Input Shaft Reassembly - Yamaha TDM850 User Manual

31.15a Slide the 4th gear pinion onto the
bush...
unusually high loading on the transmission, or the
machine has covered a very high mileage. Check
the surface of the shaft, especially where a pinion
turns on it, and renew the shaft if it has scored or
picked up, or if there are any cracks. Damage of
any kind can only be cured by renewal. Check the
shaft runout using V-blocks and a dial gauge and
renew the shaft if the runout exceeds the limit
specified at the beginning of the Chapter.
13 Check the washers and circlips and renew
any that are bent or appear weakened or
worn. It is a good policy to renew all circlips
and washers as a matter of course during a
gearshaft overhaul.

Input shaft reassembly

14 During reassembly, apply engine oil to the
31.16 Slide the 3rd gear pinion onto the shaft,
making sure it is the correct way round
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31.17c ... aligning the oil holes (arrowed)
31.15b
. then slide on the splined washer....
mating surfaces of the shaft, pinions and bushes.
When installing the circlips, do not expand their
ends any further than is necessary. Install the
stamped circlips so that their chamfered side
faces the pinion it secures and the sharp edged
sides faces the direction of thrust load (see
'correct fitting of a stamped circlip illustration' in
Tools and Workshop Tips in the Reference
section).
15 If removed, drive or press the 4th gear pinion
bush onto the shaft, aligning the oil hole in the
bush with the hole in the shaft. Slide the 4th gear
pinion, with the pinion dog holes facing away
from the integral 1st gear onto the bush (see
illustration). Slide the splined washer onto the
shaft, then fit the circlip, making sure that it
locates
31.17a Slide on the thrust washer.
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31.17d Install the 5th gear pinion over the
Engine, clutch and transmission 2»55~
31.15c ... and secure them with the circlip
correctly in the groove in the shaft (see
illustrations).
16 Slide the 3rd gear pinion onto the shaft with
the selector fork groove facing the 4th gear
pinion (see illustration).
17 Slide the thrust washer onto the shaft, then
drive or press the 5th gear pinion bush into place,
aligning the oil hole in the bush with the hole in
the shaft (see illustrations). Slide the 5th gear
pinion onto the bush (see illustration).
18 Press the 2nd gear pinion onto the left-hand
end of the shaft using a press or tubular drift,
referring to 7bo/s and Workshop Tips (Section 5)
in the Reference Section if required (see
illustration). Set the pinion so that the distance
between the outside edge of the 2nd gear pinion
and the outside edge of
bush
31.17b ... then fit the bush .
31.18a Fit the 2nd gear pinion .
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