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YAMAHA TDM850 Manuals
Manuals and User Guides for YAMAHA TDM850. We have
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YAMAHA TDM850 manuals available for free PDF download: User Manual, Owner's Manual
Yamaha TDM850 User Manual (212 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 13.3 MB
Table of Contents
Safety First!
1
Remember
1
Frame and Engine Numbers
2
Identification Numbers
2
Buying Spare Parts
2
Daily (Pre-Ride) Checks
4
Engine/Transmission Oil Level Check
4
TDM850 (1991 to 1995) and XTZ750 Models
4
TDM850 (1996-On) and TRX Models
5
Brake Fluid Level Checks
6
Front Brake Fluid Level
6
Before You Start
6
Rear Brake Fluid Level
7
Coolant Level Check
8
Tyre Tread Depth
9
Tyre Care
9
The Correct Pressures
9
Tyre Checks
9
Routine Maintenance and Servicing
10
Contents
10
Routine Maintenance
11
Specifications
11
Torque Settings
12
Recommended Lubricants and Fluids
12
Component Locations
13
Component Locations
15
Maintenance Schedule
16
Introduction
17
Every 300 Miles (500 Km)
17
Lubrication
18
Hint
18
Every 4000 Miles (6000 Km) or 6 Months
19
Spark Plugs - Check and Adjustment
19
Idle Speed - Check and Adjustment
20
Carburettors - Synchronisation
20
Air Filter - Cleaning
21
Fuel System - Check
22
Engine - Oil Change
22
Filter Cleaning
22
Brake Pads - Wear Check
23
Brake System - Check
23
Clutch - Check and Adjustment
25
Battery - Check
25
Wheels and Tyres - General Check
26
Wheel Bearings - Check
26
Sidestand and Cut-Off Switches - Check
26
Nuts and Bolts - Tightness Check
26
Cooling System - Check
27
Throttle and Choke Cables - Check
27
Throttle Cables
27
Pivot Points
28
Stand, Lever Pivots and Cables - Lubrication
28
Choke Cable
28
Swingarm and Suspension Bearings (XTZ Models) - Re-Greasing
28
Suspension - Check
29
Steering Head Bearings - Freeplay Check and Adjustment
29
Front Suspension
29
Rear Suspension
29
Every 8000 Miles (12,000 Km) or 12 Months
31
Engine - Oil and Filter Change
31
Every 16,000 Miles (24,000 Km) or Two Years
32
Fuel Filter - Renewal (1999 TDM Models)
32
Swingarm and Suspension Bearings (TDM and TRX Models) - Re-Greasing
32
Steering Head Bearings - Lubrication
32
Cooling System - Draining, Flushing and Refilling
33
Refilling
34
Valve Clearances - Check and Adjustment
34
Every 28,000 Miles (42,000 Km)
34
Shim Selection Chart - Inlet Valves
36
Shim Selection Chart - Exhaust Valves
36
Every Four Years
37
Non-Scheduled Maintenance
37
Brake Hoses - Renewal
37
Headlight Aim - Check and Adjustment
37
Cylinder Compression - Check
38
Engine - Oil Pressure Check
38
Front Forks - Oil Change
39
TDM, Trxand 1995 XTZ Models
39
1989 To 1994 XTZ Models
39
Engine, Clutch and Transmission
40
Degrees of Difficulty
40
Cylinder Head
41
Cylinder Block
41
Oil Pump
43
General Information
45
Operations Possible with the Engine in the Frame
45
Operations Requiring Engine Removal
45
Major Engine Repair - General Note
45
Engine Disassembly and Reassembly - General Information
49
Valve Cover - Removal and Installation
50
Camshafts and Followers - Removal, Inspection and Installation
51
Cam Chain Tensioner - Removal, Inspection and Installation
56
Cylinder Head - Removal and Installation
57
Valves/Valve Seats/Valve Guides - Overhaul
59
Cylinder Head and Valves - Disassembly, Inspection and Reassembly
59
Cylinder Block-Removal, Inspection and Installation
62
Pistons - Removal, Inspection and Installation
64
Piston Rings - Inspection and Installation
66
Clutch - Removal, Inspection and Installation
67
