Yamaha TDM850 1999, Service Manual

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Page 2: ...e this Supplementary Service Manual together with the following manual TDM850 96 SERVICE MANUAL 4TX AE1 TDM850 97 SUPPLEMENTARY SERVICE MANUAL 4TX AE2 TDM850 99 SUPPLEMENTARY SERVICE MANUAL 1998 by Yamaha Motor Co Ltd First Edition November 1998 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...all its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert ...

Page 4: ...elp identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an...

Page 5: ...ntify the specifications appearing in the text 10 Can be serviced with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Torque 15 Wear limit clearance 16 Engine speed 17 Ω V A Illustrated symbols 18 to 23 in the exploded dia grams indicate the types of lubricants and lubrica tion points 18 Apply engine oil 19 Apply gear oil 20 Apply molybdenum disulfide oil 21 Apply wheel bearing gr...

Page 6: ...ICATION INTERVALS 13 SEAT TAIL COVER AND FUEL TANK 15 SEAT TAIL COVER AND FUEL TANK 15 ENGINE 16 CARBURETOR SYNCHRONIZATION 16 ENGINE OIL LEVEL INSPECTION 18 ENGINE OIL REPLACEMENT 19 FUEL LINE INSPECTION 21 CLUTCH 22 CLUTCH 22 INSTALLATION 23 INSTRUMENT FUNCTIONS 24 COMBINATION METER 24 SIGNAL SYSTEM 25 CIRCUIT DIAGRAM 25 TROUBLESHOOTING 27 SIGNAL SYSTEM CHECK 28 FUEL PUMP SYSTEM 32 CIRCUIT DIAGR...

Page 7: ...ORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head MODEL LABEL The model label 1 is affixed to the frame This in formation will be needed to order spare parts ...

Page 8: ...m Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio 1st 2nd 3rd 4th 5th Spur gear 67 39 1 718 Chain drive 43 16 2 688 Constant mesh 5 speed Left foot operation 37 14 2 643 37 19 1 947 30 20 1 500 27 23 1 174 27 28 0 964 Bulb wattage quantity Meter light Indicator lights Neutral Turn High beam Fuel Water tempere 12V 2 W 3 14 V 1 4 W ...

Page 9: ...size Starter jet 1 Starter jet 2 Throttle valve size Fuel level Engine idle speed Intake vacuum 4TX4 40 147 5 65 1 6DJP17 2 6CL1 P O 87 5 120 1 0 17 5 0 8 0 9 0 8 2 0 1 5 32 5 0 9 95 4 4 X 5 4 mm 1050 X 1250 r min 36 0 X 38 7 kPa 270 X 290 mmHg Fuel pump Type Model manufacturer Output pressure Electrical type 4TX MITSUBISHI 7 kPa 0 07 kgf cm2 0 07 bar CHASSIS Item Thread size Tightening torque Rem...

Page 10: ...rer resistance full empty 4TX NIPPON SEIKI 4 X 10Ω 90 X 100Ω SSS SSS SSS Fuel pump relay Model manufacturer Coil winding resistance G8R 30Y B OMRON 225 Ω 10 SSS SSS Hazard relay Model manufacturer Coil winding resistance 4KM 00 MATSUSHITA 72 X 88 Ω at 20_C SSS SSS Circuit breakers Type Amperage for individual circuits Main fuse Headlight fuse Signal system fuse Ignition fuse Fuse position light an...

Page 11: ...ead A Fasten the right handlebar switch lead with a plastic band B Fasten the handlebar switch lead with a plastic band C 50 mm D Fasten the horn lead with a plastic band E 60 mm F Set the clamp within 10 mm from the upper end of protector G Align the brake hose white mark to the mark of bracket H Fasten the brake hose with a plas tic band and cut the end of band I Pass the speed sensor lead be tw...

