Yamaha TDM850 1999 User Manual [ru]
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.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd. is expressly
prohibited.
EB001000
NOTICE
This manual was produced by the Y amaha Motor Company primarily for use by Y amaha 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 Y amaha motorcycles has
a basic understanding of the mechanical ideas and the procedures of motorcycles repair. Repairs attempted by anyone without this knowledge are likely to render the motorcycles unsafe and unfit for use.
Y amaha Motor Company , Ltd. is continually striving to improve all its models. Modifications and significant
changes in specifications or procedures will be forwarded to all authorized Y amaha dealers and will appear
in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means A TTENTION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death
motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
CAUTION:
NOTE: A NOTE provides key information to make procedures easier or clearer.
A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
to the
EB002000
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title
2nd title
1 : This is the title of the chapter with its symbol in the upper right corner of each page.
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
T o 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
2. Numbers
5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a
4 is provided for removal and disassembly jobs.
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
GEN
INFO
3
INSP
ADJ
5
COOL
7
2
SPEC
4
ENG
6
CARB
8
ELECCHAS
EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 9 are printed on top
right of each page and indicate the subject of each
chapter.
General information
1
Specifications
2
Periodic inspection and adjustment
3
Engine
4
Cooling system
5
Carburetion
6
Chassis
7
Electrical
8
Troubleshooting
9
9
10
TRBL
SHTG
11 12
1413
16 1715
19 2018
22
Illustrated symbols
specifications appearing in the text.
Can be serviced with engine mounted
10
Filling fluid
11
Lubricant
12
Special tool
13
Torque
14
Wear limit, clearance
15
Engine speed
16
Ω, V, A
17
to 17 are used to identify the
10
Illustrated symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points.
Apply engine oil
18
Apply gear oil
19
Apply molybdenum disulfide oil
20
Apply wheel bearing grease
21
Apply lightweight lithium-soap base grease
22
Apply molybdenum disulfide grease
2321
23
24 25
Illustrated symbols 24 to 25 in the exploded diagrams indicate where to apply a locking agent
24
and when to install new parts 25.
Apply locking agent (LOCTITE)
24
replace
25
CONTENTS
GENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTORCYCLE IDENTIFICATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER 1. . . . . . . . . . . . . . . . . . . . . . . .
MODEL LABEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICA TIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC INSPECTION AND ADJUSTMENT 13. . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE/LUBRICATION INTERVALS 13. . . . . . . . . . .
SEAT, TAIL COVER AND FUEL TANK 15. . . . . . . . . . . . . . . . . . . . . . . . . . .
SEAT, TAIL COVER AND FUEL TANK 15. . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETOR SYNCHRONIZATION 16. . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL LEVEL INSPECTION 18. . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL REPLACEMENT 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL LINE INSPECTION 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INST ALLA TION 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT FUNCTIONS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMBINATION METER 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGNAL SYSTEM 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGNAL SYSTEM CHECK 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP SYSTEM 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP CIRCUIT OPERATION 33. . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL PUMP 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TDM850 ’99WIRING DIAGRAM
MOTORCYCLE IDENTIFICATION
EB100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number
into the right side of the steering head.
MODEL LABEL
The model label
formation will be needed to order spare parts.