Clutch Assembly
69
Clutch Cable - Removal and Installation
73
Starter Clutch and Idle/Reduction Gear - Removal, Inspection and Installation
74
Gearchange Mechanism External Components - Removal, Inspection and Installation
74
Oil Pumps - Removal and Installation
76
Oil Tank - Removal and Installation (1996-On TDM Models and All TRX Models)
79
Balancer Shafts - Removal, Inspection and Installation
81
Cam Chain and Guides - Removal, Inspection and Installation
84
Crankcase Halves - Separation and Reassembly
84
Crankcase Bolts - 1991 to 1995 TDM Models and XTZ Models
85
Crankcase Bolts - 1996-On TDM Models and TRX Models
85
Crankcase Halves - Inspection and Servicing
87
Main and Connecting Rod Bearings - General Information
87
Connecting Rods - Removal, Inspection and Installation
88
Oil Clearance Check
88
Bearing Shell Selection
89
Main Bearing Shell Selection
91
Transmission Shafts and Bearings - Removal and Installation
92
Transmission Shafts - Disassembly, Inspection and Reassembly
93
Input Shaft Reassembly
94
Output Shaft Disassembly
95
Output Shaft Inspection
95
Output Shaft Reassembly
95
Selector Drum and Forks Removal, Inspection and Installation
96
Initial Start-Up after Overhaul
98
Recommended Running-In Procedure
98
Cooling System
99
Radiator Pressure Cap - Check
100
Coolant Reservoir - Removal and Installation
100
Cooling Fan and Cooling Fan Switch - Check and Renewal
101
Coolant Temperature Gauge/Warning Light and Sender - Check and Renewal
102
Coolant Temperature Warning Light (1999 TDM Models)
102
Coolant Temperature Gauge (XTZ, TRX and 1991-98 TDM Models)
102
Sender Check (All Models)
102
All Models
103
Thermostat Housing and Thermostat - Removal, Check and Installation
103
Radiator - Removal and Installation
104
Water Pump - Check, Removal, and Installation
105
Coolant Hoses - Removal and Installation
106
Fuel and Exhaust Systems
107
Fuel Tank and Fuel Tap(S) - Removal and Installation
109
General Information and Precautions
109
Fuel Tank - TDM Models
109
Fuel Tank - TRX Models
110
Fuel Tank - XTZ Models
110
Fuel Tap(S)
110
Fuel Tank - Cleaning and Repair
112
Air Filter Housing - Removal and Installation
112
Idle Fuel/Air Mixture Adjustment - General Information
112
Carburettors - Removal and Installation
113
Carburettor Overhaul - General Information
113
Carburettors Cleaning and Inspection
114
1991 To 1998 TDM Models, All TRX and XTZ Models
114
Ignition System
116
Ignition HT Coils - Check, Removal and Installation
118
Ignitor Unit - Check, Removal and Installation
119
Ignition Timing - General Information and Check
120
Throttle Position Sensor (1996- % on TDM and TRX)- Check, Adjustment and Replacement
120
Frame, Suspension and Final Drive
122
Frame - Inspection and Repair
124
Footrests, Brake Pedal and Gearchange Lever - Removal and Installation
124
Brake Pedal
125
Gearchange Lever
125
Sidestand - Removal and Installation
126
Handlebars and Levers - Removal and Installation
126
Handlebars
126
Forks - Removal and Installation
128
Front Brake Lever
128
Clutch Lever
128
Forks - Disassembly, Inspection and Reassembly
130
1991 To 199S TDM Models
130
1996-On TDM Models and TRX Models
134
XTZ Models
135
Front Fork Components - XTZ Models
136
Steering Stem - Removal and Installation
137
Steering Head Bearings - Inspection and Replacement
139
Rear Shock Absorber - Removal, Inspection and Installation
140
Rear Suspension Linkage (TRX and XTZ Models) - Removal, Inspection and Installation
141
Suspension Linkage and Swingarm Assembly - TRX Models
142
Suspension - Adjustments
