YAMAHA MTN850-AH 2017 Manuals

Manuals and User Guides for YAMAHA MTN850-AH 2017. We have 1 YAMAHA MTN850-AH 2017 manual available for free PDF download: Service Manual

YAMAHA MTN850-AH 2017 Service Manual

YAMAHA MTN850-AH 2017 Service Manual (560 pages)

Brand: YAMAHA | Category: Motorcycle | Size: 36.74 MB

Table of Contents

Table of Contents

7
- General Information
  9
  - Identification
    10
  - Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    YCC-T (Yamaha Chip Controlled Throttle)
    11
    
    OUTLINE of the TCS (Traction Control System)
    13
    
    Instrument Functions
    17
  - Important Information
    22
    
    Preparation for Removal and Disassembly
    22
    
    Replacement Parts
    22
    
    Gaskets, Oil Seals and O-Rings
    22
    
    Lock Washers/Plates and Cotter Pins
    22
    
    Bearings and Oil Seals
    22
    
    Circlips
    23
    
    Rubber Parts
    23
  - Basic Service Information
    24
    
    Quick Fasteners
    24
    
    Electrical System
    25
  - Special Tools
    29
Specifications

37
- General Specifications
  38
- Engine Specifications
  39
- Chassis Specifications
  44
- Electrical Specifications
  47
- Tightening Torques
  49
- Lubrication Points and Lubricant Types
  52
  - Engine
    52
  - Chassis
    53
- Lubrication System Chart and Diagrams
  56
  - Engine Oil Lubrication Chart
    56
  - Lubrication Diagrams
    58
- Cooling System Diagrams
  68
- Cable Routing
  72
Periodic Checks and Adjustments

109
- General Maintenance and Lubrication Chart
  111
- Introduction
  111
- Periodic Maintenance
  111
- Periodic Maintenance Chart for the Emission Control System
  111
- Checking the Fuel Line
  114
- Checking the Vehicle Using the Yamaha Diagnostic Tool
  114
- Adjusting the Valve Clearance
  115
- Checking the Spark Plugs
  115
- Checking the Engine Idling Speed
  118
- Synchronizing the Throttle Bodies
  119
- Checking the Canister
  120
- Checking the Throttle Body Joints
  120
- Adjusting the Exhaust Gas Volume
  121
- Checking the Air Induction System
  121
- Checking the Cylinder Head Breather Hose
  121
- Replacing the Air Filter Element
  121
- Adjusting the Clutch Lever Free Play
  122
- Adjusting the Front Disc Brake
  123
- Checking the Brake Fluid Level
  123
- Checking the Brake Operation
  123
- Adjusting the Rear Disc Brake
  124
- Checking the Front Brake Pads
  124
- Bleeding the Hydraulic Brake System (Abs)
  125
- Checking the Front Brake Hoses
  125
- Checking the Rear Brake Hose
  125
- Checking the Rear Brake Pads
  125
- Checking the Tires
  126
- Checking the Wheels
  126
- Checking the Swingarm Operation
  128
- Checking the Wheel Bearings
  128
- Drive Chain Slack
  128
- Lubricating the Swingarm Pivot
  128
- Checking and Adjusting the Steering Head
  129
- Lubricating the Drive Chain
  129
- Checking the Chassis Fasteners
  130
- Lubricating the Brake Lever
  130
- Lubricating the Clutch Lever
  130
- Lubricating the Pedal
  130
- Lubricating the Steering Head
  130
- Adjusting the Front Fork Legs
  131
- Adjusting the Shift Pedal
  131
- Checking the Front Fork
  131
- Checking the Sidestand
  131
- Checking the Sidestand Switch
  131
- Lubricating the Sidestand
  131
- Adjusting the Rear Shock Absorber Assembly
  133
- Checking the Rear Shock Absorber Assembly
  133
- Changing the Engine Oil
  134
- Checking the Connecting Arm and Relay Arm
  134
- Checking the Engine Oil Level
  134
- Engine
  135
  - Measuring the Engine Oil Pressure
    135
  - Checking the Coolant Level
    136
  - Checking the Cooling System
    137
  - Changing the Coolant
    137
- Cooling System
  138
  - Checking the Front Brake Light Switch
    139
  - Adjusting the Rear Brake Light Switch
    139
  - Checking and Lubricating the Cables
    139
  - Checking the Throttle Grip
    139
  - Checking and Charging the Battery
    140
  - Checking the Fuses
    140
  - Adjusting the Headlight Beams
    140
Chassis

