Table of Contents
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Table of Contents
Troubleshooting
Related Manuals for Yamaha TDM850'99 4TX-AE3
Summary of Contents for Yamaha TDM850'99 4TX-AE3
- Page 2 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...
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Page 3: Important Information
EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcycles has a basic understanding of the mechanical ideas and the procedures of motorcycles repair. -
Page 4: How To Use This Manual
EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each section. - Page 5 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on top SPEC right of each page and indicate the subject of each INFO chapter. General information Specifications INSP Periodic inspection and adjustment Engine Cooling system Carburetion COOL CARB Chassis Electrical Troubleshooting CHAS...
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Page 6: Table Of Contents
CONTENTS GENERAL INFORMATION ........MOTORCYCLE IDENTIFICATION . -
Page 7: General Information
MOTORCYCLE IDENTIFICATION INFO EB100000 GENERAL INFORMATION 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. –1–... -
Page 8: Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model: TDM850 Model code: 4TX4 Basic weight (With oil and full fuel tank): 232 kg Carburetor: Type/quantity BDSR38/2 Manufacturer MIKUNI Transmission Primary reduction system Spur gear Primary reduction ratio 67/39 (1.718) Secondary reduction system Chain drive Secondary reduction ratio 43/16 (2.688) -
Page 9: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Clutch: Clutch spring free length 50 mm 48 mm Quantity Carburetor: I.D. mark 4TX4 40 Main jet #147.5 Main air jet Jet needle #1: 6DJP17 #2: 6CL1 Needle jet Pilot air jet 1 #87.5 Pilot air jet 2 #120... -
Page 10: Electrical
SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit Charging system: Type A.C. magneto Model/manufacturer TLN252/DENSO Nominal output 14 V 25 A at 5,000 r/min 0.23 X 0.35 Ω at 20_C/W-W Stator coil resistance Starter relay: Model/manufacturer MS5F-421 /JIDECO Amperage rating 180 A 4.2 X 4.6 Ω... -
Page 11: Cable Routing
SPEC CABLE ROUTING CABLE ROUTING Throttle cable 1 Ignition coil (left) lead G Align the brake hose white mark to Right handlebar switch lead Ignition coil (right) lead the mark of bracket. Brake hose Negative lead H Fasten the brake hose with a plas- Clutch cable tic band and cut the end of band. - Page 12 SPEC CABLE ROUTING L Fasten the meter lead and headlight lead with a plas- P Fasten the wireharness with a plastic band. tic band. Q Fasten the wireharness and ignition coil (left) lead M Fasten the wireharness with a plastic band. with a plastic band.
- Page 13 SPEC CABLE ROUTING Front flasher light (left) lead A.C. magneto lead A Fasten the left handlebar switch Main switch lead Air filter case breather hose lead and main switch lead with a Starter cable 1 Carburetor heater hose plastic band. Left handlebar switch lead Starter cable 2 B Route the wireharness to the rear-...
- Page 14 SPEC CABLE ROUTING D Fasten the rear flasher light (left) lead. J Clamp the speed sensor lead to the outer tube with a E Fasten the sidestand switch lead neutral switch lead holder. and A.C. magneto lead. K Clamp the speed sensor lead along the brake hose F Route the sidestand switch lead and air filter case (three position).
- Page 15 SPEC CABLE ROUTING Battery negative lead Vacuum hose (#1) D Fasten the carburetor air vent hose. Battery positive lead Vacuum hose (#2) E Route the carburetor breather Starter motor lead Coolant reservoir breather hose hoses, vacuum hose (#1) down Fuel sender lead Carburetor breather hose ward and vacuum hose (#2) up- Fuel tank drain hose...
- Page 16 SPEC CABLE ROUTING J Fasten the right handlebar switch lead and speed S Route the brake switch lead through the guide. sensor lead with a clamp. T Fasten the wireharness, rear flasher lead with a clamp. K Fasten the throttle cable and speed sensor lead with a U Fasten the wireharness with a clamp.
