Yamaha TDM850 1996, TDM850 '96, TDM850 96-99 Service Manual

4.7 (3)

EB000000

TDM850 '96

SERVICE MANUAL1996 by Yamaha Motor Co., Ltd.

First edition, March 1996

All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

NOTICE

This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowledge, attempted repairs or service to this model may render if unfit to use and/or unsafe.

Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.

PARTICULARY IMPORTANT INFORMATION

This material is distinguished by the following notation.

 

 

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

 

 

SAFETY IS INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or

 

 

 

 

 

 

 

death to the motorcycle operator, a bystander, or a person inspecting or

 

 

 

 

 

 

repairing the motorcycle.

 

 

 

 

 

CAUTION:

 

A CAUTION indicates special precautions that must be taken to avoid

NOTE:

damage to the motorcycle.

A NOTE provides key information to make procedures easier or clearer.

EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See ªIllustrated symbolsº)

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.

3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

1.An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.

2.Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step.

3.An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6 . The meanings of the symbol marks are given on the next page.

4.A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

5.For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart.

2

1

4

3

6

8

5

7

1

2

GEN

SPEC

INFO

 

3

4

INSP

ENG

ADJ

 

5

6

COOL

CARB

7

8

CHAS

ELEC

9

10

TRBL

 

SHTG

 

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1 to 9 are printed on top right of each page and indicate the subject of each chapter.

1General information

2Specifications

3Periodic inspections and adjustments

4Engine

5Cooling system

6Carburetion

7Chassis

8Electrical

9Troubleshooting

Illustrated symbols 10 to 17 are used to identify the specifications appearing in the text.

10Can be serviced with engine mounted

11Filling fluid

12Lubricant

13Special tool

14Torque

15Wear limit, clearance

16Engine speed

17Ω, V, A

Illustrated symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points.

18Apply engine oil

19Apply gear oil

20Apply molybdenum disulfide oil

21Apply wheel bearing grease

22Apply lightweight lithium soap base grease

23Apply molybdenum disulfide grease

Illustrated symbols 24 to 25 in the exploded diagrams indicate where to apply a locking agent 24 and when to install new parts 25 .

24Apply locking agent (LOCTITE )

25Replace

INDEX

GENERAL INFORMATION

 

 

GEN

1

 

INFO

 

 

 

SPECIFICATIONS

 

 

SPEC

2

 

 

 

 

PERIODIC INSPECTION AND

 

 

INSP

3

ADJUSTMENT

ADJ

 

 

 

ENGINE OVERHAUL

 

 

ENG

4

 

 

 

 

COOLING SYSTEM

 

 

COOL

5

 

 

 

 

CARBURETION

 

 

CARB

6

 

 

 

 

CHASSIS

 

 

CHAS

7

 

 

 

 

ELECTRICAL

 

 

ELEC

8

 

 

 

 

TROUBLESHOOTING

 

 

TRBL

9

 

SHTG

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 FRAME SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 PREPARATION FOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 ALL REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 GASKETS, OIL SEALS, AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . . . . 1-3 BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

CHECKING OF CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4

HOW TO USE THE CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

GEN INFO

GEN

MOTORCYCLE IDENTIFICATION INFO

EB100000

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped into the right side of the steering head.

NOTE:

The vehicle identification number is used to identify the motorcycle and may be used to register the motorcycle with a licensing authority.

EB100030

ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into the crankcase.

NOTE:

The first three digits of the engine serial number indicate the model type; the remaining digits are the unit production number.

MODEL LABEL

The model label 1 is affixed to the frame. This information will be needed to order spare parts.

1-1

GEN

IMPORTANT INFORMATION INFO

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL

1.Remove all dirt, mud dust, and foreign material before removal and disassembly.

2.Use proper tools and cleaning equipment. Refer to ªSPECIAL TOOLSº.

3.When disassembling the motorcycle keep mated parts together. This includes gears, cylinders, pistons, and other mated parts that have been ªmatedº through normal wear. Mated parts must be reused as an assembly or replaced.