143
- General Chassis (1)
  
  150
  - Removing the Air Scoops
    150
    
    Installing the Air Scoops
    150
    
    Installing the Fuel Tank Moles
    150
- General Chassis (2)
  
  151
- Front Wheel
  
  155
- Rear Wheel
  
  165
- Front Brake
  
  170
- Rear Brake
  
  182
  - Introduction
    188
  - Checking the Rear Brake Disc
    188
  - Replacing the Rear Brake Pads
    188
  - Removing the Rear Brake Caliper
    189
  - Disassembling the Rear Brake Caliper
    190
  - Checking the Rear Brake Caliper
    190
  - Assembling the Rear Brake Caliper
    191
  - Installing the Rear Brake Caliper
    191
  - Removing the Rear Brake Master Cylinder
    192
  - Checking the Rear Brake Master Cylinder
    192
  - Assembling the Rear Brake Master Cylinder
    193
  - Installing the Rear Brake Master Cylinder
    193
- Abs (Anti-Lock Brake System)
  
  194
  - Abs Components Chart
    196
  - Removing the Hydraulic Unit Assembly
    197
  - Checking the Hydraulic Unit Assembly
    197
  - Installing the Hydraulic Unit Assembly
    197
  - Hydraulic Unit Operation Tests
    199
  - Checking the Abs Warning Light
    202
- Handlebar
  
  203
  - Removing the Handlebar
    204
  - Checking the Handlebar
    204
  - Installing the Handlebar
    204
- Front Fork
  
  207
  - Removing the Front Fork Legs
    209
  - Disassembling the Front Fork Legs
    209
  - Checking the Front Fork Legs
    210
  - Assembling the Front Fork Legs
    211
  - Installing the Front Fork Legs
    215
- Steering Head
  
  216
  - Removing the Lower Bracket
    218
  - Checking the Steering Head
    218
  - Installing the Steering Head
    219
- Rear Shock Absorber Assembly
  
  221
- Swingarm
  
  224
  - Removing the Swingarm
    225
  - Checking the Swingarm
    225
  - Installing the Swingarm
    226
- Chain Drive
  
  227
  - Removing the Drive Chain
    228
  - Checking the Drive Chain
    228
  - Checking the Drive Sprocket
    229
  - Checking the Rear Wheel Sprocket
    229
  - Checking the Rear Wheel Drive Hub
    229
  - Installing the Drive Chain
    230
  - Adjusting the Shift Pedal
    231
Engine

233
- Engine Inspection
  
  236
  - Measure the Compression Pressure
    236
- Engine Removal
  
  238
  - Removing the Engine
    242
  - Installing the Engine
    242
- Camshafts
  
  244
  - Removing the Camshafts
    246
  - Checking the Camshafts
    247
  - Checking the Timing Chain and Camshaft Sprocket
    248
  - Checking the Timing Chain Guides
    248
  - Checking the Timing Chain Tensioner
    248
  - Installing the Camshafts
    249
- Cylinder Head
  
  254
- Valves and Valve Springs
  
  258
  - Removing the Valves
    258
  - Checking the Valves and Valve Guides
    258
  - Checking the Valve Seats
    260
  - Checking the Valve Springs
    261
  - Checking the Valve Lifters
    262
  - Installing the Valves
    262
- Generator and Starter Clutch
  
  266
  - Removing the Generator
    266
  - Removing the Starter Clutch
    266
  - Checking the Starter Clutch
    266
  - Installing the Starter Clutch
    267
  - Installing the Generator
    267
- Electric Starter
  
  269
  - Checking the Starter Motor
    271
  - Assembling the Starter Motor
    272
  - Installing the Starter Motor
    272
  - Clutch
    273
  - Removing the Clutch
    277
  - Checking the Friction Plates
    278
  - Checking the Clutch Plates
    278
  - Checking the Clutch Springs
    279
  - Checking the Clutch Housing
    279
  - Checking the Clutch Boss
    280
  - Checking the Pressure Plate
    280
  - Checking the Primary Drive Gear
    280
  - Checking the Primary Driven Gear
    280
  - Checking the Pull Lever Shaft and Pull Rod
    280
  - Installing the Clutch
    281
- Shift Shaft
  