143
Front Forks
143
Suspension Linkage and Swingarm Assembly - XTZ Models
143
Bearing Replacement - XTZ Models
146
Bearing Replacement - TDM and TRX Models
146
Swingarm - Inspection and Bearing Replacement
146
Drive Chain - Removal, Cleaning and Installation
147
Endless Type Chain
147
Riveted Link Type Chain
148
Sprockets - Check and Replacement
148
Rear Sprocket Coupling/Rubber Dampers - Check and Replacement
150
Table of Contents
151
Brakes, Wheels and Tyre
151
Brake Pads - Replacement
153
Brake Calipers - Removal, Overhaul and Installation
156
Overhaul
157
Brake Discs - Inspection, Removal and Installation
158
Front Brake Master Cylinder - Removal, Overhaul and Installation
158
Rear Brake Master Cylinder - Removal, Overhaul and Installation
160
Brake Hoses, Pipes and Unions - Inspectionand Replacement
162
Brake System - Bleeding
163
Wheels - Inspection and Repair
163
Front Wheel-Removal and Installation
164
Wheels - Alignment Check
164
Rear Wheel - Removal and Installation
166
Wheel Bearings - Removal, Inspection and Installation
167
Front Wheel Bearings
167
Rear Wheel Bearings
168
Sprocket Coupling Bearing
169
Tyres - General Information and Fitting
169
Common Tyre Sidewall Markings
170
Bodywork
171
Seat - Removal and Installation
172
1996-On TDM Models
172
1991 To 1995 TDM Models
172
TRX Models
172
TDM Models
173
Fainng - Removal and Installation
176
Engine Bashplate (1991-95 TDM and All XTZ) - Removal and Installation
178
Electrical System
179
Starter Motor
180
Battery-Removal, Installation, Inspection and Maintenance
181
Electrical System - Fault Finding
181
Torque Settings
181
Battery - Charging
182
Inspection and Maintenance
182
Fuses - Check and Renewal
183
Lighting System - Check
183
Headlight
183
Tail Light
183
Headlight Bulb and Auxiliary Light Bulb - Renewal
184
Auxiliary Light
184
Brake Light
184
Headlight Assembly - Removal and Installation
185
Brake/Tail Light Bulb - Renewal
185
Hazard Relay (1999 TDM Models)
186
Flasher Relay
186
Tail Light Assembly - Removal and Installation
186
Turn Signal Circuit - Check
186
Turn Signal Bulbs - Renewal
187
Turn Signal Assemblies - Removal and Installation
187
Brake Light Switches - Check and Replacement
188
Circuit Check
188
Switch Replacement
188
Front Brake Lever Switch
188
Instrument Cluster and Speedometer Cable - Removal and Installation
189
Instrument Cluster
189
Speedometer Cable (TRX, XTZ Andterminal and 1991 to 1998 TDM Models)
190
Instruments - Check, Replacement and Bulbs
190
Tachometer
191
Coolant Temperature Gauge (TRX, XTZ and 1991 to 1998 TDM Models)
191
Bulb Renewal
192
Ignition (Main) Switch - Check, Removal and Installation
192
Fuel Gauge (1999 TDM Models)
192
Fuel Gauge and Sender Unit - Check and Replacement (1999 TDM Models)
192
Handlebar Switches - Check
193
Handlebar Switches - Removal and Installation
193
Neutral Switch - Check, Removal and Installation
194
Chock
194
Sidestand Switch - Check and Replacement
195
Clutch Switch - Check and Replacement
195
Diode (XTZ Models) - Check and Replacement
195
Horn - Check and Replacement
197
Starter Relay - Check and Replacement
197
Starter Motor - Removal and Installation
198
Starter Motor - Disassembly, Inspection and Reassembly
199
Charging System Testing - General Information and Precautions
202
Charging System - Leakage and Output Test
202
Output Test
203
Regulator/Rectifier - Check and Replacement
206
Wiring Diagrams
207
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YAMAHA TDM850 Owner's Manual (110 pages)
2000
Brand:
YAMAHA