Page 12: ...lead and headlight lead with a plastic band O Connect the coupler and insert to the protector P Fasten the wireharness with a plastic band Q Fasten the wireharness and ignition coil left lead with a plastic band R Fasten the wireharness right handlebar switch lead main switch lead fan motor lead with a plastic band S Set the ignition coil at the mark upward T Protector is under the coupler ...

Page 13: ...ss to the rear side of the frame pipe C Route the starter cable through ra diator hose upward and spark plug lead rear side and in front of air fil ter case breather hose Route the spark plug lead to the outside of the carburetor starter bracket and carburetor heater hose 1 Front flasher light left lead 2 Main switch lead 3 Starter cable 1 4 Left handlebar switch lead 5 Spark plug lead 6 Carbureto...

Page 14: ... the idle ad just bracket I Route the air filter case breather hose to the outside of the carburetor heater hose and route the carburetor heater hose to the inside of the air filter case breather hose J Clamp the speed sensor lead to the outer tube with a holder K Clamp the speed sensor lead along the brake hose three position L Connect the coupler and insert the protector Set the protector betwee...

Page 15: ... lead 22 CYCLELOCK lead A Route the battery positive lead and battery negative lead through the clamp B Fasten the wireharness Coolant breather hose and flasher relay lead C Route the carburetor breather hoses through the engine clamp D Fasten the carburetor air vent hose E Route the carburetor breather hoses vacuum hose 1 down ward and vacuum hose 2 up ward through the guide F Route the vacuum ho...

Page 16: ...reservoir breather hose fuel tank drain hose carburetor breather hose through the guide P Route the carburetor breather hoses through the clamp Q Route the fuel tank drain hose fuel tank breather hose through the hole of the frame bracket R Route the coolant reservoir breather hose fuel tank breather hoseand fuel tank drain hose through the guide S Route the brake switch lead through the guide T F...

Page 17: ... Coolant reservoir breather hose 19 Coolant reservoir hose 20 Fuel hose 21 Carburetor breather hose 22 Cylinder head breather hose 23 Air filter case breather hose A Fasten the meter lead headlight lead wireharness with a clamp B Fasten the wireharness coolant reservoir hose with a clamp C Fasten the fuel hose with a clamp D Route the starter relay lead and fuel sender lead through the guide of br...

Page 18: ...hrottle posi tion sensor lead K Fasten the wireharness with a clamp L To left flasher M Fasten the headlight lead with a clamp N To head light O To auxiliary light P To meter Q Fasten the meter lead headlight lead with a clamp R Fasten the meter lead headlight lead and right flash er lead connecter with a clamp S To right flasher T Fasten the meter lead headlight lead relay assembly lead and right...

Page 19: ...Check operation fluid level and vehicle for fluid leakage Correct accordingly Replace brake pads if necessary 9 Wheels Check balance runout and for damage Rebalance or replace if necessary 10 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary 11 Wheel bearings Check bearing for looseness or damage Replace if necessary 12 Swingarm Check swingram pivo...

Page 20: ...ck coolant level and vehicle for coolant leakage Correct if necessary Change coolant every 24 000 km or 24 months whichever comes first Since these items require special tools data and technical skills they should be serviced by a Yamaha dealer The air filter needs more frequent service if you are riding in unusually wet or dusty areas Hydraulic brake system When disassembling the master cylinder ...

Page 21: ...upler Tail cover Side cover Fuel hose Fuel tank breather hose Fuel tank Fuel sender coupler 1 1 1 2 1 1 1 1 Remove the parts in the order below Refer to COWLINGS Disconnect Set the fuel cock fuel tank side to OFF before disconnecting the fuel hoses Disconnect For installation reverse the removal procedure NOTE 3 8 Nm 0 38m kg 16 Nm 1 6m kg SEAT TAIL COVER AND FUEL TANK ...

