FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the TDM850 ’99. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. TDM850 ’96 SERVICE MANUAL: 4TX-AE1 TDM850 ’97 SUPPLEMENTARY SERVICE MANUAL: 4TX-AE2 TDM850 ’99 SUPPLEMENTARY SERVICE MANUAL 1998 by Yamaha Motor Co., Ltd. First Edition, November 1998 All rights reserved.
EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcycles has a basic understanding of the mechanical ideas and the procedures of motorcycles repair.
EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page.
EB003000 1 GEN INFO 3 2 ILLUSTRATED SYMBOLS SPEC Illustrated symbols 1 to 9 are printed on top right of each page and indicate the subject of each chapter. 4 1 General information 2 Specifications INSP ADJ ENG 3 Periodic inspection and adjustment 4 Engine 5 5 Cooling system 6 6 Carburetion COOL CARB 7 Chassis 8 Electrical 7 9 Troubleshooting 8 CHAS ELEC Illustrated symbols 10 to 17 are used to identify the specifications appearing in the text.
CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTORCYCLE IDENTIFICATION GEN INFO EB100000 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model: TDM850 Model code: 4TX4 Basic weight (With oil and full fuel tank): 232 kg Carburetor: Type/quantity Manufacturer BDSR38/2 MIKUNI Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio Bulb wattage quantity Meter light Indicator lights Neutral Turn High beam Fuel Water tempere 1st 2nd 3rd 4th 5th Spur gear 67/39 (
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Clutch: Clutch spring free length Quantity 50 mm 6 48 mm Carburetor: I.D. mark Main jet Main air jet Jet needle Needle jet Pilot air jet 1 Pilot air jet 2 Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Pilot screw Valve seat size Starter jet 1 Starter jet 2 Throttle valve size Fuel level Engine idle speed Intake vacuum 4TX4 40 #147.5 #65 #1: 6DJP17 #2: 6CL1 P-O #87.5 #120 1.0 #17.5 0.8 0.9 0.8 2.0 1.5 #32.
MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item Standard Limit Charging system: Type Model/manufacturer Nominal output Stator coil resistance A.C. magneto TLN252/DENSO 14 V 25 A at 5,000 r/min 0.23 X 0.35 Ω at 20_C/W-W SSS SSS SSS SSS Starter relay: Model/manufacturer Amperage rating Coil winding resistance MS5F-421 /JIDECO 180 A 4.2 X 4.
CABLE ROUTING SPEC CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Throttle cable 1 Right handlebar switch lead Brake hose Clutch cable Main switch lead Left handlebar switch lead Horn lead Starter cable Speed sensor lead Coolant reservoir hose Headlight lead Meter light lead Thermo unit lead Thermo switch lead Fan motor lead 16 Ignition coil (left) lead 17 Ignition coil (right) lead 18 Negative lead A Fasten the right handlebar switch lead with a plastic band.
CABLE ROUTING L Fasten the meter lead and headlight lead with a plastic band. M Fasten the wireharness with a plastic band. N Fasten the wireharness, right handlebar switch lead meter lead and headlight lead with a plastic band. O Connect the coupler and insert to the protector. SPEC P Fasten the wireharness with a plastic band. Q Fasten the wireharness and ignition coil (left) lead with a plastic band.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 Front flasher light (left) lead Main switch lead Starter cable 1 Left handlebar switch lead Spark plug lead Carburetor breather hose Fuel hose Coolant reservoir hose Sidestand switch lead Neutral switch lead 11 12 13 14 15 16 17 18 19 20 A.C.