4.During the motorcycle disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled.

5.Keep away from fire.

ALL REPLACEMENT PARTS

1.Use only genuine Yamaha parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. Other brands may be similar in function and appearance, but inferior in quality.

GASKETS, OIL SEALS, AND O-RINGS

1.All gaskets, seals and O-rings should be replaced when an engine is overhauled.

All gaskets surfaces, oil seal lips and O-rings must be cleaned.

2.Properly oil all mating parts and bearing during reassembly. Apply grease to the oil seal lips.

1-2

GEN

IMPORTANT INFORMATION INFO

LOCK WASHERS/PLATES AND COTTER PINS

1. All lock washers/plates 1 and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.

BEARINGS AND OIL SEALS

1. Install the bearing(s) and oil seal(s) with their manufacturer's marks or numbers facing outward. (In other word, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.

1 Oil seal

CAUTION:

Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

2 Bearing

CIRCLIPS

1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlips 1 , make sure that the sharp edged corner 2 is positioned opposite to the thrust 3 it receives. See the sectional view.

4 Shaft

1-3

GEN

CHECKING OF CONNECTIONS INFO

CHECKING OF CONNECTIONS

Dealing with stains, rust, moisture, etc. on the connector.

1.Disconnect:

Connector

2.Dry each terminal with an air blower.

3.Connect and disconnect the connector two or three times.

4.Pull the lead to check that it will not come off.

5.If the terminal comes off, bend up the pin 1 and reinsert the terminal into the connector.

6.Connect:

Connector

NOTE:

The two connectors ªclickº together.

7. Check for continuity with a tester.

NOTE:

If there is no continuity, clean the terminals.

Be sure to perform the steps 1 to 7 listed above when checking the wireharness.

For a field remedy, use a contact revitalizer available on the market.

Use the tester on the connector as shown.

1-4

GEN

HOW TO USE THE CONVERSION TABLE INFO

HOW TO USE THE CONVERSION TABLE

All specification data in this manual are listed in SI and METRIC UNITS.

Use this table to convert METRIC unit data to IMPERIAL unit data.

Ex.

 

 

 

 

METRIC

 

MULTIPLIER

 

IMPERIAL

**mm

 

0.03937

=

**in

2 mm

 

0.03937

=

0.08 in

CONVERSION TABLE

METRIC TO IMPERIAL

 

Metric unit

Multiplier

Imperial unit

 

 

 

 

 

m kg

7.233

ft lb

Torque

m kg

86.794

in lb

cm kg

0.0723

ft lb

 

 

cm kg

0.8679

in lb

Weight

kg

2.205

lb

g

0.03527

oz

 

 

 

 

 

Speed

km/hr

0.6214

mph

 

 

 

 

 

km

0.6214

mi

Dis-

m

3.281

ft

m

1.094

yd

tance

cm

0.3937

in

 

 

mm

0.03937

in

 

 

 

 

 

cc (cm3)

0.03527

oz (IMP liq.)

Volume/

cc (cm3)

0.06102

cu in

Capacity

lit (liter)

0.8799

qt (IMP liq.)

 

lit (liter)

0.2199

gal (IMP liq.)

 

 

 

 

 

kg/mm

55.997

lb/in

Miscel-

kg/cm2

14.2234

psi (lb/in2)

laneous

Centigrade

9/5+32

Fahrenheit

 

(_C)

 

(_F)

1-5

GEN

SPECIAL TOOLS INFO

SPECIAL TOOLS

The proper special tools are necessary for complete and accurate tune-up and assembly.

Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.

Tool No.

Tool name/How to use

Illustration

90890-01083 Slide hammer bolt

90890-01084 Weight

 

These tools are used to remove the

 

main axle assembly cover.

 

 

90890-01304

Piston pin puller

 

This tool is used to remove the piston

 

pin.

 

 

90890-01312

Fuel level gauge

 

This gauge is used to measure the fuel

 

level in the float chamber.

 

90890-01325 Radiator cap tester

90890-01352

Adapter

 

This tester is needed for checking the

 

cooling system.