  284
  - Checking the Shift Shaft
    285
  - Checking the Stopper Lever
    285
  - Installing the Shift Shaft
    285
- Oil Pump
  
  286
  - Checking the Sprocket and Chain
    288
  - Checking the Oil Pump
    288
  - Checking the Relief Valve
    288
  - Assembling the Oil Pump
    289
  - Installing the Oil Pump
    289
- Oil Pan
  
  290
  - Removing the Oil Pan
    291
  - Checking the Oil Strainer
    291
  - Installing the Oil Pan
    291
- Crankcase
  
  292
  - Disassembling the Crankcase
    293
  - Checking the Crankcase
    293
  - Assembling the Crankcase
    293
- Connecting Rods and Pistons
  
  297
  - Removing the Connecting Rods and Pistons
    297
  - Checking the Cylinder and Piston
    297
  - Checking the Piston Rings
    298
  - Checking the Piston Pin
    299
  - Checking the Connecting Rods
    299
  - Installing the Connecting Rod and Piston
    302
- Crankshaft and Balancer Shaft
  
  307
  - Removing the Crankshaft and Balancer Shaft
    307
  - Checking the Oil Nozzles
    307
  - Checking the Crankshaft
    307
  - Checking the Balancer Shaft
    309
  - Installing the Crankshaft
    310
  - Installing the Balancer Assembly
    311
- Transmission
  
  312
  - Removing the Transmission
    316
  - Checking the Shift Forks
    316
Cooling System

321
- Radiator
  
  322
  - Checking the Radiator
    323
  - Installing the Radiator
    323
- Oil Cooler
  
  325
  - Checking the Oil Cooler
    326
  - Installing the Oil Cooler
    326
- Thermostat
  
  327
  - Checking the Thermostat
    328
  - Installing the Thermostat Assembly
    328
- Water Pump
  
  329
  - Disassembling the Water Pump
    331
  - Checking the Water Pump
    331
  - Assembling the Water Pump
    331
Fuel System

333
- Fuel Tank
  
  336
  - Removing the Fuel Tank
    336
    
    Removing the Fuel Pump
    336
    
    Checking the Fuel Pump Body
    336
    
    Checking the Fuel Pump Operation
    336
    
    Installing the Fuel Pump
    337
    
    Installing the Fuel Tank
    337
- Throttle Bodies
  
  338
  - Checking the Injectors (before Removing)
    341
    
    Removing the Fuel Hose (Fuel Rail Side)
    341
    
    Removing the Injectors
    341
    
    Checking the Injectors
    341
    
    Checking and Cleaning the Throttle Bodies
    341
    
    Replacing the Throttle Bodies
    343
    
    Installing the Injectors
    343
    
    Checking the Injector Pressure
    343
    
    Checking the Fuel Pressure
    344
    
    Installing the Fuel Hose (Fuel Rail Side)
    345
    
    Adjusting the Throttle Position Sensor
    345
    
    Adjusting the Accelerator Position Sensor
    346
- Air Induction System
  
  348
  - Checking the Air Induction System
    352
  - Installing the Air Induction System
    352
Electrical System

355
- Ignition System
  
  358
  - Circuit Diagram
    358
  - Engine Stopping Due to Sidestand Operation
    360
  - Troubleshooting
    362
- Electric Starting System
  
  364
  - Circuit Diagram
    364
  - Starting Circuit Cut-Off System Operation
    366
  - Troubleshooting
    368
- Charging System
  
  370
  - Circuit Diagram
    370
  - Troubleshooting
    372
- Lighting System
  
  374
  - Circuit Diagram
    374
  - Troubleshooting
    376
- Signaling System
  
  378
  - Circuit Diagram
    378
  - Troubleshooting
    380
- Cooling System
  
  386
  - Circuit Diagram
    386
  - Troubleshooting
    388
- Fuel Injection System
  
  390
  - Circuit Diagram
    390
  - Ecu Self-Diagnostic Function
    392
  - Troubleshooting Method
    392
  - Yamaha Diagnostic Tool
    393
- Fuel Pump System
  
  394
  - Troubleshooting Details (Fault Code)
    394
  - Troubleshooting
    394
  - Troubleshooting
    533

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