CABLE ROUTING D Fasten the rear flasher light (left) lead. E Fasten the sidestand switch lead neutral switch lead and A.C. magneto lead. F Route the sidestand switch lead and air filter case breather hose to the inside of the engine cover. G Fasten the sidestand switch lead to the air filter case breather hose. H Route the air filter case breather hose over the idle adjust bracket.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Battery negative lead Battery positive lead Starter motor lead Fuel sender lead Fuel tank drain hose Fuel tank breather hose (for DEU) Water hose Spark plug lead Clutch cable Brake hose Throttle cable Right handlebar switch lead Headlight lead Meter light lead Speed sensor lead Carburetor heater hose 17 18 19 20 21 22 Vacuum hose (#1) Vacuum hose (#2) Coolant reservoir breather hose Carburetor breather hose Rear brake switch lead CYCLELOCK lead A Rout
CABLE ROUTING J Fasten the right handlebar switch lead and speed sensor lead with a clamp. K Fasten the throttle cable and speed sensor lead with a clamp. L Route the coolant reservoir hose through the outside of clutch cable. M Fasten the wireharness, right handlebar switch lead, meter lead and headlight lead with a clamp. N Route the clutch cable through the guide of stay. O Route the coolant reservoir breather hose, fuel tank drain hose, carburetor breather hose through the guide.
CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 Head light lead Wireharness Meter light lead Throttle cable Throttle stop screw cable Vacuum hose (#2) Vacuum hose (#1) Fuel tank breather hose Fuel hose Carburetor air vent hose Carburetor breather hose 12 13 14 15 16 17 18 19 20 21 22 23 Fuel tank drain hose Fuel hose Fuel sender lead Starter motor lead Battery positive lead Battery negative lead Coolant reservoir breather hose Coolant reservoir hose Fuel hose Carburetor breather hose Cylinder head breather hose Ai
CABLE ROUTING H Fasten the carburetor breather hose and see the hose mark. I In order to carburetor breather hose, idle adjust cable coolant breather hose from downward. J Route the air filter drain hose to outside of throttle position sensor lead. K Fasten the wireharness with a clamp. L To left flasher. M Fasten the headlight lead with a clamp. N O P Q R SPEC To head light. To auxiliary light. To meter. Fasten the meter lead, headlight lead with a clamp.
INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS INSP ADJ PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspection and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as new vehicles that are being prepared for sale.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS INSP ADJ EVERY NO. ITEM CHECKS AND MAINTENANCE JOBS INITIAL (1,000 km) 6,000 km 6 months (whichever comes first) 12,000 km 12 months (whichever comes first) 21 * Carburetors Check engine idling speed, synchronization and starter oper ation. Adjust if necessary. √ √ √ 22 Engine oil Check oil level and vehicle for oil leakage. Correct if necessary. Change. (Warm engine before draining.) √ √ √ 23 Engine oil filter element Replace.
SEAT, TAIL COVER AND FUEL TANK INSP ADJ SEAT, TAIL COVER AND FUEL TANK 16 Nm (1.6m kg) 3.8 Nm (0.38m kg) Order Job name/Part name 1 2 3 4 5 Seat, tail cover and fuel tank removal Side cowling Seat Taillight lead coupler Tail cover Side cover Fuel hose 1 1 1 2 1 6 7 8 Fuel tank breather hose Fuel tank Fuel sender coupler 1 1 1 Q’ty –15– Remarks Remove the parts in the order below. Refer to “COWLINGS”.
CARBURETOR SYNCHRONIZATION INSP ADJ ENGINE CARBURETOR SYNCHRONIZATION NOTE: Valve clearance and idling speed should be adjusted properly before synchronizing the carburetors. 1. Place the motorcycle on a level surface. NOTE: Place the motorcycle on its centerstand if a centerstand is equipped. If not, place a suitable stand under the motorcycle. 2. Remove: Side cowling Seat Side cover Fuel tank Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK”. 3.
CARBURETOR SYNCHRONIZATION INSP ADJ 7. Adjust: Carburetor synchronization Adjustment steps: Synchronize carburetor #1 to carburetor #2 by turning synchronizing screw 1 until both gauges read the same. Race the engine for less than a second, two or three times and check the synchronization again. Intake vacuum at idle speed: 36.0 – 38.7 kPa (270 – 290 mm Hg) NOTE: The difference between both carburetors should be 0.67 kPa (5 mm Hg) or less. 8.