 

 

90890-01362

Flywheel puller

90890-01382

Crankshaft protector

 

These tools are used to remove the A.C.

 

magneto.

 

90890-01367 Fork seal driver weight

90890-01374

Adapter

 

These tools are used when installing the

 

fork seal.

 

90890-01326 T-handle

90890-01465 Damper rod holder

 

These tools are used to loosen and

 

tighten the front fork damper rod

 

holding bolt.

 

 

90890-01403

Ring nut wrench

 

This tool is used to loosen and tighten

 

the steering ring nut.

1-6

 

SPECIAL TOOLS

 

 

GEN

 

 

 

 

INFO

 

 

 

 

 

Tool No.

Tool name/How to use

 

Illustration

 

 

 

 

 

 

 

90890-01701

Sheave holder

 

 

 

 

 

 

This tool is used to hold the rotor when

 

 

 

 

 

 

loosening and tightening the rotor bolt.

 

 

 

 

 

 

 

 

 

 

 

 

90890-03081

Compression gauge

 

 

 

 

 

 

This gauge is used to measure the

 

 

 

 

 

 

engine compression.

 

 

 

 

 

 

 

 

 

 

 

 

90890-03094

Vacuum gauge

 

 

 

 

 

 

This gauge is needed for carburetor

 

 

 

 

 

 

synchronization.

 

 

 

 

 

 

 

 

 

 

 

 

90890-03112

Pocket tester

 

 

 

 

 

 

This instrument is invaluable for

 

 

 

 

 

 

checking the electrical system.

 

 

 

 

 

 

 

 

 

 

 

 

90890-03113

Engine tachometer

 

 

 

 

 

 

This tool is needed for detecting

 

 

 

 

 

 

engine rpm.

 

 

 

 

 

 

 

 

 

 

 

 

90890-03141

Timing light

 

 

 

 

 

 

This tool is necessary for checking

 

 

 

 

 

 

ignition timing.

 

 

 

 

 

 

 

 

 

 

 

 

90890-04016

Valve guide remover, installer and

 

 

 

 

 

 

reamer (5.5 mm)

 

 

 

 

 

 

These tools are used to remove, install

 

 

 

 

 

 

and rebore the valve guide.

 

 

 

 

 

 

 

 

 

 

 

 

90890-04019

Valve spring compressor

 

 

 

 

 

90890-04108

Attachment

 

 

 

 

 

 

These tools are needed to remove and

 

 

 

 

 

 

install the valve assemblies.

 

 

 

 

 

 

 

 

 

 

 

 

90890-04086

Universal clutch holder

 

 

 

 

 

 

This tool is used to hold the clutch when

 

 

 

 

 

 

removing or installing the clutch boss

 

 

 

 

 

 

nut.

 

 

 

 

 

 

 

 

 

 

 

 

90890-06754

Ignition checker

 

 

 

 

 

 

This instrument is necessary for

 

 

 

 

 

 

checking the ignition system components.

 

 

 

 

 

 

 

 

 

 

 

 

1-7

 

SPECIAL TOOLS

 

 

GEN

 

 

 

 

INFO

 

 

 

 

Tool No.

Tool name/How to use

Illustration

90890-85505 Yamaha bond No. 1215

This sealant (bond) is used on crankcase mating surfaces, etc.

1-8

SPEC

CHAPTER 2.

SPECIFICATIONS

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

LUBRICATION POINT AND GRADE OF LUBRICANT . . . . . . . . . . . . . . . . 2-18 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-20

CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-25

SPEC

 

GENERAL SPECIFICATIONS

SPEC

 

 

 

 

 

 

 

SPECIFICATIONS

GENERAL SPECIFICATIONS

 

 

Item

Standard

 

 

Model:

TDM850

 

 

Model code:

4TX1

 

 

 

 

 

Dimensions:

 

 

 

 

Overall length

2,165 mm, 2,200 mm (D, DK, SF, N, S)

Overall width

790 mm

Overall height

1,285 mm

Seat height

805 mm

Wheelbase

1,475 mm

Minimum ground clearance

165 mm

Minimum turning radius

2,900 mm

 