Page 22: ...ble stand under the motorcycle 2 Remove Side cowling Seat Side cover Fuel tank Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK 3 Remove Vacuum hose 1 1 carburetor 1 Vacuum hose 2 2 carburetor 2 4 Attach Adapters Vacuum gauge 1 Engine tachometer 2 to 1 spark plug lead Vacuum gauge 90890 03094 Engine tachometer 90890 03113 5 Start the engine and let it warm up for several minutes 6 Check Engine idli...

Page 23: ...nchronization again Intake vacuum at idle speed 36 0 38 7 kPa 270 290 mm Hg The difference between both carburetors should be 0 67 kPa 5 mm Hg or less 8 Check Engine idling speed Out of specification Adjust 9 Stop the engine and detach the measuring equipment 10 Adjust Throttle cable free play Refer to THROTTLE CABLE FREE PLAY AD JUSTMENT Free play 3 5 mm At throttle grip flange 11 Install Fuel ta...

Page 24: ... a suitable stand under the motorcycle 2 Inspect Oil level Oil level should be between the maximum a and minimum b marks Oil level is below the minimum mark Add oil up to the proper level Recommended oil Refer to the following chart for selection of oils which are suited to the atmospheric temperatures Recommended engine oil classifica tion API STANDARD API SE or higher grade Do not put in any che...

Page 25: ...1 Oil filter drain bolt with gasket 2 Drain the crankcase and oil tank of its oil 5 If the oil filter is to be replaced during this oil change remove the following parts and rein stall them Replacement steps Remove the oil filter cover 1 and oil filter ele ment 2 Check the O rings 3 if cracked or damaged replace them with a new one Install the oil filter element and oil filter cover Oil filter cov...

Page 26: ...oil Then start the engine and race it five or six times Continue idling the engine a few min utes Stop the engine and fill it with oil to the specified level Oil quantity Total amount 4 2 L Periodic oil change 3 5 L With oil filter replacement 3 6 L 8 Install Oil filler plug 9 Inspect Engine for oil leaks Oil level Refer to ENGINE OIL LEVEL INSPECTION ...

Page 27: ... Fuel tank Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK 2 Inspect Fuel hoses 1 Cracks Damage Replace Loose connection Connect properly Drain and flush the fuel tank if abrasive damage to any components is evident 3 Install All removed parts Install all removed parts in reversed order of their removal ...

Page 28: ...Pull rod Friction plate Friction plate Clutch plate Clutch boss nut Lock washer Clutch boss Thrust plate Spacer Bearing Clutch housing Thrust plate 2 Thrust plate 1 6 1 1 1 1 7 2 8 1 1 1 1 1 1 1 1 1 Remove the parts in the order below For installation reverse the removal procedure Refer to REMOVAL and INSTALLATION 70 Nm 7 0m kg 8 Nm 0 8m kg CLUTCH CLUTCH ...

Page 29: ...he friction plates are made in two types The first and last friction plates are different in ma terial from the other ones and black on the sur face Assembly should be done in the correct order Mount friction and clutch plate alternately Lubricate the friction plates with engine oil ...

Page 30: ...2 ODO To reset a trip odometer to 0 0 select it by pushing the select button and push the reset button for at least one second Clock To change the display to the clock mode push both the select and reset buttons To set the clock 1 Push both the select and reset buttons for at least two seconds 2 When the hour digits start flashing push the re set button to set the hours 3 Push the select button to...

Page 31: ... 25 SIGNAL SYSTEM ELEC EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM ...

Page 32: ...ttery 8 Main fuse 22 Fuel sender 25 Fuel meter 27 Fuel level indicator light 32 Turn indicator light left 33 Turn indicator light right 34 Speed meter 35 Speed sensor 36 Front flasher light 37 Rear flasher light 44 Hazard switch 45 Turn switch 48 Flasher relay 49 Hazard relay ...

Page 33: ... sys tem s wiring Check the condition of each of the signal ing system s circuits Refer to SIGNAL SISTEM CHECK SIGNAL SYSTEM ELEC NOTE S Check the main and signaling system fuses for continuity Refer to FUSE INSPECTION S Are the main and signaling system fuses OK 1 Main and signal system fuses YES NO Replace the fuse s EB806010 TROUBLESHOOTING S Any of the following fail to light flasher light tru...

