Table Of Contents - Yamaha TDM850 User Manual

Table of Contents

Safety First!1
Remember1
Frame And Engine Numbers2
Identification Numbers2
Buying Spare Parts2
Daily (Pre-Ride) Checks4
Engine/Transmission Oil Level Check4
Tdm850 (1991 To 1995) And Xtz750 Models4
Tdm850 (1996-On) And Trx Models5
Brake Fluid Level Checks6
Front Brake Fluid Level6
Before You Start6
Rear Brake Fluid Level7
Coolant Level Check8
Tyre Checks9
The Correct Pressures9
Tyre Care9
Tyre Tread Depth9
Routine Maintenance And Servicing10
Contents10
Routine Maintenance11
Specifications11
Torque Settings12
Recommended Lubricants And Fluids12
Component Locations13
Maintenance Schedule16
Introduction17
Every 300 Miles (500 Km)17
Lubrication18
Hint18
Every 4000 Miles (6000 Km) Or 6 Months19
Spark Plugs - Check And Adjustment19
Idle Speed - Check And Adjustment20
Carburettors - Synchronisation20
Air Filter - Cleaning21
Fuel System - Check22
Engine - Oil Change22
Filter Cleaning22
Brake Pads - Wear Check23
Brake System - Check23
Clutch - Check And Adjustment25
Battery - Check25
Wheels And Tyres - General Check26
Wheel Bearings - Check26
Sidestand And Cut-Off Switches - Check26
Nuts And Bolts - Tightness Check26
Cooling System - Check27
Throttle And Choke Cables - Check27
Throttle Cables27
Stand, Lever Pivots And Cables - Lubrication28
Swingarm And Suspension Bearings (Xtz Models) - Re-Greasing28
Choke Cable28
Pivot Points28
Suspension - Check29
Steering Head Bearings - Freeplay Check And Adjustment29
Front Suspension29
Rear Suspension29
Every 8000 Miles (12,000 Km) Or 12 Months31
Engine - Oil And Filter Change31
Every 16,000 Miles (24,000 Km) Or Two Years32
Fuel Filter - Renewal (1999 Tdm Models)32
Swingarm And Suspension Bearings (Tdm And Trx Models) - Re-Greasing32
Steering Head Bearings - Lubrication32
Cooling System - Draining, Flushing And Refilling33
Every 28,000 Miles (42,000 Km)34
Valve Clearances - Check And Adjustment34
Refilling34
Shim Selection Chart - Inlet Valves36
Shim Selection Chart - Exhaust Valves36
Every Four Years37
Non-Scheduled Maintenance37
Brake Hoses - Renewal37
Headlight Aim - Check And Adjustment37
Cylinder Compression - Check38
Engine - Oil Pressure Check38
Front Forks - Oil Change39
Tdm, Trxand 1995 Xtz Models39
1989 To 1994 Xtz Models39
Engine, Clutch And Transmission40
Degrees Of Difficulty40
Cylinder Head41
Cylinder Block41
Oil Pump43
General Information45
Operations Possible With The Engine In The Frame45
Operations Requiring Engine Removal45
Major Engine Repair - General Note45
Engine Disassembly And Reassembly - General Information49
Valve Cover - Removal And Installation50
Camshafts And Followers - Removal, Inspection And Installation51
Cam Chain Tensioner - Removal, Inspection And Installation56
Cylinder Head - Removal And Installation57
Valves/Valve Seats/Valve Guides - Overhaul59
Cylinder Head And Valves - Disassembly, Inspection And Reassembly59
Cylinder Block-Removal, Inspection And Installation62
Pistons - Removal, Inspection And Installation64
Piston Rings - Inspection And Installation66
Clutch - Removal, Inspection And Installation67
Clutch Assembly69
Clutch Cable - Removal And Installation73
Starter Clutch And Idle/Reduction Gear - Removal, Inspection And Installation74
Gearchange Mechanism External Components - Removal, Inspection And Installation74
Oil Pumps - Removal And Installation76
Oil Tank - Removal And Installation (1996-On Tdm Models And All Trx Models)79
Balancer Shafts - Removal, Inspection And Installation81
Cam Chain And Guides - Removal, Inspection And Installation84
Crankcase Halves - Separation And Reassembly84
Crankcase Bolts - 1991 To 1995 Tdm Models And Xtz Models85
Crankcase Bolts - 1996-On Tdm Models And Trx Models85
Crankcase Halves - Inspection And Servicing87
Main And Connecting Rod Bearings - General Information87
Connecting Rods - Removal, Inspection And Installation88
Oil Clearance Check88
Bearing Shell Selection89
Main Bearing Shell Selection91
Transmission Shafts And Bearings - Removal And Installation92
Transmission Shafts - Disassembly, Inspection And Reassembly93
Input Shaft Reassembly94
Output Shaft Disassembly95
Output Shaft Inspection95
Output Shaft Reassembly95
Selector Drum And Forks Removal, Inspection And Installation96
Initial Start-Up After Overhaul98
Recommended Running-In Procedure98
Cooling System99
Radiator Pressure Cap - Check100
Coolant Reservoir - Removal And Installation100
Cooling Fan And Cooling Fan Switch - Check And Renewal101
Coolant Temperature Gauge/Warning Light And Sender - Check And Renewal102
Coolant Temperature Warning Light (1999 Tdm Models)102
Coolant Temperature Gauge (Xtz, Trx And 1991-98 Tdm Models)102
Sender Check (All Models)102
Thermostat Housing And Thermostat - Removal, Check And Installation103
All Models103
Radiator - Removal And Installation104
Water Pump - Check, Removal, And Installation105
Coolant Hoses - Removal And Installation106
Fuel And Exhaust Systems107
