Yamaha TDM850 1996 Bedienungsanleitung

EB000000

TDM850 ’96

SERVICE MANUAL

1996 by Yamaha Motor Co., Ltd.

First edition, March 1996

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

WARNING

CAUTION:

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 as-

sumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles have a

basicunderstandingofthemechanicalconceptsandproceduresinherentinmotorcyclerepairtechnology.

Withoutsuchknowledge,attemptedrepairsorservicetothismodelmayrenderifunfittouseand/orunsafe.

YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveallmodelsmanufacturedbyYamaha.Modifi-

cationsand significant changes in specificationsor procedures will be forwardedto 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!

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.

A CAUTION indicates special precautions that must be taken to avoid

damage to the motorcycle.

NOTE: 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 “Illustrated symbols”)

1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page.

2ndtitle 2 :Thistitleindicatesthesectionofthechapterandonlyappearsonthefirstpageofeachsection.

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

Tohelp identify parts and clarify procedure steps, there are exploded diagramsatthestartofeachremoval

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. Anexplanationofjobsandnotesispresentedinaneasy-to-readwaybytheuseofsymbolmarks 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. Forjobs requiringmoreinformation,thestep-by-step formatsupplements 8 aregiveninaddition tothe

exploded diagram and the job instruction chart.

24 25

2321

19 2018

16 1715

1413

11 12

GEN

INFO SPEC

ENG

CARB

ELECCHAS

COOL

INSP

ADJ

TRBL

SHTG

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1 to 9 are printed on top

rightofeachpageandindicatethesubjectofeach

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.

10 Can be serviced with engine mounted

11 Filling fluid

12 Lubricant

13 Special tool

14 Torque

15 Wear limit, clearance

16 Engine speed

17 Ω, V, A

Illustrated symbols 18 to 23 in the exploded dia-

gramsindicatethetypes of lubricants and lubrica-

tion points.

18 Apply engine oil

19 Apply gear oil

20 Apply molybdenum disulfide oil

21 Apply wheel bearing grease

22 Apply lightweight lithium soap base grease

23 Apply molybdenum disulfide grease

Illustrated symbols 24 to 25 in the exploded dia-

grams indicate where to apply a locking agent 24

and when to install new parts 25 .

24 Apply locking agent (LOCTITE)

25 Replace

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND

ADJUSTMENT

ENGINE OVERHAUL

COOLING SYSTEM

CARBURETION

CHASSIS

ELECTRICAL

TROUBLESHOOTING

GEN

INFO 1

SPEC 2

ENG 4

COOL 5

CARB 6

CHAS 7

ELEC 8

TRBL

SHTG 9

INSP

ADJ

INDEX

GEN

INFO

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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