Yamaha TDM850 User Manual Download

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I UNREGISTERED VI

Wiring diagrams 9»31

____ Scaned by Stalker

| UNREGISTERED VERSION OF PICTURE-DESK

Summary of Contents for TDM850

Page 1: ...ances in damp conditions and again beware of creating a spark or applying excessive heat in the vicinity of fuel or fuel vapour Also ensure that the appliances meet national safety standards A severe...

Page 2: ...ound all the identification numbers record them for reference when buying parts Since the manufacturers change specifications parts and vendors companies that manufacture various components on the mac...

Page 3: ...e a k e r s y ard for direct comparison Whether buying new used or rebuilt parts the best course is to deal directly with someone who specialises in parts for your particular make Started by Stalker...

Page 4: ...hemical oil additives or oils with a grade of SH CD or higher or oils labelled ENERGY CONSERVING II Such additives or oils could cause clutch slip Oil type API grade SE SF or SG Oil viscosity SAE10W30...

Page 5: ...cle held vertical the oil level should lie between the upper and lower level lines marked on the oil tank arrowed r If the level is below the lower line remove the filler cap arrowed from the top of t...

Page 6: ...on of an hydraulic leak somewhere in the system which should be investigated immediately Check for signs of fluid leakage from the hydraulic hoses and components if found rectify immediately Check the...

Page 7: ...y it must be above LOWER level line arrowed f If topping up is required on TDM models remove the seat and J on TRX models remove the side covers see Chapter 8 On TRX and XTZ models remove the cap clam...

Page 8: ...e at any time the surplus should be siphoned or drained off to prevent the possibility of it being expelled out of the breather hose If the coolant level falls steadily check the system for leaks see...

Page 9: ...dels Rider only Rider and passenger or high speed 28 psi 2 0 Bar 28 psi 2 0 Bar 33 psi 2 25 Bar 36 psi 2 50 Bar 1996 on TDM models All loads speeds 40 psi 2 75 Bar 33 psi 2 25 Bar TRX models Rider onl...

Page 10: ...dels 23 Fuel system check 6 Headlight aim check and adjustment 30 Idle speed check and adjustment 3 Nuts and bolts tightness check 15 Sidestand check 14 Sidestand lever pivots and cables lubrication 1...

Page 11: ...rpm 250 to 270 mm Hg 270 to 290 mm Hg 240 to 260 mm Hg carburettors 10 mm Hg 5 mm Hg 0 15 to 0 20 mm 0 25 to 0 30 mm 152 psi 10 5 Bar 158 psi 10 9 Bar 146 psi 10 1 Bar 14 5 psi 1 0 Bar 175 psi 12 0 B...

Page 12: ...nd all TRX models Oil change 3 5 litres Oil and filter change 3 6 litres Following engine overhaul dry engine new filter 4 2 litres Coolant type 50 distilled water 50 corrosion inhibited ethylene glyc...

Page 13: ...r 7 Drive chain adjuster 8 Idle speed adjuster 9 Oil drain plug Scaned by Stalker TDM 1 Rear brake fluid reservoir 2 Oil level window 1996 on 3 Oil filler cap 1996 on 4 Front brake fluid reservoir 5 T...

Page 14: ...le upper adjuster 7 Radiator pressure cap 8 Coolant drain plug on water pump 9 Clutch cable lower adjuster 10 Oil filter and filter housing drain plug TRX 1 Clutch cable upper adjuster 2 Steering head...

Page 15: ...Front brake fluid reservoir 5 Steering head bearing adjuster 6 Coolant drain plug on water pump 7 Clutch cable lower adjuster 8 Oil filter and filter housing drain plug Radiator pressure cap Clutch c...

Page 16: ...ds Section 8 Check the brake system and brake light switch operation Section 9 Check and adjust the clutch Section 10 Check the battery Section 11 D Check the condition of the wheels and tyres Section...

Page 17: ...ifications see illustration As the chain stretches with wear adjustment will periodically be necessary see below Since the chain will rarely wear evenly roll the bike forwards so that another section...

Page 18: ...ed tighten the nut to align it DO NOT loosen it Lubrication 14 If required wash the chain in paraffin l Hd On TDM and XTZ models check the relative position of the marker A and the notches B on each s...

Page 19: ...plugs by sandblasting is permitted provided you clean the plugs with a high flash point solvent afterwards 8 Before installing the plugs make sure they are the correct type and heat range and check t...