- Page 17 SPEC CABLE ROUTING Head light lead Fuel tank drain hose A Fasten the meter lead, headlight Wireharness Fuel hose lead wireharness with a clamp. Meter light lead Fuel sender lead B Fasten the wireharness, coolant Throttle cable Starter motor lead reservoir hose with a clamp.
- Page 18 SPEC CABLE ROUTING H Fasten the carburetor breather hose and see the N To head light. hose mark. O To auxiliary light. I In order to carburetor breather hose, idle adjust cable P To meter. coolant breather hose from downward. Q Fasten the meter lead, headlight lead with a clamp.
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Page 19: Periodic Inspection And Adjustment
INTRODUCTION/ INSP PERIODIC MAINTENANCE/LUBRICATION INTERVALS PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspection and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as new vehicles that are being prepared for sale. - Page 20 Cooling system S 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. NOTE: S The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
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Page 21: Seat, Tail Cover And Fuel Tank
INSP SEAT, TAIL COVER AND FUEL TANK SEAT, TAIL COVER AND FUEL TANK 16 Nm (1.6mSkg) 3.8 Nm (0.38mSkg) Order Job name/Part name Q’ty Remarks Seat, tail cover and fuel tank removal Remove the parts in the order below. Side cowling Refer to “COWLINGS”. -
Page 22: Engine
INSP CARBURETOR SYNCHRONIZATION ENGINE CARBURETOR SYNCHRONIZATION NOTE: Valve clearance and idling speed should be ad- justed properly before synchronizing the carbure- tors. 1. Place the motorcycle on a level surface. NOTE: Place the motorcycle on its centerstand if a cen- terstand is equipped. - Page 23 INSP CARBURETOR SYNCHRONIZATION 7. Adjust: S Carburetor synchronization Adjustment steps: S Synchronize carburetor #1 to carburetor #2 by turning synchronizing screw 1 until both gauges read the same. S Race the engine for less than a second, two or three times and check the synchronization again.
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Page 24: Engine Oil Level Inspection
INSP ENGINE OIL LEVEL INSPECTION ENGINE OIL LEVEL INSPECTION NOTE: Position the motorcycle straight up when inspect- ing the oil level. 1. Place the motorcycle on a level surface. NOTE: S After idling the engine a few minutes. The summer season is about 5 minutes and the winter season is about 15 minutes. -
Page 25: Engine Oil Replacement
INSP ENGINE OIL REPLACEMENT ENGINE OIL REPLACEMENT 1. Start the engine and let it warm up for several minutes. 2. Stop the engine and place an oil pan under the drain bolt. 3. Remove: S Oil filler plug 1 4. Remove: S Drain bolt (with gasket) 1 S Oil filter drain bolt (with gasket) 2 Drain the crankcase and oil tank of its oil. - Page 26 INSP ENGINE OIL REPLACEMENT 7. Fill: S Crankcase CAUTION: The engine should be filled with oil in two steps. First fill the engine with 3.2 liters of oil. Then start the engine and race it five or six times. Continue idling the engine a few min- utes.
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Page 27: Fuel Line Inspection
INSP FUEL LINE INSPECTION FUEL LINE INSPECTION 1. Remove: S Side cowling S Seat S Side cover S Fuel tank Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK”. 2. Inspect: S Fuel hoses 1 Cracks /Damage ! Replace. Loose connection ! Connect properly. NOTE: Drain and flush the fuel tank if abrasive damage to any components is evident. -
Page 28: Clutch
CLUTCH CLUTCH CLUTCH 70 Nm (7.0mSkg) 8 Nm (0.8mSkg) Order Job name/Part name Q’ty Remarks Clutch removal Remove the parts in the order below. Clutch spring Pressure plate Plain washer/Bearing Pull rod Friction plate Friction plate Clutch plate Refer to “REMOVAL”, and Clutch boss nut “INSTALLATION”. -
Page 29: Installation
CLUTCH INSTALLATION 1. Install: S friction plates S clutch plates CAUTION: The 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. -
Page 30: Instrument Functions
ELEC INSTRUMENT FUNCTIONS INSTRUMENT FUNCTIONS This combination meter is equipped with the fol- lowing. COMBINATION METER S An odometer S Two trip odometers S A clock Odometer and trip meters Use the trip meters to estimate how far you can Speedometer ride on a tank of fuel. -
Page 31: Signal System
ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM –25–... - Page 32 ELEC SIGNAL SYSTEM Main switch Fuse (position light and hazard) Battery Main fuse Fuel sender Fuel meter Fuel level indicator light Turn indicator light (left) Turn indicator light (right) Speed meter Speed sensor Front flasher light Rear flasher light Hazard switch Turn switch Flasher relay Hazard relay...