Basic weight (With oil and full fuel tank): 229 kg

 

 

 

 

 

Engine:

 

 

 

 

Engine type

Liquid-cooled 4-stroke, DOHC, 5 valve

Cylinder arrangement

Forward-inclined parallel 2-cylinder

Displacement

0.849 L

Bore stroke

89.5 67.5 mm

Compression ratio

10.5 : 1

 

 

 

Compression pressure (STD)

1,200 kPa (12 kg/cm2, 12 bar) at 300 r/min

Starting system

Electric starter

 

 

Lubrication system:

Dry sump

 

 

 

 

 

Oil type or grade:

 

 

 

 

Engine oil

 

 

 

 

 

API Standard:

 

API SE or higher grade

 

 

Oil capacity:

 

Engine oil

 

Periodic oil change

3.5 L

With oil filter replacement

3.6 L

Total amount

4.2 L

2-1

 

GENERAL SPECIFICATIONS

 

SPEC

 

 

 

 

 

 

 

 

 

 

 

 

 

Item

 

Standard

 

 

 

 

 

 

 

 

 

Air filter:

 

Dry type element

 

 

 

 

 

 

 

 

 

Fuel:

 

 

 

 

 

Type

 

Regular unleaded gasoline

 

 

 

Fuel tank capacity

 

20 L

 

 

 

Fuel reserve amount

 

3.1 L

 

 

 

 

 

 

 

 

 

Carburetor:

 

 

 

 

 

Type/quantity

 

BDST38/2

 

 

 

Manufacturer

 

MIKUNI

 

 

 

 

 

 

 

 

 

Spark plug:

 

 

 

 

 

Type

 

DPR8EA-9/X24EPR-U9

 

 

 

Manufacturer

 

NGK/NIPPONDENSO

 

 

 

Spark plug gap

 

0.8 X 0.9 mm

 

 

 

 

 

 

 

 

 

Clutch type:

 

Wet, multiple-disc

 

 

 

 

 

 

 

 

 

Transmission:

 

 

 

 

 

Primary reduction system

 

Spur gear

 

 

 

Primary reduction ratio

 

67/39 (1.718)

 

 

 

Secondary reduction system

 

Chain drive

 

 

 

Secondary reduction ratio

 

42/17 (2.471)

 

 

 

Transmission type

 

Constant mesh 5-speed

 

 

 

Operation

 

Left foot operation

 

 

 

Gear ratio

1st

37/13 (2.846)

 

 

 

 

2nd

37/20 (1.850)

 

 

 

 

3rd

30/21 (1.429)

 

 

 

 

4th

27/23 (1.174)

 

 

 

 

5th

28/27 (1.037)

 

 

 

 

 

 

 

 

 

Chassis:

 

 

 

 

 

Frame type

 

Diamond

 

 

 

Caster angle

 

24.5

 

 

 

Trail

 

103 mm

 

 

 

 

 

 

 

 

 

Tire:

 

 

 

 

 

Type

 

Tubeless

 

 

 

Size

front

110/80 ZR18

 

 

 

 

rear

150/70 ZR17

 

 

 

Manufacturer

front

BRIDGESTONE/PIRELLI/MICHELIN

 

rear

BRIDGESTONE/PIRELLI/MICHELIN

Type

front

BT54F/MTR03/MACADAM90X

 

 

 

 

rear

BT54R/MTR04/MACADAM90X

 

 

 

2-2

 

GENERAL SPECIFICATIONS

SPEC

 

 

 

 

 

 

 

 

 

 

 

 

Item

 

Standard

 

 

 

 

 

 

 

 

Tire pressure (cold tire):

 

 

 

 

 

Maximum load-except motorcycle

180 kg

 

 

Loading condition A*

 

0 90 kg

 

 

 

front

225 kPa (2.25 kg/cm2, 2.25 bar)

 

 

 

rear

275 kPa (2.75 kg/cm2, 2.75 bar)

 

 

Loading condition B*

 