Page 20: ...any kind of work on the fuel system wear safety glasses and have a fire extinguisher suitable for a Class B type fire flammable liquids on hand gauge take off points on the intake manifolds Do not al...

Page 21: ...pond to small changes in pressure 11 The vacuum readings for both cylinders should be the same If the vacuum readings differ proceed as follows 12 The carburettors are adjusted by turning the synchron...

Page 22: ...f fuel starvation is suspected 5 On TRX XTZ and 1991 to 1998 TDM models the fuel filters are mounted in the tank On TDM models the filters are integral with the fuel outlet assembly from the tank On T...

Page 23: ...nt that the indicators contact the disc itself as the disc will be damaged 3 On XTZ models the indicators are in the form of grooves in the brake pad friction material when the pads are worn so that t...

Page 24: ...wise If the brake light comes on too soon or is permanently on turn the ring anti clockwise If the switch doesn t operate the brake light check it see Chapter 9 9 5c Rear brake light switch XTZ models...

Page 25: ...l the required amount of freeplay is obtained see illustration To increase freeplay turn the adjuster clockwise To reduce freeplay turn the adjuster anti clockwise Tighten the locking ring securely 5...

Page 26: ...ng sound loose ones will produce a lower pitch and overtightened ones will be higher pitched A spoke wrench will be needed if any of the spokes require adjustment Unevenly tensioned spokes will promot...

Page 27: ...d indicating there is still pressure in the system wait until it stops Now press down on the cap and continue turning the cap until it can be removed Check the condition of the coolant in the system I...

Page 28: ...lever pivots and cables lubrication Pivot points 1 Since the controls cables and various other components of a motorcycle are exposed to the elements they should be lubricated periodically to ensure...

Page 29: ...to compress see illustration Any freeplay felt in either check indicates worn bearings in the suspension linkage TRX and XTZ models or swingarm or worn shock absorber mountings The worn components mus...

Page 30: ...liminated 10 If the Yamaha tool is not available using either a C spanner a peg spanner or a drift located in one of the notches slacken the adjuster nut slightly until pressure is just released then...

Page 31: ...nning of the Chapter see illustration 22 16 20 Re check the bearing adjustment as described above and re adjust if necessary 21 Install the handlebars see Chapter 6 Every 8000 miles 12 000 km or 12 mo...

Page 32: ...y Check with your local refuse disposal company disposal facility or environmental agency to see whether they will accept the used oil for recycling Don t pour used oil into drains or onto the ground...

Page 33: ...panel see Chapter 8 On 1991 to 1995 TDM models and XTZ models remove the engine bashplate see Chapter 8 On TRX models remove the security bolt holding the radiator cap see illustration 16 6a Remove th...

Page 34: ...he specified mixture until it reaches the top of the filler neck Refit the cap then on TRX models fit the security bolt 17 Check the coolant level in the reservoir and top up if necessary 18 Check the...

Page 35: ...turn the engine anti clockwise 270 3 4 turn so that the camshaft lobes for the No 2 right hand cylinder are facing away from each other The No 2 cylinder is now at TDC on the compression stroke Measu...

Page 36: ...STALLED SHIM SIZE 12 0 125 130 13 5 14 0 14 5 15 0 15 5 16 0 16 5 17 0 17 5 18 0 18 5 19 0 19 5 20 0 20 5 21 0 21 5 22 0 22 5 23 0 23 5 24 0 0 00 0 04 12 0 12 5 13 0 13 5 14 0 14 5 15 0 15 5 16 0 16 5...

Page 37: ...t may cause problems for oncoming traffic or provide poor unsafe illumination of the road ahead Before adjusting the headlight aim be sure to consult with local traffic laws and regulations for UK mod...

Page 38: ...bolt in the left hand side of the cylinder head there is no need to remove it see illustration 4 Start the engine and allow it to idle After a short while oil should begin to seep out from the oil gal...

Page 39: ...clear It is advisable to wear some form of eye and face protection when carrying out this operation 6 Hold a piece of thick card to act as a chute beneath the fork drain screw on one fork slider then...

Page 40: ...ief valve removal inspection and installation 22 Oil tank removal and installation 1996 on TDM and TRX models 21 Operations possible with the engine in the frame 2 Operations requiring engine removal...

Page 41: ...7 mm Service limit max 0 08 mm Head diameter 25 9 to 26 1 mm Face width 2 06 to 2 46 mm Seat width 0 9 to 1 1 mm Margin thickness 0 8 to 1 2 mm Exhaust valve Stem diameter Standard 5 460 to 5 475 mm S...

