Yamaha TRX850H Manuals

Manuals and User Guides for Yamaha TRX850H. We have 1 Yamaha TRX850H manual available for free PDF download: Service Manual

Yamaha TRX850H Service Manual (307 pages)

4XG-AE1

Brand: Yamaha | Category: Motorcycle | Size: 11.91 MB

How to Use the Manual
4
Illustrated Symbols
5
Index
6
General Information
7
Motorcycle Identification
8
Frame Serial Number
8
Engine Serial Number
8
Model Lebel
8
Preparation for Removal
9
Note on Gaskets, Oil Seals and O-Rings
9
Note on Lock Washers/Plates and Cotter Pins
10
Note on Bearings and Oil Seals
10
Note on Circlips
10
Checking of Connections
11
How to Use the Conversion Table
12
Special Tools
13
Specifications
16
Crankcase Tightening Sequence
27
Tightening Torques
30
General Torque Specifications
33
Lubrication Point and Grade of Lubricant
34
Lubrication Diagrams
36
Cable Routing
41
Periodic Inspection and Adjustment
50
Periodic Maintenance/Lubrication Intervals
52
Upper Cowling, Seat, Side Cover and Fuel Tank
54
Air Filter Case
56
Valve Clearance Adjustment
57
Carburetor Synchronization
64
Idling Speed Adjustment
66
Throttle Cable Adjustment
67
Spark Plug Inspection
68
Ignition Timing Check
69
Compression Pressure Measurement
71
Engine Oil Level Inspection
73
Engine Oil Replacement
74
Clutch Adjustment
76
Air Filter Cleaning
76
Carburetor Joint Inspection
77
Fuel Line Inspection
78
Breather Hose Inspection
78
Exhaust System Inspection
79
Coolant Level Inspection
79
Coolant Replacement
80
Handling Notes for Coolant
82
Cooling System Inspection
83
Front Brake Adjustment
84
Rear Brake Adjustment
84
Brake Fluid Level Inspection
86
Brake Pad Inspection
87
Brake Light Switch Adjustment
87
Brake Hose Inspectin
88
Air Bleeding (Hydraulic Brake System)
88
Drive Chain Slack Adjustment
89
Drive Chain Lubrication
91
Steering Head Inspection
91
Front Fork Inspection
93
Front Fork Adjustment
94
Spring Preload
94
Rear Shock Absorber Adjustment
95
Rebound Damping
95
Compression Damping
96
Tire Inspection
97
Wheel Inspection
99
Cable Inspection and Lubrication
99
Lever and Pedal Lubrication
100
Sidestand and Rear Suspension Lubrication
100
Battery Inspection
101
Charging Method Using a Variable-Current (Voltage) Type Charger
104
Charging Method Using a Constant-Voltage Type Charger
105
Fuse Inspection
106
Headlight Beam Adjustment
108
Headlight Bulb Replacement
108
Engine Overhaul
110
Engine Assembly
112
Drive Sprocket and Exhaust Pipe
113
Camshaft
116
Cylinder Head Cover
116
Camshaft Removal
118
Camshaft Inspection
119
Camshaft Installation
121
Cylinder Head
123
Cylinder Head Inspection
124
Cylinder Head Installation
124
Valve and Valve Spring
125
Valve and Valve Spring Removal
126
Valve and Valve Spring Inspection
127
Cylinder and Piston Removal
133
Cylinder and Piston Inspection
134
Cylinder and Piston Installation
137
Clutch
139
Crankcase Cover (Right) Removal
139
Clutch Removal
140
Clutch Inspection
141
Clutch Installation
142
Crankcase Cover (Left) Removal
144
Shift Shaft Removal
145
Shift Shaft Inspection
146
Shift Shaft Installation
146
AC Magneto and Starter Wheel Gear
147
Stator Coil Removal
147
AC Magneto and Starter Wheel Gear Removal
148
AC Magneto and Starter Wheel Gear Inspection
149
AC Magneto and Starter Wheel Gear Installation
150
Oil Pump Cover and Oil Pump Driven Gears Removal
151
Oil Pump Removal
152
Oil Pump Inspection
153
Oil Tank
154
Oil Hose Removal
154
Oil Tank Removal
155
Oil Pan Removal
156
Balancer Weight Removal