90 180 kg

 

 

 

front

225 kPa (2.25 kg/cm2, 2.25 bar)

 

 

 

rear

275 kPa (2.75 kg/cm2, 2.75 bar)

 

 

High speed riding

 

225 kPa (2.25 kg/cm2, 2.25 bar)

 

 

 

front

 

 

 

rear

275 kPa (2.75 kg/cm2, 2.75 kg/cm2)

 

 

Brake:

 

 

 

 

 

Front brake

type

Dual disc brake

 

 

 

operation

Right hand operation

 

 

Rear brake

type

Single disc brake

 

 

 

operation

Right foot operation

 

 

 

 

 

 

 

 

Suspension:

 

 

 

 

 

Front suspension

 

Telescopic fork

 

 

Rear suspension

 

Swingarm (monocross)

 

 

 

 

 

 

 

 

Shock absorber:

 

 

 

 

 

Front shock absorber

 

Coil spring/Oil damper

 

 

Rear shock absorber

 

Coil spring/Gas-oil damper

 

 

 

 

 

 

 

 

Wheel travel:

 

 

 

 

 

Front wheel travel

 

149 mm

 

 

Rear wheel travel

 

144 mm

 

 

 

 

 

 

 

 

Electrical:

 

 

 

 

 

Ignition system

 

T.C.I. (digital)

 

 

Generator system

 

A.C. magneto

 

 

Battery type

 

GT12B-4

 

 

Battery capacity

 

12 V 10 AH

 

 

 

 

 

 

 

Headlight type:

 

Quartz bulb (halogen)

 

 

 

 

 

 

 

 

Bulb wattage quantity:

 

 

 

 

 

Headlight

 

12 V 55 W 2

 

 

Auxiliary light

 

12 V 5 W 1

 

 

Tail/brake light

 

12 V 5/21 W 2

 

 

Flasher light

 

12 V 21 W 4

 

 

Meter light

 

12 V 3.4 W 1

 

 

 

 

12 V 1.7 W 2

 

 

 

 

12 V 3.0 W 1

 

 

Indicator lights

 

 

 

 

 

Neutral

 

12 V 3.4 W 1

 

 

Turn

 

12 V 3.4 W 1

 

 

High beam

 

12 V 3.4 W 1

 

 

 

 

 

 

 

 

* Load is total weight of cargo, rider, passenger and accessories

2-3

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item

Standard

Limit

Cylinder head:

 

0.03 mm

Warp limit

 

 

 

 

Cylinder:

 

 

Bore size

89.500 X 89.505 mm

89.6 mm

Taper limit

 

0.05 mm

Out of round limit

 

0.03 mm

 

 

 

Camshaft:

Timing chain (right)

 

Drive method

 

Camshaft cap inside diameter

25.000 X 25.021 mm

 

Camshaft outside diameter

24.967 X 24.980 mm

 

Camshaft-to-cap clearance

0.020 X 0.054 mm

 

Cam dimensions

 

 

Intake

ªAº

35.95 X 36.05 mm

35.85mm

 

ªBº

27.95 X 28.05 mm

27.85mm

 

ªCº

7.9 X 8.1 mm

 

Exhaust

ªAº

35.95 X 36.05 mm

35.85 mm

 

ªBº

27.95 X 28.05 mm

27.85 mm

 

ªCº

7.9 X 8.1 mm

 

Camshaft runout limit

 

 

0.03 mm

 

 

 

 

Cam chain:

 

82RH2015/138

 

Cam chain type/No. of links

 

Cam chain adjustment method

Automatic

 

 

 

 

Valve, valve seat, valve guide:

 

 

Valve clearance (cold)

IN

0.15 X 0.20 mm

 

Valve dimensions:

EX

0.25 X 0.30 mm

 

 

 

 

Head Dia Face Width Seat Width Margin Thickness

ªAº head diameter

IN

25.9 X 26.1 mm

 

 

EX

27.9 X 28.1 mm

 

 

 

 

 

 

 

2-4

 

 

MAINTENANCE SPECIFICATIONS

 