ENGINE OIL LEVEL INSPECTION INSP ADJ ENGINE OIL LEVEL INSPECTION NOTE: Position the motorcycle straight up when inspecting the oil level. 1. Place the motorcycle on a level surface. NOTE: After idling the engine a few minutes. The summer season is about 5 minutes and the winter season is about 15 minutes. Turn off the engine and wait a few minutes until the oil settle. The motor cycle is vertical. Then check that the oil level is between the maximum and minimum marks.
ENGINE OIL REPLACEMENT INSP ADJ ENGINE OIL REPLACEMENT 1. Start the engine and let it warm up for several minutes. 2. Stop the engine and place an oil pan under the drain bolt. 3. Remove: Oil filler plug 1 4. Remove: Drain bolt (with gasket) 1 Oil filter drain bolt (with gasket) 2 Drain the crankcase and oil tank of its oil. 5. If the oil filter is to be replaced during this oil change, remove the following parts and reinstall them.
ENGINE OIL REPLACEMENT INSP ADJ 7. Fill: Crankcase CAUTION: The engine should be filled with oil in two steps. First fill the engine with 3.2 liters of oil. Then start the engine and race it five or six times. Continue idling the engine a few minutes. Stop the engine and fill it with oil to the specified level. Oil quantity: Total amount: 4.2 L Periodic oil change: 3.5 L With oil filter replacement: 3.6 L 8. Install: Oil filler plug 9.
FUEL LINE INSPECTION INSP ADJ FUEL LINE INSPECTION 1. Remove: Side cowling Seat Side cover Fuel tank Refer to “COWLINGS, SEAT, TAIL COVER AND FUEL TANK”. 2. Inspect: Fuel hoses 1 Cracks /Damage Replace. Loose connection Connect properly. NOTE: Drain and flush the fuel tank if abrasive damage to any components is evident. 3. Install: All removed parts NOTE: Install all removed parts in reversed order of their removal.
CLUTCH ENG CLUTCH CLUTCH 70 Nm (7.0m kg) 8 Nm (0.8m kg) Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Job name/Part name Clutch removal Clutch spring Pressure plate Plain washer/Bearing Pull rod Friction plate Friction plate Clutch plate Clutch boss nut Lock washer Clutch boss Thrust plate Spacer/Bearing Clutch housing Thrust plate 2 Thrust plate 1 Q’ty Remarks Remove the parts in the order below. 6 1 1/1 1 7 2 8 1 1 1 1 1/1 1 1 1 Refer to “REMOVAL”, and “INSTALLATION”.
CLUTCH ENG INSTALLATION 1. Install: friction plates clutch plates CAUTION: The friction plates are made in two types. The first and last friction plates are different in material from the other ones and black on the surface. Assembly should be done in the correct order. NOTE: Mount friction and clutch plate alternately. Lubricate the friction plates with engine oil.
INSTRUMENT FUNCTIONS This combination meter is equipped with the following. An odometer Two trip odometers A clock INSTRUMENT FUNCTIONS COMBINATION METER 1 2 3 4 ELEC Odometer and trip meters Use the trip meters to estimate how far you can ride on a tank of fuel.
SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM –25– ELEC
SIGNAL SYSTEM 3 Main switch 4 Fuse (position light and hazard) 6 Battery 8 Main fuse 22 Fuel sender 25 Fuel meter 27 Fuel level indicator light 32 Turn indicator light (left) 33 Turn indicator light (right) 34 Speed meter 35 Speed sensor 36 Front flasher light 37 Rear flasher light 44 Hazard switch 45 Turn switch 48 Flasher relay 49 Hazard relay –26– ELEC
SIGNAL SYSTEM EB806010 ELEC EB802401 TROUBLESHOOTING S Any of the following fail to light: flasher light, trun and fuel level indicator light. S The fuel meter fails to operate. 2. Battery S Check the condition of the battery. Refer to “BATTERY INSPECTION”. Open-circuit voltage 12.8 V or more at 20_C Check: 1. main and signal system fuses 2. battery 3. main switch 4. wiring (of the entire signal system) S Is the battery OK? YES S Clean the battery terminals. S Recharge or replace the battery.
