Yamaha TDM850 Service Manual

–4–MAINTENANCE SPECIFICATIONSSPECELECTRICALItem Standard LimitCharging system:TypeModel/manufacturerNominal outputStator coil resistanceA.C. magnetoTL

–5–1 Throttle cable 12 Right handlebar switch lead3 Brake hose4 Clutch cable5 Main switch lead6 Left handlebar switch lead7 Horn lead8 Starter cable9

–6–CABLE ROUTINGSPECL Fasten the meter lead and headlight lead with a plas-tic band.M Fasten the wireharness with a plastic band.N Fasten the wireharn

–7–11 A.C. magneto lead12 Air filter case breather hose13 Carburetor heater hose14 Starter cable 215 Thermo switch lead16 Brake hose17 Speed sensor le

–8–D Fasten the rear flasher light (left) lead.E Fasten the sidestand switch lead neutral switch leadand A.C. magneto lead.F Route the sidestand switc

–9–1 Battery negative lead2 Battery positive lead3 Starter motor lead4 Fuel sender lead5 Fuel tank drain hose6 Fuel tank breather hose (for DEU)7 Wate

–10–J Fasten the right handlebar switch lead and speedsensor lead with a clamp.K Fasten the throttle cable and speed sensor lead with aclamp.L Route t

–11–CABLE ROUTINGSPEC1 Head light lead2 Wireharness3 Meter light lead4 Throttle cable5 Throttle stop screw cable6 Vacuum hose (#2)7 Vacuum hose (#1)8

–12–CABLE ROUTINGSPECH Fasten the carburetor breather hose and see thehose mark.I In order to carburetor breather hose, idle adjust cablecoolant breat

–13–INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALSINSPADJPERIODIC INSPECTION AND ADJUSTMENTINTRODUCTIONThis chapter includes all information

FOREWORDThis Supplementary Service Manual has been prepared to introduce new service and data for the TDM850’99. For complete service information proc

–14–PERIODIC MAINTENANCE/LUBRICATION INTERVALSINSPADJNOTE:EVERYNO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL(1,000 km)6,000 km6 months(whichevercomes fi

–15–SEAT, TAIL COVER AND FUEL TANKINSPADJOrderJob name/Part name Q’ty Remarks12345678Seat, tail cover and fuel tank removalSide cowlingSeatTaillight l

–16–CARBURETOR SYNCHRONIZATIONINSPADJNOTE:NOTE:ENGINECARBURETOR SYNCHRONIZATIONValve clearance and idling speed should be ad-justed properly before sy

–17–CARBURETOR SYNCHRONIZATIONINSPADJNOTE:7. Adjust: Carburetor synchronizationAdjustment steps: Synchronize carburetor #1 to carburetor #2 byturnin

–18–ENGINE OIL LEVEL INSPECTIONINSPADJNOTE:NOTE:CAUTION:ENGINE OIL LEVEL INSPECTIONPosition the motorcycle straight up when inspect-ing the oil level.

–19–ENGINE OIL REPLACEMENTINSPADJNew35 Nm (3.5 mkg)30 Nm (3.0 mkg)ENGINE OIL REPLACEMENT1. Start the engine and let it warm up for severalminutes.2.

–20–ENGINE OIL REPLACEMENTINSPADJCAUTION:7. Fill: CrankcaseThe engine should be filled with oil in twosteps. First fill the engine with 3.2 liters of

–21–FUEL LINE INSPECTIONINSPADJNOTE:NOTE:FUEL LINE INSPECTION1. Remove: Side cowling Seat Side cover Fuel tankRefer to “COWLINGS, SEAT, TAIL COVER

–22–CLUTCHENGOrderJob name/Part name Q’ty Remarks123456789101112131415Clutch removalClutch springPressure platePlain washer/BearingPull rodFriction pl

–23–CLUTCHENGCAUTION:NOTE:INSTALLATION1. Install: friction plates clutch platesThe friction plates are made in two types. Thefirst and last friction

NOTE:CAUTION:EB001000NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and theirqualified mechanics. It i

–24–INSTRUMENT FUNCTIONSELECINSTRUMENT FUNCTIONSCOMBINATION METERSpeedometerClock, odometerSelect buttonReset button1234NOTE:This combination meter is

–25–SIGNAL SYSTEMELECEB806000SIGNAL SYSTEMCIRCUIT DIAGRAM

–26–SIGNAL SYSTEMELEC3Main switch4Fuse (position light and hazard)6Battery8Main fuse22Fuel sender25Fuel meter27Fuel level indicator light32Turn indica

–27–EB8024012. BatteryS Check the condition of the battery.Refer to “BATTERY INSPECTION”.Open-circuit voltage12.8 V or more at 20_CS Is the battery OK

–28–SIGNAL SYSTEMELEC Turn the main switch to “ON” or “P”. Check for voltage (12 V) on the “Brouwn/Red”lead at the flasher relay terminal. Is the v

–29–SIGNAL SYSTEMELECS Drain the fuel and remove the fuel senderfrom the fuel tank.S Disconnect the fuel sender coupler from thewire harness.S Connect

–30–SIGNAL SYSTEMELEC Connect the pocket tester (DC 20 V) and bat-tery (12 V)to the speed sensor coupler asshown. Speed sensor coupler (speed sensor

–31–SIGNAL SYSTEMELECBattery positive terminal  red Battery negative terminal  black Tester positive probe  white Tester negative probe  black  S

–32–FUEL PUMP SYSTEMELECMain switch36811131861BatteryMain fuseFuel pumpFuel relayIgnitor unitEngine stop switchIgnition fuse62EB808000FUEL PUMP SYSTEM

–33–FUEL PUMP SYSTEMELEC1 Battery2 Main fuse3 Main switch4 Ignition fuse5 Engine stop switch6 Ignitor unit7 Fuel pump relay8 Fuel pumpEB808010FUEL PUM

12465738EB002000HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See “Illustrated symbo

–34–FUEL PUMP SYSTEMELECEB8024012. BatteryCheck the condition of the battery.Refer to “BATTERY INSPECTION”.Open-circuit voltage12.8 V or more at 20C

–35–FUEL PUMP SYSTEMELEC5. Fuel pump relay Disconnect the relay unit from the coupler. Connect the pocket tester (Ω  1) and battery(12 V) to the re

–36–FUEL PUMP SYSTEMELECWARNINGEB808410CHECKING THE FUEL PUMPGasoline is extremely flammable and undercertain circumstances there can be a dangerof an

COLOR CODEB Black. . . . . . Br Brown. . . . . Ch Chocolate. . . . Dg Dark green. . . . G Green. . . . . Gy Gray. . . . L Blue. . . . . . Lg Light gre

2213579248624 25232119 201816 1715141311 1210GENINFOSPECENGCARBELECCHASCOOLINSPADJTRBLSHTGEB003000ILLUSTRATED SYMBOLSIllustrated symbols 1 to 9 ar

CONTENTSGENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOTORCYCLE IDENTIFICATION 1. . . . . . .

–1–MOTORCYCLE IDENTIFICATIONGENINFOEB100000GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONVEHICLE IDENTIFICATION NUMBERThe vehicle identification number

–2–GENERAL SPECIFICATIONSSPECSPECIFICATIONSGENERAL SPECIFICATIONSItem StandardModel: TDM850Model code: 4TX4Basic weight (With oil and full fuel tank):

–3–MAINTENANCE SPECIFICATIONSSPECMAINTENANCE SPECIFICATIONSENGINEItem Standard LimitClutch:Clutch spring free lengthQuantity50 mm648 mmCarburetor:I