SPEC

 

 

 

 

 

 

 

 

 

 

 

 

Item

 

Standard

 

Limit

 

 

 

 

 

ªBº face width

IN

2.06 X 2.46 mm

 

 

 

EX

2.06 X 2.46 mm

 

 

ªCº seat width

IN

0.9 X 1.1 mm

 

 

 

EX

0.9 X 1.1 mm

 

 

ªDº margin thickness

IN

0.8 X 1.2 mm

 

 

 

EX

0.8 X 1.2 mm

 

 

Stem outside diameter

IN

5.475 X 5.490 mm

 

5.445 mm

 

EX

5.460 X 5.475 mm

 

5.43 mm

Guide inside diameter

IN

5.500 X 5.512 mm

 

5.55 mm

 

EX

5.500 X 5.512 mm

 

5.55 mm

Stem-to-guide clearance

IN

0.010 X 0.037 mm

 

0.08 mm

 

EX

0.025 X 0.052 mm

 

0.10 mm

Stem runout limit

 

 

 

0.01 mm

Valve seat width

IN

0.9 X 1.1 mm

1.6 mm

 

EX

0.9 X 1.1 mm

1.6 mm

 

 

 

 

Valve spring:

 

 

 

Free length

IN

37.29 mm

35.2 mm

 

EX

37.29 mm

35.2 mm

Set length (valve closed)

IN

30.39 mm

 

 

EX

30.39 mm

 

Compressed pressure

 

 

 

(installed)

IN

 

 

 

EX

10.0 X 11.6 kg

 

Tilt limit

IN

10.0 X 11.6 kg

 

 

EX

 

2.5_/1.7 mm

 

 

 

2.5_/1.7 mm

Direction of winding

 

 

 

(top view)

IN

Clockwise

 

 

EX

Clockwise

 

2-5

MAINTENANCE SPECIFICATIONS

 

SPEC

 

 

 

 

 

 

 

 

 

 

Item

Standard

 

Limit

 

 

 

 

 

Piston:

 

 

 

 

Piston to cylinder clearance

0.065 0.085 mm

 

0.15 mm

Piston size ªDº

89.420 89.435 mm

 

 

Measuring point ªHº

4.5 mm

 

Piston off-set

1 mm

 

Piston off-set direction

IN side

 

Piston pin bore inside diameter

20.002 20.013 mm

20.043 mm

Piston pin outside diameter

19.991 20.000 mm

19.975 mm

 

 

 

Piston rings:

 

 

Top ring:

 

 

Type

Barrel

 

Dimensions (B T)

1.0 3.5 mm

 

End gap (installed)

0.30 0.45 mm

0.7 mm

Side clearance (installed)

0.035 0.070 mm

0.12 mm

2nd ring:

Type

Taper

 

Dimensions (B T)

1.0 3.5 mm

 

End gap (installed)

0.30 0.45 mm

0.8 mm

Side clearance (installed)

0.035 0.070 mm

0.12 mm

Oil ring:

Dimensions (B T)

2.00 2.85 mm

 

End gap (installed)

0.2 0.7 mm

 

 

 

 

Connecting rod:

 

 

Oil clearance

0.026 0.050 mm

0.09 mm

2-6

 

MAINTENANCE SPECIFICATIONS

 

SPEC

 

 

 

 

 

 

 

 

 

 

Item

Standard

 

Limit

Crankshaft:

Assembly width ªAº

 

153.6 X 154.4 mm

 

Crank width ªBº

 

64.75 X 65.25 mm

 

Runout limit ªCº

 

 

0.035 mm

Big end side clearance ªDº

0.160 X 0.272 mm

0.5 mm

Small end free play ªFº

 

0.8 X 1.0 mm

 

Journal oil clearance

 

0.020 X 0.038 mm

0.1 mm

 

 

 

 

Balancer:

 

 

 

Balancer drive method

 

Gear

 

 

 

 

 

Clutch:

 

 

 

Friction plate thickness

 

2.9 X 3.1 mm

2.8 mm

Quantity

 