157
Oil Pan Installation
160
Crankshaft Assembly
162
Crankshaft Removal
162
Connecting Rod Removal
163
Crankshaft Inspection
165
Crankshaft Installation
170
Transmission, Shift Cam and Shift Fork Removal
173
Transmission, Shift Cam and Shift Fork Inspection
175
Transmission, Shift Cam and Shift Fork Installation
176
Cooling System
178
Radiator Removal
179
Radiator Inspection
180
Radiator Installation
181
Thermostatic Valve
182
Thermostatic Assembly Removal
182
Thermostatic Valve Housing Disassembly
183
Thermostatic Valve Housing Inspection
184
Thermostatic Valve Housing Assembly
184
Water Pump Removal
185
Water Pump Installation
186
Carburetion
187
Carburetor Assembly Removal
188
Carburetor Disassembly
189
Carburetor Assembly
191
Fuel Level Adjustment
192
TPS (Throttle Position Sensor) Adjustment and Inspection
192
Chassis
195
Front Wheel and Brake Discs Removal
197
Front Wheel Disassembly
198
Front Wheel Inspection
199
Front Wheel Installation
201
Static Wheel Balance Adjustment
202
Rear Wheel Removal
204
Brake Disc and Drive Sprocket Removal
205
Rear Wheel Disassembly
206
Rear Wheel Inspection
207
Driven Sprocket Replacement Steps
208
Front and Rear Brake
209
Front Brake Pad Removal
209
Rear Brake Pad Removal
210
Front Brake Master Cylinder Removal
214
Front Brake Master Cyinder Disassembly
215
Rear Brake Master Cylinder Removal
216
Rear Brake Master Cylinder Disconnection
217
Master Cylinder Inspection
218
Master Cylinder Assembly
218
Front Brake
219
Rear Brake
220
Front Brake Caliper Removal
222
Front Brake Caliper Disassembly
223
Rear Brake Caliper Removal
224
Rear Brake Caliper Disassembly
225
Caliper Disassembly
226
Caliper Inspection and Repair
227
Caliper Assembly
227
Caliper Installation
228
Front Fork Removal
229
Front Fork Disassembly
230
Front Fork Assembly
233
Front Fork Installation
236
Left Handlebar Removal
237
Right Handlebar Removal
238
Right Handlebar Inspection
239
Right Handlebar Installation
239
Steering Head
241
Lower Bracket Removal
241
Lower Bracket Inspection
243
Lower Bracket Installation
244
Rear Shock Absorber and Relay Arm Removal
245
Shock Absorber Disposal
247
Swingarm and Drive Chain Removal
248
Swingarm and Drive Chain Inspection
250
Electrical
252
Electrical Components Diagram
253
Switch Inspection
254
Switch Continuity Inspection
255
Wiring Diagram
258
Ignition System Troubleshooting
259
Electric Starting System
264
Starting Circuit Operation
265
Electric Starting System Troubleshooting
266
Starter Motor Removal and Disassembly
270
Starter Motor Inspection and Repair
271
Starter Motor Assembly
272
Charging System Circuit Diagram
274
Charging System Troubleshooting
275
Lighting System Circuit Diagram
278
Lighting System Troubleshooting
279
Lighting System Check
281
Signal System Circuit Diagram
284
Signal System Troubleshooting
286
Signal System Check
287
Cooling System Circuit Diagram
292
Cooling System Troubleshooting
293
TPS (Throttle Position Sensor) Self Diagnosis
297
Troubleshooting
299
Starting Failure/Hard Starting
301
Poor Idle Speed Performance
302
Poor Medium and High Speed Performance
302
Faulty Gear Shifting
303
Clutch Slipping/Dragging
303
Overheating
304
Faulty Brake
304
Front Fork Oil Leakage and Front Fork Malfunction
304
Instable Handling
305
Faulty Lighting and Signal System
305

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Yamaha TRX850H Service Manual (307 pages)

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