Yamaha TDM850'99 4TX-AE3 Bedienungsanleitung

FOREWORD

ThisSupplementaryServiceManualhasbeenpreparedtointroducenewserviceanddatafortheTDM850

’99.ForcompleteserviceinformationproceduresitisnecessarytousethisSupplementaryServiceManual

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

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd. is expressly

prohibited.

NOTE:

CAUTION:

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

assumedthatanyonewhousesthisbooktoperformmaintenanceandrepairsonYamahamotorcycleshas

a basic understanding of the mechanical ideas and the procedures of motorcycles repair. Repairs at-

tempted by anyone without this knowledge are likely to render the motorcycles unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant

changesinspecificationsorprocedureswillbeforwardedtoallauthorizedYamahadealersandwillappear

in future editions of this manual where applicable.

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 ATTENTION! BECOME ALERT! YOUR SAFETY

IS INVOLVED!

FailuretofollowWARNINGinstructionscouldresultinsevere injury ordeathtothe

motorcycle operator, a bystander or a person inspecting or repairing the motor-

cycle.

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 : This titleindicatesthesectionofthechapterandonlyappearsonthefirstpageofeachsection.

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 identifyparts andclarify procedure steps, there are exploded diagramsat thestart ofeach 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. 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. Forjobsrequiringmoreinformation,the step-by-step formatsupplements 8 aregivenin additiontothe

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 inspection and adjustment

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-

gramsindicatethe typesoflubricants andlubrica-

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

CONTENTS

GENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOTORCYCLE IDENTIFICATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION NUMBER 1. . . . . . . . . . . . . . . . . . . . . . . .

MODEL LABEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION 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

–1–

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

Themodel label 1 isaffixedto theframe. Thisin-

formation will be needed to order spare parts.

–2–

GENERAL SPECIFICATIONS SPEC

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 1st

2nd

3rd

4th

5th

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)

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

–3–

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit

Clutch:

Clutch spring free length

Quantity 50 mm

648 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

#32.5

0.9

#95

4.4 X5.4 mm

1050 X1250 r/min

36.0 X38.7 kPa (270 X290 mmHg)



Fuel pump:

Type

Model/manufacturer

Output pressure

Electrical type

4TX/MITSUBISHI

7 kPa (0.07 kgf/cm2, 0.07 bar)



CHASSIS

Item Thread size Tightening

torque Remarks

Nm mkgf

Fuel sender and fuel tank

Fuel pump and bracket

Bracket and frame

3.8

6.5

0.38

0.65

–4–

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 X0.35 Ωat 20_C/W-W

SSS

Starter relay:

Model/manufacturer

Amperage rating

Coil winding resistance

MS5F-421/JIDECO

180 A

4.2 X4.6 Ωat 20_C

SSS

Fuel sender:

Model/manufacturer

resistance full

empty

4TX/NIPPON/SEIKI

4 X10Ω

90 X100Ω

SSS

Fuel pump relay:

Model/manufacturer

Coil winding resistance G8R-30Y-B/OMRON

225 Ω±10%

SSS

Hazard relay:

Model/manufacturer

Coil winding resistance 4KM-00/MATSUSHITA

72 X88 Ωat 20_C

SSS

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

Fuse

30 A 1

15 A 1

10 A 1

7.5 A 1

5 A 1

15 A 1

10 A 1

5 A 1

SSS

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