9

 

Clutch plate thickness

 

1.9 X 2.1 mm

 

Quantity

 

8

 

Warp limit

 

 

0.1 mm

Clutch spring free length

 

55 mm

53 mm

Quantity

 

6

 

Clutch release method

 

Outer pull, rack & pinion pull

 

 

 

 

 

Transmission:

 

 

 

Main axle deflection limit

 

 

0.08 mm

Drive axle deflection limit

 

 

0.08 mm

 

 

 

 

Shifter:

 

 

 

Shifter type

 

Guide bar

 

Guide bar bending limit

 

 

0.1 mm

 

 

 

 

Carburetor:

 

 

 

I.D.mark

 

4TX 00

 

Main jet

(M.J)

#142.5

 

Main air jet

(M.A.J)

#60

 

Jet needle

(J.N)

5EI85-2/3

 

Needle jet

(N.J)

Y-2

 

Pilot air jet 1

(P.A.J.1)

#70

 

Pilot air jet 2

(P.A.J.2)

1.4

 

Pilot outlet

(P.O)

0.9

 

Pilot jet

(P.J)

#45

 

Bypass 1

(B.P.1)

0.8

 

Bypass 2

(B.P.2)

0.9

 

Bypass 3

(B.P.3)

0.8

 

Pilot screw

(P.S)

2.0

 

2-7

 

MAINTENANCE SPECIFICATIONS

 

SPEC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Item

 

Standard

 

Limit

 

 

 

 

 

 

 

Valve seat size

(V.S)

1.7

 

 

 

 

Starter jet 1

(G.S.1)

#75

 

 

 

 

Starter jet 2

(G.S.2)

0.8

 

 

 

 

Throttle valve size

(Th. V)

#130

 

 

 

 

Fuel level

(F.L)

15.8 16.8 mm

 

 

Engine idle speed

 

1,050 1,250 r/min

 

 

Intake vacuum

 

36.0 38.7 kPa (270 290 mmHg)

 

 

 

 

 

 

 

 

 

 

Fuel pump:

 

 

 

 

 

 

 

Type

 

Vacuum type

 

 

Model/manufacturer

 

4NX/MIKUNI

 

 

Output pressure

 

10 kPa (0.1 kg/cm2, 0.1 bar)

 

 

Lubrication system:

 

 

 

 

 

 

 

Oil filter type

 

Paper type

 

 

Oil pump type

 

Trochoid type

 

 

Tip clearance

 

0 0.12 mm

 

0.17 mm

Side clearance

 

0.03 0.08 mm

 

0.15 mm

Bypass valve setting pressure

39 78 kPa (0.4 0.8 kg/cm2,

 

 

 

 

0.4 0.8 bar)

 

 

 

Relief valve operating pressure

343 441 kPa (3.5 4.5 kg/cm2,

 

 

 

 

3.5 4.5 bar)

 

 

 

 

 

 

 

 

 

 

 

Cooling system:

 

 

 

 

 

 

 

Radiator core size

 

 

 

 

 

 

 

Width/height/thickness

 

300/180.6/27 mm

 

 

Radiator cap opening pressure

75 105 kPa (0.75 1.05 kg/cm2,

 

 

 

 

0.75 1.05 bar)

 

 

 

Reservoir tank capacity

 

0.3 L

 

 

<From low to full level>

 

0.2 L

 

 

Water pump

 

 

 

 

 

 

 

Type

 

Single suction centrifugal pump

 

 

Reduction ratio

 

44/44 38/27 (1.407)

 

 

 

 

 

 

 

 

 

 

2-8

MAINTENANCE SPECIFICATIONS

 

 

SPEC

 

Tightening torques

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Thread

 

Tightening

 

 

Part to be tightened

Part name

Q'ty

torque

Remarks

size

 

 

 

Nm

mSkg

 

 

 

 

 

 

 

 

Camshaft cap

Flange bolt

M6

16

10

1.0

 

 

Cylinder head

Nut

M10

6

40

4.0

 

 

 

Bolt

M6

2

10

1.0

 