| Category:
Motorcycle
| Size: 5.55 MB
Table of Contents
Table of Contents
7
Important Manual Information
5
Give Safety the Right of Way
9
Description
11
Instrument and Control Functions
15
Main Switch/Steering Lock
16
Instrument and Control Functions
17
Indicator and Warning Lights
17
Speedometer Unit
18
Tachometer
19
Self-Diagnosis Device
19
Anti-Theft Alarm (Optional)
20
Fuel Gauge
20
Handlebar Switches
20
Clutch Lever
22
Shift Pedal
22
Brake Lever
22
Brake Pedal
23
Fuel Tank Cap
24
Fuel
24
Fuel Tank Breather Hose (for Germany Only)
25
Starter (Choke) Lever
25
Seat
26
Helmet Holder
26
Storage Compartment
27
Adjusting the Front Fork
28
Adjusting the Shock Absorber Assembly
30
Luggage Strap Holders
32
Sidestand
32
Ignition Circuit Cut-Off System
33
Pre-Operation Checks
35
Pre-Operation Check List
36
Operation and Important Riding Points
39
Starting a Warm Engine
41
Recommended Shift Points (for Switzerland Only)
42
Shifting
42
Engine Break-In
43
Tips for Reducing Fuel Consumption
43
Parking
44
Periodic Maintenance and Minor Repair
45
Owner's Tool Kit
46
Periodic Maintenance and Lubrication Chart
47
Removing and Installing Cowlings and Panels
50
Checking the Spark Plugs
52
To Change Engine Oil
54
Engine Oil and Oil Filter Element
54
Coolant
56
Cleaning the Air Filter Element
60
Adjusting the Carburetors
63
Adjusting the Engine Idling Speed
63
Adjusting the Throttle Cable Free Play
64
Adjusting the Valve Clearance
64
Tires
64
Adjusting the Brake Pedal Position
68
Adjusting the Clutch Lever Free Play
68
Adjusting the Rear Brake Light Switch
69
Checking the Brake Fluid Level
70
Checking the Front and Rear Brake Pads
70
Changing the Brake Fluid
71
Drive Chain Slack
72
Checking and Lubricating the Cables
74
Lubricating the Drive Chain
74
Checking and Lubricating the Brake and Shift Pedals
75
Checking and Lubricating the Throttle Grip and Cable
75
Checking and Lubricating the Brake and Clutch Levers
76
Checking and Lubricating the Sidestand
76
Checking the Front Fork
77
Lubricating the Rear Suspension
77
Checking the Steering
78
Checking the Wheel Bearings
78
Battery
79
Replacing the Fuses
80
Replacing a Headlight Bulb
81
Replacing the Tail/Brake Light Bulb
82
Replacing a Turn Signal Light Bulb
83
Front Wheel
84
Supporting the Motorcycle
84
Rear Wheel
86
Troubleshooting
88
Troubleshooting Charts
89
Motorcycle Care and Storage
91
Specifications
97
Specifications
98
Conversion Table
102
Consumer Information
103
Identification Numbers
104
Key Identification Number
104
Vehicle Identification Number
104
Model Label
105
YAMAHA TDM850 Owner's Manual (99 pages)
1999
Brand:
YAMAHA
| Category:
Motorcycle
| Size: 4.71 MB
Table of Contents
Table of Contents
6
Important Manual Information
4
Give Safety the Right of Way
8
Description
10
Instrument and Control Functions
14
Main Switch/Steering Lock
15
Indicator Lights
16
Speedometer
17
Tachometer
18
Antitheft Alarm (Optional)
19
Diagnosis Device
19
Fuel Gauge
19
Handlebar Switches
20
Starter (Choke)
21
Description
22
Instrument and Control Functions
22
Clutch Lever
22
Shift Pedal
22
Front Brake Lever
23
Rear Brake Pedal
23
Fuel Tank Cap
24
Fuel
25
Fuel Tank Breather Hose (for Germany Only)
26
Seat
26
Helmet Holder
27
Storage Compartment
27
Front Fork Adjustment
28
Rear Shock Absorber Adjustment
29
Luggage Strap Holders
31
Sidestand
31
Sidestand/Clutch Switch Operation Check
31
Pre-Operation Checks
34
Pre-Operation Check List
35
Operation and Important Riding Points
38
Starting the Engine
39
Shifting
42
Starting a Warm Engine
42
Engine Break-In
