
1991 to 1995 TDM models ........................................................................
1996-on TDM models and TRX models ...................................................
XTZ models ...............................................................................................
Cylinder numbering ....................................................................................
Cooling system ..............................................................................................
Clutch ...........................................................................................................
Transmission .................................................................................................
Final drive .....................................................................................................
Major engine repair - general note .......................................................... 4
Neutral switch - check, removal and installation ................... see Chapter 9
Oil and filter - change ..........................................................see Chapter 1
Oil level - check ................................................. see Daily (pre-ride) checks
Oil pressure - check ............................................................ see Chapter 1
Oil pumps - removal, inspection and installation ...................................... 20
Oil sump, oil strainer and pressure relief valve -
Oil tank - removal and installation (1996-on TDM and TRX models) . 21
Operations possible with the engine in the frame..................................... 2
Operations requiring engine removal
Pistons - removal, inspection and installation
Piston rings - inspection and installation ................................................ 15
Pick-up coil assembly - removal and installation ......................................
Recommended running-in procedure ....................................................... 34
Selector drum and forks - removal, inspection and installation .... 32
Spark plug gap - check and adjustment ................................. see Chapter 1
5 Starter clutch and idle/reduction gear - removal,
6
Starter motor - removal and installation ............................... see Chapter 9
Transmission shafts and bearings - removal and installation ................... 30
Transmission shafts - disassembly, inspection and reassembly ... 31
1
Valve clearances - check and adjustment .............................. see Chapter 1
Valve cover - removal and installation .................................................... 7
Valves/valve seats/valve guides - servicing ............................................. 11
with §^ some
Fairly difficult,
!jS
suitable for competent ^
DIY mechanic
Four-stroke parallel twin
849 cc
749 cc
89.5 mm
87.0 mm
67.5 mm
63 mm
9.2 to 1
10.5 to 1
9.5 to 1
No. 1 (left-hand), No. 2 (right-hand)
Liquid cooled
Wet multi-plate
Five-speed constant mesh
Chain
removal, inspection and installation ................................................... 22
see Chapter 5
inspection and installation .................................................................... 18
Difficult, suitable for ^,
.|
experienced DIY ^
mechanic
^S
2*1
.................................................... 3
....................................... 14
|5
Very difficult,
suitable for expert DIY >SJ
or professional 5S
Staged by Stalker
2