YamahaTDM850SupplementaryServiceManualformodel99

FOREWORDThisSupplementaryServiceManualhasbeenpreparedtointroducenewserviceanddatafortheTDM850’99.ForcompleteserviceinformationproceduresitisnecessarytousethisSupplementaryServiceManualtogetherwiththefollowingmanual.TDM850’96SERVICEMANUAL:4TX-AE1TDM850’97SUPPLEMENTARYSERVICEMANUAL:4TX-AE2TDM850’99SUPPLEMENTARYSERVICEMANUAL1998byYamahaMotorCo.,Ltd.FirstEdition,November1998Allrightsreserved.AnyreproductionorunauthorizedusewithoutthewrittenpermissionofYamahaMotorCo.,Ltd.isexpresslyprohibited.NOTE:CAUTION:EB001000NOTICEThismanualwasproducedbytheYamahaMotorCompanyprimarilyforusebyYamahadealersandtheirqualifiedmechanics.Itisnotpossibletoincludealltheknowledgeofamechanicinonemanual,soitisassumedthatanyonewhousesthisbooktoperformmaintenanceandrepairsonYamahamotorcycleshasabasicunderstandingofthemechanicalideasandtheproceduresofmotorcyclesrepair.Repairsat-temptedbyanyonewithoutthisknowledgearelikelytorenderthemotorcyclesunsafeandunfitforuse.YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveallitsmodels.ModificationsandsignificantchangesinspecificationsorprocedureswillbeforwardedtoallauthorizedYamahadealersandwillappearinfutureeditionsofthismanualwhereapplicable.Designsandspecificationsaresubjecttochangewithoutnotice.IMPORTANTINFORMATIONParticularlyimportantinformationisdistinguishedinthismanualbythefollowingnotations.TheSafetyAlertSymbolmeansATTENTION!BECOMEALERT!YOURSAFETYISINVOLVED!FailuretofollowWARNINGinstructionscouldresultinsevereinjuryordeathtothemotorcycleoperator,abystanderorapersoninspectingorrepairingthemotor-cycle.ACAUTIONindicatesspecialprecautionsthatmustbetakentoavoiddamagetothemotorcycle.NOTE:ANOTEprovideskeyinformationtomakeprocedureseasierorclearer.12465738EB002000HOWTOUSETHISMANUALMANUALORGANIZATIONThismanualconsistsofchaptersforthemaincategoriesofsubjects.(See“Illustratedsymbols”)1sttitle1:Thisisthetitleofthechapterwithitssymbolintheupperrightcornerofeachpage.2ndtitle2:Thistitleindicatesthesectionofthechapterandonlyappearsonthefirstpageofeachsection.Itislocatedintheupperleftcornerofthepage.3rdtitle3:Thistitleindicatesasub-sectionthatisfollowedbystep-by-stepproceduresaccompaniedbycorrespondingillustrations.EXPLODEDDIAGRAMSTohelpidentifypartsandclarifyproceduresteps,thereareexplodeddiagramsatthestartofeachremovalanddisassemblysection.1.Aneasy-to-seeexplodeddiagram4isprovidedforremovalanddisassemblyjobs.2.Numbers5aregivenintheorderofthejobsintheexplodeddiagram.Anumberthatisenclosedbyacircleindicatesadisassemblystep.3.Anexplanationofjobsandnotesispresentedinaneasy-to-readwaybytheuseofsymbolmarks6.Themeaningsofthesymbolmarksaregivenonthenextpage.4.Ajobinstructionchart7accompaniestheexplodeddiagram,providingtheorderofjobs,namesofparts,notesinjobs,etc.5.Forjobsrequiringmoreinformation,thestep-by-stepformatsupplements8aregiveninadditiontotheexplodeddiagramandthejobinstructionchart.22135792486242523211920181617151413111210GENINFOSPECENGCARBELECCHASCOOLINSPADJTRBLSHTGEB003000ILLUSTRATEDSYMBOLSIllustratedsymbols1to9areprintedontoprightofeachpageandindicatethesubjectofeachchapter.1Generalinformation2Specifications3Periodicinspectionandadjustment4Engine5Coolingsystem6Carburetion7Chassis8Electrical9TroubleshootingIllustratedsymbols10to17areusedtoidentifythespecificationsappearinginthetext.10Canbeservicedwithenginemounted11Fillingfluid12Lubricant13Specialtool14Torque15Wearlimit,clearance16Enginespeed17Ω,V,AIllustratedsymbols18to23intheexplodeddia-gramsindicatethetypesoflubricantsandlubrica-tionpoints.18Applyengineoil19Applygearoil20Applymolybdenumdisulfideoil21Applywheelbearinggrease22Applylightweightlithium-soapbasegrease23ApplymolybdenumdisulfidegreaseIllustratedsymbols24to25intheexplodeddia-gramsindicatewheretoapplyalockingagent24andwhentoinstallnewparts25.24Applylockingagent(LOCTITE)25replaceCONTENTSGENERALINFORMATION1........................................MOTORCYCLEIDENTIFICATION1...............................VEHICLEIDENTIFICATIONNUMBER1........................MODELLABEL1............................................SPECIFICATIONS2................................................GENERALSPECIFICATIONS2...................................MAINTENANCESPECIFICATIONS3..............................ENGINE3..................................................CHASSIS3.................................................ELECTRICAL4.............................................CABLEROUTING5.............................................PERIODICINSPECTIONANDADJUSTMENT13.......................INTRODUCTION13..............................................PERIODICMAINTENANCE/LUBRICATIONINTERVALS13...........SEAT,TAILCOVERANDFUELTANK15...........................SEAT,TAILCOVERANDFUELTANK15........................ENGINE16......................................................CARBURETORSYNCHRONIZATION16........................ENGINEOILLEVELINSPECTION18...........................ENGINEOILREPLACEMENT19...............................FUELLINEINSPECTION21...................................CLUTCH22.............................................