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Page 33: Troubleshooting
ELEC SIGNAL SYSTEM EB806010 EB802401 TROUBLESHOOTING 2. Battery S Any of the following fail to light: flasher S Check the condition of the battery. light, trun and fuel level indicator light. Refer to “BATTERY INSPECTION”. S The fuel meter fails to operate. Open-circuit voltage 12.8 V or more at 20_C Check:... -
Page 34: Signal System Check
ELEC SIGNAL SYSTEM SIGNAL SYSTEM CHECK 4. Voltage 1. Flasher light and/or turn indicator light does S Connect the pocket tester (DC 20 V) to the not blink. flasher relay coupler. 1. Flasher/turn indicator light bulb and socket Tester (+) lead ! Brown/Red terminal S Check the flasher/turn indicator light bulb and Tester (–) lead ! Frame ground socket for continuity. - Page 35 ELEC SIGNAL SYSTEM 2. The fuel level indicator light fails to come on or S Turn the main switch to “ON” or “P”. the fuel meter fails to operator. S Check for voltage (12 V) on the “Brouwn/White” 1. Fuel level indicator light bulb and socket lead at the flasher relay terminal.
- Page 36 ELEC SIGNAL SYSTEM S Set the main switch to “ON”. S Is the fuel sender OK? S Measure the voltage (12 V). S Is the voltage within specification? Replace fuel sender. This circuit is OK. The wiring circuit from the main switch to the 3.
- Page 37 ELEC SIGNAL SYSTEM Battery positive terminal ! red Battery negative terminal ! black Tester positive probe ! white Tester negative probe ! black S Set the main switch to “ON”. S Elevate the front wheel and slowly rotate it. S Does the voltage (5V) read cycle 4 times with each, full rotation of the front wheel? Replace the speed sensor.
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Page 38: Fuel Pump System
ELEC FUEL PUMP SYSTEM EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM –32–... -
Page 39: Fuel Pump Circuit Operation
ELEC FUEL PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump. Battery Main fuse Main switch Ignition fuse Engine stop switch Ignitor unit Fuel pump relay Fuel pump –33–... -
Page 40: Troubleshooting
ELEC FUEL PUMP SYSTEM EB808020 EB802401 TROUBLESHOOTING 2. Battery _Check the condition of the battery. The fuel pump fails to operate. Refer to “BATTERY INSPECTION”. Check: Open-circuit voltage 1. main and ignition fuses 12.8 V or more at 20 C 2. - Page 41 ELEC FUEL PUMP SYSTEM S Measure the fuel pump resistance. 5. Fuel pump relay S Disconnect the relay unit from the coupler. Fuel pump resistance 4 X 10 Ω at 20_C S Connect the pocket tester (Ω 1) and battery (12 V) to the relay unit ferminals as shown.
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Page 42: Checking The Fuel Pump
ELEC FUEL PUMP SYSTEM EB808410 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: _ Stop the engine before refuelling. _ Do not smoke and keep away from open flames, sparks or any other source of fire. -
Page 43: Tdm850 '99Wiring Diagram
TDM850 ’99 WIRING DIAGRAM A.C. maguneto / pickup coil Rectifier / regulator Main switch Fuse (position light and hazard) Backup fuse (odometer) Battery Starter relay Main fuse Starter motor Thermo unit Fuel pump Starting circuit cutoff relay Fuel pump relay Relay unit T.P.S (throttle position sensor) Gear position switch...