Page 42: ...to 0 50 mm Service limit max 0 70 mm Piston ring to groove clearance Standard 0 03 to 0 07 mm Service limit max 0 12 mm 2 nd middle ring 1991 to 1995 TDM models Ring width 3 5 mm Ring thickness 1 0 m...

Page 43: ...ce limit max 0 15 mm Rotor end float 0 03 to 0 08 mm Connecting rods Big end side clearance Standard 0 160 to 0 272 mm Service limit max 0 5 mm Big end oil clearance Standard 0 026 to 0 050 mm Service...

Page 44: ...ng bolt nut 75 Nm Upper front mounting bolts 55 Nm Engine bracket to engine bolts left hand side 30 Nm Engine bracket to frame bolt left hand side 55 Nm Engine bracket to engine bolt with collar right...

Page 45: ...assembly and relief valve The oil tank is mounted behind the engine on 1991 to 1995 TDM models and all XTZ models and on the engine behind the cylinders on later TDM models and all TRX models The oil...

Page 46: ...to a suitable working height on an hydraulic ramp or a suitable platform Make sure the motorcycle is secure and will not topple over see Tools and Workshop Tips in the Reference section When disconne...

Page 47: ...J 5 19b Slacken the clamp screw arrowed and detach the hose see illustration Discard the O ring as anew one must be used 20 At this point position an hydraulic or mechanical jack under the engine wit...

Page 48: ...he underside of the engine at the back and remove the brackets see illustrations 22 On TRX models unscrew the bolts securing the engine bracket to the frame and the engine on each side and remove the...

Page 49: ...ting bolts not forgetting the washers with the upper and lower rear bolts they locate under the bolt head not the nut and the collar between the right hand engine bracket and the engine and tighten th...

Page 50: ...oolant see Chapter 1 2 On TDM and TRX models remove the thermostat housing see Chapter 3 When removing the housing remove it along with the pipe that bolts onto the valve cover rather than separating...

Page 51: ...an anti clockwise direction only see illustration Alternatively place the motorcycle on an auxiliary stand so that the rear wheel is off the ground select a high gear and rotate the rear wheel by hand...

Page 52: ...er or bar through the hole in the centre of the camshaft see illustration 8 29a or by counter holding the alternator rotor 6 Remove the cam chain tensioner see Section 9 7 Make a mark on each sprocket...

Page 53: ...d into ten compartments and label each compartment 8 12a Check the lobes of the camshaft for wear here s an example of damage requiring camshaft repair or renewal with the location of its correspondin...

Page 54: ...and are not binding on the dowels While doing this don t let the camshafts rotate 16 Now unscrew the bolts a evenly and a little at a time in a criss cross pattern and carefully lift off the camshaft...

Page 55: ...ulphide oil a 50 50 mixture of molybdenum disulphide grease and engine oil to each of them Also apply it to the camshaft lobes 25 Verify that the T mark on the timing rotor is still aligned with the n...

Page 56: ...ith everything correctly aligned tighten the sprocket bolts to the torque setting specified at the beginning of the Chapter using a screwdriver or bar inserted through the hole in each camshaft to pre...

Page 57: ...Cylinder head fb removal and installation gs Caution The engine must be completely cool before beginning this procedure or the cylinder head may become warped Note 1 The cylinder head can be removed...

Page 58: ...careful not to let any of the gasket material fall into the crankcase the cylinder bores or the oil passages IJTHJT33 Refer to Tools and milUSi workshop Tips in the HiWT 12 If removed install the dowe...

Page 59: ...he risk of damaging them a valve spring compressor is absolutely essential Make sure that it is suitable for motorcycle work Disassembly 3 Before proceeding arrange to label and store the valves along...

Page 60: ...se Prussian blue to determine the extent of valve seat wear Uniformly coat the seat with the Prussian blue then install the valve and rotate it back and forth using a lapping tool Remove the valve and...

Page 61: ...he valve 21 Apply a small amount of coarse grinding compound to the valve face then slip the valve into the guide see illustration Note Make sure each valve is installed in its correct guide and be ca...

Page 62: ...e spring retainer with its shouldered side facing down so that it fits into the top of the spring see illustrations 27 Apply a small amount of grease to the collets to help hold them in place as the p...

Page 63: ...and honed by a Yamaha dealer or engineer If the cylinders are rebored they will require oversize pistons and rings 8 If the precision measuring tools are not available take the block and pistons to a...