Fuel Tank And Fuel Tap(S) - Removal And Installation109
General Information And Precautions109
Fuel Tank - Tdm Models109
Fuel Tank - Trx Models110
Fuel Tank - Xtz Models110
Fuel Tap(S)110
Fuel Tank - Cleaning And Repair112
Air Filter Housing - Removal And Installation112
Idle Fuel/Air Mixture Adjustment - General Information112
Carburettor Overhaul - General Information113
Carburettors - Removal And Installation113
Carburettors Cleaning And Inspection114
1991 To 1998 Tdm Models, All Trx And Xtz Models114
Ignition System116
Ignition Ht Coils - Check, Removal And Installation118
Ignitor Unit - Check, Removal And Installation119
Ignition Timing - General Information And Check120
Throttle Position Sensor (1996- % On Tdm And Trx)- Check, Adjustment And Replacement120
Frame, Suspension And Final Drive122
Frame - Inspection And Repair124
Footrests, Brake Pedal And Gearchange Lever - Removal And Installation124
Brake Pedal125
Gearchange Lever125
Sidestand - Removal And Installation126
Handlebars And Levers - Removal And Installation126
Handlebars126
Clutch Lever128
Front Brake Lever128
Forks - Removal And Installation128
Forks - Disassembly, Inspection And Reassembly130
1991 To 199S Tdm Models130
1996-On Tdm Models And Trx Models134
Xtz Models135
Front Fork Components - Xtz Models136
Steering Stem - Removal And Installation137
Steering Head Bearings - Inspection And Replacement139
Rear Shock Absorber - Removal, Inspection And Installation140
Rear Suspension Linkage (Trx And Xtz Models) - Removal, Inspection And Installation141
Suspension Linkage And Swingarm Assembly - Trx Models142
Suspension - Adjustments143
Front Forks143
Suspension Linkage And Swingarm Assembly - Xtz Models143
Swingarm - Inspection And Bearing Replacement146
Bearing Replacement - Tdm And Trx Models146
Bearing Replacement - Xtz Models146
Drive Chain - Removal, Cleaning And Installation147
Endless Type Chain147
Riveted Link Type Chain148
Sprockets - Check And Replacement148
Rear Sprocket Coupling/Rubber Dampers - Check And Replacement150
Brakes, Wheels And Tyre151
Table Of Contents151
Brake Pads - Replacement153
Brake Calipers - Removal, Overhaul And Installation156
Overhaul157
Brake Discs - Inspection, Removal And Installation158
Front Brake Master Cylinder - Removal, Overhaul And Installation158
Rear Brake Master Cylinder - Removal, Overhaul And Installation160
Brake Hoses, Pipes And Unions - Inspectionand Replacement162
Brake System - Bleeding163
Wheels - Inspection And Repair163
Wheels - Alignment Check164
Front Wheel-Removal And Installation164
Rear Wheel - Removal And Installation166
Wheel Bearings - Removal, Inspection And Installation167
Front Wheel Bearings167
Rear Wheel Bearings168
Sprocket Coupling Bearing169
Tyres - General Information And Fitting169
Common Tyre Sidewall Markings170
Bodywork171
Seat - Removal And Installation172
1996-On Tdm Models172
1991 To 1995 Tdm Models172
Trx Models172
Tdm Models173
Fainng - Removal And Installation176
Engine Bashplate (1991-95 Tdm And All Xtz) - Removal And Installation178
Electrical System179
Starter Motor180
Battery-Removal, Installation, Inspection And Maintenance181
Electrical System - Fault Finding181
Battery - Charging182
Inspection And Maintenance182
Fuses - Check And Renewal183
Lighting System - Check183
Headlight183
Tail Light183
Headlight Bulb And Auxiliary Light Bulb - Renewal184
Auxiliary Light184
Brake Light184
Headlight Assembly - Removal And Installation185
Brake/Tail Light Bulb - Renewal185
Tail Light Assembly - Removal And Installation186
Turn Signal Circuit - Check186
Flasher Relay186
Hazard Relay (1999 Tdm Models)186
Turn Signal Bulbs - Renewal187
Turn Signal Assemblies - Removal And Installation187
Brake Light Switches - Check And Replacement188
Circuit Check188
Switch Replacement188
Front Brake Lever Switch188
Instrument Cluster And Speedometer Cable - Removal And Installation189
Instrument Cluster189
Speedometer Cable (Trx, Xtz Andterminal And 1991 To 1998 Tdm Models)190
Instruments - Check, Replacement And Bulbs190
Tachometer191
Coolant Temperature Gauge (Trx, Xtz And 1991 To 1998 Tdm Models)191
Fuel Gauge And Sender Unit - Check And Replacement (1999 Tdm Models)192
Fuel Gauge (1999 Tdm Models)192
Bulb Renewal192
Ignition (Main) Switch - Check, Removal And Installation192
Handlebar Switches - Check193
Handlebar Switches - Removal And Installation193
Neutral Switch - Check, Removal And Installation194
Chock194
Sidestand Switch - Check And Replacement195
Clutch Switch - Check And Replacement195
Diode (Xtz Models) - Check And Replacement195
Horn - Check And Replacement197
Starter Relay - Check And Replacement197
Starter Motor - Removal And Installation198
Starter Motor - Disassembly, Inspection And Reassembly199
Charging System Testing - General Information And Precautions202
Charging System - Leakage And Output Test202
Output Test203
Regulator/Rectifier - Check And Replacement206
Wiring Diagrams207