43
Tips for Reducing Fuel Consumption
43
Parking
44
Periodic Maintenance and Minor Repair
46
Tool Kit
47
Periodic Maintenance and Lubrication
48
Cowling and Panel Removal and Installation
51
Cowlings a and B
51
Panels a and B
52
Spark Plugs
52
Engine Oil
54
Cooling System
56
Changing the Coolant
57
Air Filter
59
Carburetor Adjustment
61
Idle Speed Adjustment
61
Throttle Cable Free Play Inspection
62
Valve Clearance Adjustment
62
Tires
63
Clutch Lever Free Play Adjustment
65
Rear Brake Pedal Height Adjustment
66
Brake Light Switch Adjustment
67
Checking the Front and Rear Brake Pads
67
Inspecting the Brake Fluid Level
68
Brake Fluid Replacement
69
Drive Chain Slack Adjustment
69
Drive Chain Slack Check
69
Cable Inspection and Lubrication
70
Drive Chain Lubrication
70
Brake and Clutch Lever Lubrication
71
Brake and Shift Pedal Lubrication
71
Throttle Cable and Grip Lubrication
71
Rear Suspension Lubrication
72
Sidestand Lubrication
72
Front Fork Inspection
73
Steering Inspection
73
Battery
74
Wheel Bearings
74
Fuse Replacement
75
Headlight Bulb Replacement
76
Tail/Brake Light Bulb Replacement
77
Troubleshooting
78
Turn Signal Light Bulb Replacement
78
Troubleshooting Chart
79
Engine Overheating
80
Motorcycle Care and Storage
82
Specifications
88
Specifications
89
How to Use the Conversion Table
93
Consumer Information
94
Identification Number Records
95
Key Identification Number
95
Vehicle Identification Number
95
Consumer Information
96
Model Label
96
Left View
97
Right View
98
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Yamaha TDM850 Owner's Manual (103 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 3.04 MB
Table of Contents
Table of Contents
4
Otorcycle Identification
9
Identification Numbers Record.3-1
9
Frame Serial Number.3-2
10
Engine Serial Number.3-2
10
Main Switch.4-1
11
Indicator Lights.4-2
12
Speedometer.4-2
12
Tachometer
13
Engine Temperature Gauge.4-3
13
Handlebar Switches.4-4
14
Clutch Lever.4-7
17
Shift Pedal.4-7
17
Front Brake Lever.4-8
18
Rear Brake Pedal.4-8
18
Fuel Tank Cap.4-8
18
Fuel Cock.4-9
19
Starter Knob (CHOKE).4-10
20
Steering Lock
20
Helmet Holder.4-13
22
Side Cowl/Upper Cowl.4-13
22
Front Fork.4-14
23
Rear Shock Absorber.4-15
24
Sidestand.4-15
24
Sidestand/Clutch Switch Operation Check.4-16
25
Pre-Operation Checks.5-1
27
Brake Fluid Leakage.5-4
30
Throttle Grip.5-4
30
Engine Oil.5-4
30
Tubeless Tires and Cast Wheels.5-9
35
Fittings/Fasteners.5-11
37
Lights and Signals.5-11
37
Switches.5-11
37
Fuel.5-11
37
Operation and Important
39
Starting the Engine.6-2
40
Starting a Warm Engine.6-5
43
Shifting.6-5
43
Recommended Shift Point
44
For Switzerland Only).6-6
44
Engine Break
44
Parking.6-7
45
Periodic Maintenance and Minor Repair.7-1
46
Tool Kit.7-1
46
Periodic Maintenance/Lubrication.7-3
48
Torque Specifications.7-5
50
Engine Oil.7-6
51
Cooling System.7-10
55
Electric Fan
58
Air Filter.7-14
59
Carburetor Adjustment.7-16
61
Idle Speed Adjustment.7-16
61
Throttle Cable Adjustment.7-17
62
Valve Clearance Adjustment.7-18
63
Spark Plug Inspection.7-18
63
Front Brake Lever Position Adjustment.7-20
65
Rear Brake Adjustment
65
Brake Light Switch Adjustment.7-21
66
Checking the Front and Rear Brake Pads.7-21
66
Inspecting the Brake Fluid Level.7-22
67
Brake Fluid Replacement.7-23
68
Clutch Adjustment.7-24
69
Drive Chain Slack Check.7-24
69
Cable Inspection and Lubrication.7-27
72
Throttle Cable and Grip Lubrication
73
Brake and Shift Pedals.7-28
73
Brake and Clutch Levers.7-28
73
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