Page 64: ...use force if the block appears to be stuck as the pistons and or rings will be damaged If clamps are used remove them once the pistons are in the bore 19 When the pistons are correctly installed in th...

Page 65: ...ry careful to remove only the carbon deposits Do not remove any metal and do not nick or gouge the sides of the ring grooves 8 Once the deposits have been removed clean the pistons with solvent and dr...

Page 66: ...e piston and cylinder during the end gap measurement procedure and engine assembly 3 To measure the installed ring end gap insert the top ring into the top of the first cylinder and square it up with...

Page 67: ...h side of it The oil ring must be installed by hand 16 Clutch removal inspection lfe and installation Note The clutch can be removed with the engine in the frame If the engine has been removed ignore...

Page 68: ...ti judder assembly can be left intact unless the clutch has been chattering juddering excessively If it is necessary to remove it remove the wire retainer ring plain plate anti judder spring and sprin...

Page 69: ...ngth of each clutch spring using a vernier caliper see illustration If any spring is below the service limit specified renew all the springs as a set 16 Inspect the clutch assembly for burrs and 1 E c...

Page 70: ...Check the pressure plate thrust bearing and plate washer for signs of roughness wear or damage and renew any parts as necessary 19 On 1989 XTZ models if removed check the clutch centre anti judder as...

Page 71: ...entre rotates freely after tightening Bend up the tabs of the lockwasher to secure the nut see illustration 27 On 1991 to 1995 TDM models and 1990 on XTZ models fit the inner plain plate 16 26e Bend u...

Page 72: ...ign the shaft so that the operating lever is facing back but angled out slightly 32 Insert the dowels in the crankcase then set the pullrod so that its teeth point towards the rear Install the clutch...

Page 73: ...hanism lever noting how it fits see illustrations 17 1c and d 3 On all models fully slacken the lockring on the adjuster at the handlebar end of the cable then screw the adjuster fully in see illustra...

Page 74: ...e starter clutch should be renewed 5 Examine the teeth of the starter idle reduction gear and the corresponding teeth of the starter driven gear and starter motor shaft Renew the gears and or starter...

Page 75: ...rm for cracks distortion and wear of its pawls and check for any corresponding wear on the selector pins in the selector drum Also check the stopper arm roller and the detents in the selector drum for...

Page 76: ...ough the case until the splined end comes out the other side see illustration 19 5 Locate the selector arm pawls onto the pins on the selector drum Make sure the centralising spring ends locate correc...

Page 77: ...the scavenge pump and remove it if it is loose Inspection 7 If required the pumps can be disassembled for cleaning Remove the single assembly screw and separate the pump housing on the feed pump notin...

Page 78: ...hem if necessary Damage to the steel drive gear is unlikely but if found will necessitate crankshaft renewal 14 If the pump is good make sure all the components are clean then lubricate them with new...

Page 79: ...M models andallTRXmodels Note To remove the oil tank the engine must be removed from the frame Removal 1 Remove the engine from the frame see Section 5 2 Unscrew the banjo bolts securing the oil pipe...

Page 80: ...er 4 2 Drain the engine oil and remove the oil filter see Chapter 1 3 Unscrew the sump bolts slackening them evenly in a criss cross sequence to prevent distortion and remove the sump see illustration...

Page 81: ...ection and installation Note On 1991 to 1995 TDM models and XTZ models the balancer shafts can be removed with the engine in the frame If the engine has been removed ignore the steps which do not appl...

Page 82: ...orth checking with a Yamaha dealer or bearing specialist 10 Check the shafts are straight by rolling them on a flat surface such as a piece of glass Also check the bearing surfaces for scuffing and we...

Page 83: ...stration 15 Fit a new O ring around the oil passage collar see illustration 23 5b then fit the oil strainer holder see illustration Apply a suitable non permanent thread locking compound to the holder...

Page 84: ...as a set if necessary see Chapter 8 Chain guides 7 Check the guides for excessive wear deep grooves cracking and other obvious damage and renew them if necessary Check the condition of the pivot hard...

Page 85: ...screw the 6 mm lower crankcase bolts the 8 mm bolts and the 10 mm bolts see illustrations 25 4a and b Unscrew the bolts evenly a little at a time in a reverse of the numerical sequence until they are...

Page 86: ...nd 1215 to the outer mating surface of one crankcase half see illustration Caution Do not apply an excessive amount of sealant as it will ooze out when the case halves are assembled and may obstruct o...