SIGNAL SYSTEM SIGNAL SYSTEM CHECK 1. Flasher light and/or turn indicator light does not blink. 4. Voltage Connect the pocket tester (DC 20 V) to the flasher relay coupler. 1. Flasher/turn indicator light bulb and socket Tester (+) lead Brown/Red terminal 1 Tester (–) lead Frame ground Check the flasher/turn indicator light bulb and socket for continuity. Are the flasher/turn indicator light bulb and socket OK? YES ELEC NO Replace the flasher/turn indicator light balb, socket or both. 2.
SIGNAL SYSTEM 2. The fuel level indicator light fails to come on or the fuel meter fails to operator. S Turn the main switch to “ON” or “P”. S Check for voltage (12 V) on the “Brouwn/White” lead at the flasher relay terminal. S Is the voltage within specification. YES 1. Fuel level indicator light bulb and socket S Check the fuel level indicator bulb and socket continuity. S Are the fuel level indicator light bulb and socket OK? NO Replace the flasher relay. YES 5.
SIGNAL SYSTEM Set the main switch to “ON”. Measure the voltage (12 V). Is the voltage within specification? Is the fuel sender OK? YES NO Replace sender. the ELEC YES fuel This circuit is OK. 3. Fuel meter Drain the fuel and remove the fuel sender from the fuel tank. Connect the fuel sender to wireharness. Move the float to “UP” 1 or “DOWN” 2 . NO The wiring circuit from the main switch to the meter assembly coupler is faulty and must be repaired. 2.
SIGNAL SYSTEM Battery positive terminal red 2 Battery negative terminal black 3 Tester positive probe white 1 Tester negative probe black 3 Set the main switch to “ON”. Elevate the front wheel and slowly rotate it. Does the voltage (5V) read cycle 4 times with each, full rotation of the front wheel? YES NO Replace the speed sensor. 2. Wiring Check the entire wiring signal system’s wiring. Refer to “CIRCUIT DIAGRAM”.
3 Main switch 6 Battery 8 Main fuse 11 Fuel pump 13 Fuel relay 18 Ignitor unit 61 Engine stop switch 62 Ignition fuse FUEL PUMP SYSTEM –32– ELEC EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM
FUEL PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump.
FUEL PUMP SYSTEM EB808020 ELEC EB802401 TROUBLESHOOTING 2. Battery Check the condition of the battery. Refer to “BATTERY INSPECTION”. The fuel pump fails to operate. Check: 1. main and ignition fuses 2. battery 3. main switch 4. engine stop switch 5. fuel pump relay 6. fuel pump 7. wiring (the entire fuel pump system) Open-circuit voltage 12.8 V or more at 20 C Is the battery OK? YES NO Clean the battery terminals. Recharge or replace the battery.
FUEL PUMP SYSTEM ELEC Measure the fuel pump resistance. 5. Fuel pump relay Disconnect the relay unit from the coupler. Connect the pocket tester (Ω 1) and battery (12 V) to the relay unit ferminals as shown. Fuel pump resistance 4 10 Ω at 20 C Is the fuel pump OK? Battery positive terminal red/black 1 Battery negative terminal blue/red 2 YES Tester positive probe red/black 1 Tester negative probe blue/black 3 NO Relpace the fuel pump. EB808401 7.
FUEL PUMP SYSTEM ELEC EB808410 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: Stop the engine before refuelling. Do not smoke and keep away from open flames, sparks or any other source of fire. If you do accidentally spill gasoline, wipe it up immediately with dry rags. If gasoline touches the engine when it is hot, a fire may occur.
TDM850 ’99 WIRING DIAGRAM COLOR CODE B ...... Br . . . . . Ch . . . . Dg . . . . G ..... Gy . . . . Black Brown Chocolate Dark green Green Gray L ...... Lg . . . . . Or . . . . . R...... Sb . . . . . W ..... Blue Light green Orange Red Sky blue White Y ...... B/L . . . . Br / L . . . Br / R . . . Br / W . . B/W . . . Yellow Black / Blue Brown / Blue Brown / Red Brown / White Black / White B/Y . . . . G/B . . . G/R . . . G/W . . . G/Y . . . L/R . . . .