1 is affixed to the frame. This in-
GEN
INFO
1 is stamped
–1–
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
Transmission
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Gear ratio 1st
2nd
3rd
4th
5th
BDSR38/2
MIKUNI
Spur gear
67/39 (1.718)
Chain drive
43/16 (2.688)
Constant mesh 5-speed
Left foot operation
37/14 (2.643)
37/19 (1.947)
30/20 (1.500)
27/23 (1.174)
27/28 (0.964)
SPEC
Bulb wattage quantity
Meter light
Indicator lights
Neutral
Turn
High beam
Fuel
Water tempere
12V 2 W 3
14 V 1.4 W 1
14 V 1.4 W 2
14 V 1.4 W 1
12 V 2 W 1
14 V 1.4 W 1
–2–
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Clutch:
Clutch spring free length
Quantity
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
50 mm
6
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
#32.5
0.9
#95
4.4 X 5.4 mm
1050 X 1250 r/min
36.0 X 38.7 kPa (270 X 290 mmHg)
SPEC
48 mm
Fuel pump:
Type
Model/manufacturer
Output pressure
CHASSIS
Item Thread size
Fuel sender and fuel tank
Fuel pump and bracket
Bracket and frame
Electrical type
4TX/MITSUBISHI
7 kPa (0.07 kgf/cm
M5
M6
M6
2
, 0.07 bar)
Tightening
torque
Nm mkgf
3.8
6.5
6.5
Remarks
0.38
0.65
0.65
–3–
MAINTENANCE SPECIFICATIONS
ELECTRICAL
Item Standard Limit
Charging system:
Type
Model/manufacturer
Nominal output
Stator coil resistance
Starter relay:
Model/manufacturer
Amperage rating
Coil winding resistance
Fuel sender:
Model/manufacturer
resistance full
empty
Fuel pump relay:
Model/manufacturer
Coil winding 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
MS5F-421/JIDECO
180 A
4.2 X 4.6 Ω at 20_C
4TX/NIPPON/SEIKI
4 X 10Ω
90 X 100Ω
G8R-30Y-B/OMRON
225 Ω ± 10%
SPEC
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Hazard relay:
Model/manufacturer
Coil winding resistance
Circuit breakers:
Type
Amperage for individual circuits
Main fuse
Headlight fuse
Signal system fuse
Ignition fuse
Fuse (position light and hazard)
Radiator fan fuse
Back up
Reserve fuse
Reserve fuse
Reserve fuse
4KM-00/MATSUSHITA
72 X 88 Ω at 20_C
Fuse
30 A 1
15 A 1
15 A 1
10 A 1
10 A 1
7.5 A 1
5 A 1
15 A 1
10 A 1
5 A 1
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
–4–
CABLE ROUTING
1 Throttle cable 1
2 Right handlebar switch lead
3 Brake hose
4 Clutch cable
5 Main switch lead
6 Left handlebar switch lead
7 Horn lead
8 Starter cable
9 Speed sensor lead
10 Coolant reservoir hose
11 Headlight lead
12 Meter light lead
13 Thermo unit lead
14 Thermo switch lead
15 Fan motor lead
CABLE ROUTING
16 Ignition coil (left) lead
17 Ignition coil (right) lead
18 Negative lead
A Fasten the right handlebar switch
lead with a plastic band.
B Fasten the handlebar switch lead
with a plastic band.
C 50 mm
D Fasten the horn lead with a plastic
band.
E60 mm
F Set the clamp within 10 mm from
the upper end of protector.
SPEC
G Align the brake hose white mark to
the mark of bracket.
H Fasten the brake hose with a plas-
tic band and cut the end of band.
I Pass the speed sensor lead be-
tween throttle cable and clutch
cable and fasten to the frame head
pipe.
J Pass the wireharness and hoses
under the frame.
K Fasten the coolant reservoir hose
with a plastic band.
–5–
CABLE ROUTING
SPEC
L Fasten the meter lead and headlight lead with a plas-
tic 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.
P Fasten the wireharness with a plastic band.
Q Fasten the wireharness and ignition coil (left) lead
with a plastic band.
R Fasten the wireharness right handlebar switch lead,
main switch lead fan motor lead with a plastic band.
S Set the ignition coil at the mark upward.
T Protector is under the coupler.
–6–
CABLE ROUTING
SPEC
1 Front flasher light (left) lead
2 Main switch lead
3 Starter cable 1
4 Left handlebar switch lead
5 Spark plug lead
6 Carburetor breather hose
7 Fuel hose
8 Coolant reservoir hose
9 Sidestand switch lead
10 Neutral switch lead
11 A.C. magneto lead
12 Air filter case breather hose
13 Carburetor heater hose
14 Starter cable 2
15 Thermo switch lead
16 Brake hose
17 Speed sensor lead
18 Wire harness
19 Flasher relay lead
20 Fuel pump lead
A Fasten the left handlebar switch
lead and main switch lead with a
plastic band.
B Route the wireharness to the rear-
side of the frame pipe.
C Route the starter cable through ra-
diator hose upward and spark plug
lead rear side and in front of air filter case breather hose. Route the
spark plug lead to the outside of
the carburetor starter bracket and
carburetor heater hose.
–7–
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