Engine Disassembly And Reassembly - General Information - Yamaha TDM850 User Manual

U.Hi.lS.iHiD.iHSin.nFPICUHi-DiSK
2»10 Engine, clutch and transmission
5.23a Lower front mounting bolt (arrowed)
5.23c Downtube lower bolts (arrowed)
(see illustration). Unscrew the four bolts
securing each of the frame downtubes and
remove the downtubes (see illustrations).
Remove the cap from each end of the upper rear
mounting bolt, then unscrew the nut and
withdraw the bolt (see illustration). Unscrew the
nut on the lower rear mounting bolt and remove
the bolt. Remove the cap from each end of the
swingarm pivot bolt, then unscrew the nut on its
right-hand end. The swingarm pivot bolt also acts
as the middle rear engine mounting bolt, so it
must be removed. To prevent the swingarm/rear
wheel assembly from
partially withdraw the pivot bolt from the left-hand
side and slide into its place from the right-hand
side a suitable bolt that will support the
swingarm, making sure that it does not go into
the engine mount. Withdraw the pivot bolt further
until the engine is free, but leave it partially
inserted so that it still supports the left-hand side
of the swingarm.
24 The engine can now be removed from the
frame. Check that all wiring, cables and hoses
are well clear, then carefully lower the engine
and manoeuvre it forward and out of the side
of the frame (see Caution above).
Installation
25 Installation is the reverse of removal,
noting the following points:
a) Make sure no wires, cables or hoses
become trapped between the engine and the
frame when installing the engine.
b) Many of the engine mounting bolts are of
different size and length. Make sure the
5.23b Downtube upper bolts (arrowed)
5.23d Upper and lower rear mounting bolts
correct bolt is installed in its correct location,
with its washer if fitted. Install all of the bolts
and nuts finger-tight until they are all located,
then tighten them in the order given in the
relevant Step below to their torque settings
as specified at the beginning of the Chapter.
c) On TDM models, if removed, and before the
engine is mounted, fit the small triangular
mounting bracket onto the left-hand side of
the engine and the bracket to the underside
of the engine at the back and tighten their
bolts to the specified torque setting (see
illustration 5.21e and f). Locate all the
becoming unstable,
mounting bolts, not forgetting the washers
with the engine bracket-to-engine mounting
bolts, and tighten them finger-tight. Now
tighten the lower rear mounting bolt first, then
the upper rear mounting bolt nut, then the
engine bracket-to-engine bolts, and finally
the engine bracket-to-frame bolts, tightening
them all to their specified torque. Fit the caps
into each end of the upper rear bolt.
d) On TRX models, locate all the mounting
bolts, not forgetting the washers with the
upper and lower rear bolts (they locate under
the bolt head, not the nut), and the collar
between the right-hand engine bracket and
the engine, and tighten them finger-tight.
Now tighten the lower rear mounting bolt nut
first, then the upper rear mounting bolt nut,
then the upper front mounting bolts (left-hand
side first), then the engine bracket-to-engine
and
(arrowed)
frame bolts (left-hand side), and finally the
engine bracket-to-engine and frame bolts
(right-hand side), tightening them all to their
specified torque. Fit the caps into the upper
front bolts.
e) On XTZ models, locate the swingarm pivot
bolt first, followed by the lower and upper and
rear mounting bolts, then fit the frame
downtubes, and finally locate the lower front
bolt, not forgetting the washers with the
swingarm bolt nut and the lower rear bolt nut,
and tighten them finger-tight. Now tighten
them in the same order to the specified
torque settings. Fit the caps into each end of
the swingarm pivot and the upper rear bolt.
f) On 1991 to 1995 TDM models and all XTZ
models, use a new O-ring on the oil pipe to oil
pump cover union and tighten the bolts to the
specified torque setting.
g) Use new gaskets on the exhaust pipe
connections.
h) Make sure all wires, cables and hoses are
correctly routed and connected, and
secured by any clips or ties, i) Refill the
engine with oil and coolant (see
Chapter 1). i) Adjust the throttle and
clutch cable
freeplay and engine idle speed (see
Chapter 1). k) Adjust the drive chain slack
(see Chapter 1). I) Start the engine and check
that there are
no oil or coolant leaks before installing the
body panels.
6 Engine disassembly and
reassembly - general
information
Disassembly
1 Before disassembling the
external surfaces of the unit
thoroughly cleaned and degreased. This will
prevent contamination of the engine internals,
and will also make working a lot easier and
cleaner. A high flash-point solvent, such as
paraffin (kerosene) can be used, or better still,
a proprietary engine degreaser.
paintbrushes and toothbrushes to work the
solvent into the various recesses of the engine
casings. Take care to exclude solvent or water
from the electrical components and inlet and
exhaust ports.
A Warning: The use of petrol
(gasoline) as a cleaning agent should
be avoided because of the risk of fire.
2 When clean and dry, arrange the unit
on
workbench, leaving suitable clear area for
working. Gather a selection
containers and plastic bags so that parts can
be grouped together in an easily identifiable
manner. Some paper and a pen should be on
hand so that notes can be made and labels
attached where necessary. A supply of clean
rag is also required.
engine, the
should be
Use old
the
of small
Scaned by Stalker