 

Cylinder head cover

Bolt

M6

8

10

1.0

 

 

Coolant drain bolt (cylinder body)

Bolt

M6

1

10

1.0

 

 

Spark plug

Ð

M12

2

18

1.8

 

 

Connecting rod

Nut

M9

4

48

4.8

 

 

Rotor

Flange bolt

M12

1

130

13.0

 

 

Camshaft sprocket

Flange bolt

M7

4

24

2.4

 

 

Timing chain tensioner

Bolt

M6

2

10

1.0

 

 

Radiator

Flange bolt

M6

4

7

0.7

 

 

Delivery hose (crankcase-cylinder)

Bolt

M10

2

21

2.1

 

 

 

Bolt

M6

2

10

1.0

 

 

Oil pump assembly

Screw

M6

6

6

0.6

 

 

Oil baffle plate

Flange bolt

M6

2

10

1.0

 

 

Drain bolt (oil pan)

Bolt

M14

1

35

3.5

 

 

Oil strainer

Screw

M6

4

7

0.7

Stake

Stay (relief valve)

Flange bolt

M6

1

10

1.0

 

 

Oil filter cover

Flange bolt

M10

1

30

3.0

 

 

 

Flange bolt

M6

1

10

1.0

 

 

Ring nut (exhaust pipe)

Nut

M8

4

20

2.0

 

 

Exhaust pipe (CO test)

Bolt

M6

2

10

1.0

 

 

Exhaust pipe and frame

Flange bolt

M8

1

24

2.4

 

 

Exhaust pipe and muffler

Screw

M8

1

20

2.0

 

 

Muffler

Bolt

M10

2

24

2.4

 

 

Crankcase

Flange bolt

M10

6

40

4.0

 

 

 

Flange bolt

M6

12

12

1.2

 

 

 

Flange bolt

M8

11

24

2.4

 

 

Balancer shaft

Screw

M6

2

12

1.2

 

 

Balancer holder

Flange bolt

M6

4

10

1.0

 

 

Chain cover

Flange bolt

M6

2

5

0.5

 

 

Drive sprocket cover

Flange bolt

M6

5

5

0.5

 

 

Oil tank case 2

Flange bolt

M6

2

10

1.0

 

 

Engine bracket

Flange bolt

M8

2

24

2.4

 

 

Crankcase cover (left)

Flange bolt

M6

1

10

1.0

 

 

Starter clutch

Bolt

M6

3

10

1.0

 

 

Clutch spring

Screw

M6

6

8

0.8

 

 

Clutch boss

Nut

M20

1

70

7.0

Use lock washer

Main axle bearing housing

Screw

M6

3

12

1.2

 

 

Drive sprocket

Nut

M18

1

70

7.0

Use lock washer

Drive axle cover plate

Bolt

M6

5

10

1.0

 

 

Shift cam stopper lever

Bolt

M6

1

10

1.0

 

 

Shift fork guide

Flange bolt

M6

2

12

1.2

 

 

Shift arm

Flange bolt

M6

1

12

1.2

 

 

Shift rod

Nut

M6

2

8

0.8

 

 

Shift pedal

Bolt

M8

1

22

2.2

 

 

Stopper bolt

Bolt

M8

1

22

2.2

 

 

2-9

Yamaha TDM850 1996, TDM850 '96, TDM850 96-99 Service Manual

MAINTENANCE SPECIFICATIONS

 

 

 

SPEC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Thread

 

Tightening

 

 

 

 

Part to be tightened

Part name

Q'ty

 

torque

 

Remarks

 

size

 

 

 

 

 

 

Nm

 

 

mSkg

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Stator coil

Screw

M6

3

 

7

 

 

0.7

 

 

 

 

Starter motor

Flange bolt

M6

2

 

10

 

1.0

 

 

 

 

Thermo switch

Ð

M6

1

 

28

 

2.8

 

 

 

 

Thermo switch housing

Ð

PT1/8

1

 

15

 

1.5

 

 

 

 

Crankcase tightening sequence:

2-10

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