Balancer Shafts - Removal, Inspection And Installation - Yamaha TDM850 User Manual

2*42 Engine, clutch and transmission
22.12 Fit the new gasket, making sure the
dowels (arrowed) are in place ...
Installation
10 Fit a new O-ring onto the relief valve and
smear it with clean oil, then push the valve into
its socket in the crankcase. Fit the holder, then
apply a suitable non-permanent thread locking
compound to the bolt and tighten it to the torque
setting specified at the beginning of the Chapter
(see illustration 22.5).
11 Install the oil strainer and its cover (see
illustrations 22.4c, b and a). Apply a suitable
non-permanent thread locking compound to the
cover screws and tighten them to the torque
setting specified at the beginning of the Chapter.
12 If removed, fit the sump dowels into the
crankcase. Lay a new gasket onto the sump (if
the engine is in the frame) or onto the
23.3 Remove the screws (arrowed) and lift off
the cover
23.4b Unscrew the bolts (arrowed) and
remove the cover, noting the earth cable
(A), cable guide (B) and copper washer (C)
22.13 ... then fit the sump
crankcase (if the engine has been removed and
is positioned upside down on the work surface)
(see illustration). Make sure the holes in the
gasket align correctly with the bolt holes.
13 Position the sump onto the crankcase, then
apply a suitable non-permanent thread locking
compound to the bolts and install them finger-
tight (see illustration). Tighten the bolts evenly
in a criss-cross pattern to the specified torque
setting.
14 Install the oil filter and cover and fill the
engine with the correct type and quantity of oil
(see Chapter 1).
15 On TDM and TRX models install the exhaust
system (see Chapter 4). On 1991 to 1995 TDM
models and XTZ models, install the
23.4a Unscrew the banjo bolts (A) and the
bracket bolt (B) and remove the pipe
23.5a Unscrew the bolts (arrowed) and
remove the holder
UNREGISTERED VI
engine bashplate (see Chapter 8). Start the
engine and check that there are no oil leaks
around the sump and oil filter cover.
23 Balancer shafts - removal,
inspection and installation
Note: On 1991 to 1995 TDM models and
XTZ models, the balancer shafts can be removed
with the engine in the frame. If the engine has
been removed, ignore the steps which do not
apply. On 1996-on TDM models and all TRX
models, the engine must be removed from the
frame.
Removal
1 On 1991 to 1995 TDM models and XTZ
models, remove the seat, side covers and engine
bashplate (see Chapter 8), the fuel tank and
exhaust system (see Chapter 4), the starter
clutch and idle/reduction gear (see Section 18),
and the oil sump (see Section 22).
2 On 1996-on TDM models and TRX models,
remove the oil tank (see Section 21), the starter
clutch and idle/reduction gear (see Section 18),
and the oil sump (see Section 22).
3 On 1992 to 1995 TDM models, unscrew the
bolts securing the mudflap/engine top cover and
remove the cover, feeding the earth cable
through as you do (see illustration).
4 On 1991 to 1995 TDM models and XTZ
models, unscrew the oil pipe banjo bolts and the
bracket bolt securing the oil pipe to the cylinder
head and the crankcase top cover and remove
the pipe (see illustration). Discard the sealing
washers as new ones must be used. Working
evenly in a criss-cross pattern, unscrew the bolts
securing the cover to the top of the crankcase
and remove the cover (see illustration). Note
the position of the earth cable and cable guide(s)
and of the bolt with the copper sealing washer.
Discard the gasket as a new one must be used.
Note the positions of the dowels and remove
them if they are loose.
5 Unscrew the bolts securing the oil strainer
holder and remove the holder (see illustration).
Remove the O-ring from the oil passage collar in
the crankcase (see illustration); a new O-ring is
required for reassembly.
23.5b The O-ring (arrowed) should be
renewed
UNREGISTERED VERSION OF PICTURE-DESK
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