Page 34: ...ster DC 20 V to the hazard relay coupler Tester lead Brown Red terminal Tester lead Frame ground YES NO Wiring circuit from main switch to hazard relay connector is faulty repair 4 Voltage Connect the pocket tester DC 20 V to the flasher relay coupler Tester lead Brown Red terminal Tester lead Frame ground YES NO Wiring circuit from main switch to flasher relay connector is faulty repair Turn the ...

Page 35: ...r P S Turn the turn switch to L or R S Check for voltage 12 V on the Chocolate lead or Dark green lead at the bulb socket connector S Is the voltage with in specification YES NO Wiring circuit from turn switch to bulb socket connector is faulty repair This circuit is good 1 Fuel level indicator light bulb and socket S Check the fuel level indicator bulb and socket continuity S Are the fuel level i...

Page 36: ...uel meter Turn the main switch to ON Check the fuel gauge needle moves F or E Float position Needle moves Float UP F Float DOWN E 4 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler wire harness side as shown Tester positive probe Brown Tester negative probe Green Red 1 2 1 2 Set the main switch to ON Measure the voltage 12 V Is the voltage within specification YES NO The wir...

Page 37: ...wheel and slowly rotate it Does the voltage 5V read cycle 4 times with each full rotation of the front wheel YES NO Replace the speed sensor 2 Wiring Check the entire wiring signal system s wiring Refer to CIRCUIT DIAGRAM Is the signal system s wiring properly con nected and with out defects YES NO Properly connect or repair the signal sys tem s wiring Replace the speed meter 1 2 3 3 ...

Page 38: ... 32 FUEL PUMP SYSTEM ELEC Main switch 3 6 8 11 13 18 61 Battery Main fuse Fuel pump Fuel relay Ignitor unit Engine stop switch Ignition fuse 62 EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM ...

Page 39: ... ELEC 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay 8 Fuel pump EB808010 FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump ...

Page 40: ...y Refer to SWITCH INSPECTION Is the engine stop switch OK YES NO Replace the right han dlebar switch NOTE 1 Main and ignition fuses Check the main and ignition fuses for continu ity Refer to SWITCH INSPECTION Are the main and ignition fuses OK YES NO Replace the fuse s EB808020 TROUBLESHOOTING The fuel pump fails to operate Check 1 main and ignition fuses 2 battery 3 main switch 4 engine stop swit...

Page 41: ...e relay unit 6 Fuel pump resistance Disconnect the fuel pump coupler from the wire harness Connect the pocket tester Ω 1 to the fuel pump coupler fuel pump side as shown 1 2 EB808400 Tester positive probe black blue Tester negative probe black YES NO Relpace the fuel pump Measure the fuel pump resistance Fuel pump resistance 4 10 Ω at 20 C Is the fuel pump OK 7 Wiring Check the entire fuel pump sy...

Page 42: ...accidentally spill gasoline wipe it up immediately with dry rags If gasoline touches the engine when it is hot a fire may occur Therefore make sure that the engine is completely cool before per forming the following test 1 Check fuel pump operation a Fill the fuel tank b Put the end of the fuel hose into an open con tainer c Connect the battery 12 V to the fuel pump coupler as shown Battery positi...

Page 43: ...ear position switch 17 Sidestand switch 18 Ignitor unit 19 Ignition coil 20 Spark plug 21 CYCLELOCK option 22 Fuel sender 23 Meter assembly 24 Tachometer 25 Fuel meter 26 Meter light 27 Fuel level indicator light 28 Neutral indicator light 29 Water temperature meter 30 Combination meter 31 High beam indicator light 32 Turn indicator light left 33 Turn indicator light right 34 Speed meter 35 Speed ...