Page 87: ...lars using new O rings 27 Main and connecting rod bearings general information 1 Even though main and connecting rod bearings are generally renewed during the engine overhaul the old bearings should b...

Page 88: ...check for any freeplay between the two see illustration Measure the pin external and compare the result to the specifications at the beginning of the Chapter see illustration If the piston pin is wor...

Page 89: ...The left hand number is for the left hand No 1 cylinder journal The connecting rod numbers are marked in ink on the flat face of the connecting rod and cap see illustration 22 A range of bearing shel...

Page 90: ...runout exceeds the limit the crankshaft must be renewed Oil clearance check 9 Whether new bearing shells are being fitted or the original ones are being re used the main bearing oil clearance should...

Page 91: ...rance falls into the specified range new bearing shells are not required provided they are in good condition If the clearance is beyond the service limit refer to the marks on the case and the marks o...

Page 92: ...lling on the bolt see illustration Discard the plug O Ting as a new one must be used Once the plug is removed tap on the end of the shaft using a soft faced mallet to free it from the crankcase 5 If n...

Page 93: ...r direction 2 Remove the 2nd gear pinion from the left hand end of the shaft using a puller referring to Tools and Workshop Tips Section 5 in the Reference Section if required see illustration If a le...

Page 94: ...If removed drive or press the 4th gear pinion bush onto the shaft aligning the oil hole in the bush with the hole in the shaft Slide the 4th gear pinion with the pinion dog holes facing away from the...

Page 95: ...engine oil to the mating surfaces of the shaft pinions and bushes When installing the circlips do not expand their ends any further than is necessary Install the stamped circlips so that their chamfe...

Page 96: ...3rd gear pinion followed by the 1st gear pinion and the thrust washer see illustrations 41 Fit the caged ball bearing onto the right hand end of the shaft see illustration 42 Check that all component...

Page 97: ...maged 9 The selector fork shaft can be checked for trueness by rolling it along a flat surface A bent shaft will cause difficulty in selecting gears and make the gearchange action heavy Renew the shaf...

Page 98: ...r use of the transmission and a restraining hand on the throttle until at least 600 miles 1000 km have been covered There s no point in keeping to any set speed limit the main idea is to keep from lab...

Page 99: ...ent J Difficult suitable for experienced DIY 5j mechanic Very difficult suitable for expert DIY or professional S Specifications Coolant Mixture type and capacity see Chapter 1 Radiator Cap valve open...

Page 100: ...off any spills immediately with plenty of water Antifreeze is highly toxic if ingested Never leave antifreeze tying around in an open container or in puddles on the floor children and pets are attrac...

Page 101: ...is procedure 4 Remove the radiator see Section 7 5 Unscrew the three bolts securing the fan shroud and fan assembly to the radiator see illustration On TDM and TRX models unscrew the bolts on the fron...

Page 102: ...urn the ignition switch ON see illustrations 4 9a b and c The temperature gauge needle should be on the C on the gauge Now earth the sender wire on the engine The needle should swing immediately over...

Page 103: ...rew the sender and remove it from the thermostat housing 16 Apply a suitable thread locking and sealing compound to the sender threads then install the sender and tighten it to the torque setting spec...

Page 104: ...at the top see illustration 6 6b 11 Fit a new O ring onto the cover using a dab of grease to keep it in place if required see illustration Fit the cover onto the housing then install the two bolts an...

Page 105: ...age from the drainage hole remove the pump and renew it individual components except O rings and bolts are not available Removal 4 Drain the coolant see Chapter 1 Place a suitable container below the...

Page 106: ...ewdriver to slacken the larger bore hose clamps then slide them back along the hose and clear of the union spigot see illustrations 6 3 7 3a and b The smaller bore hoses are secured by spring clamps w...

Page 107: ...uel tank and fuel tap s removal and installation 2 General information and precautions 1 Idle fuel air mixture adjustment general information 5 Idle speed check see Chapter 1 Throttle and choke cables...

Page 108: ...All other models 142 5 Main air jet 1991 to 1995 TDM models 50 1999 TDM models 65 All other models 60 Jet needle 1991 to 1995 TDM models 5G52 3 1996 to 1998 TDM models and all TRX models 5E185 2 5 19...

Page 109: ...ls cutters etc create sparks in the normal course of operation and must not be used near petrol gasoline or any component containing it Again remember the possible presence of fumes before using elect...

Page 110: ...d and secured by their clamps b Start the engine and check that there is no sign of fuel leakage then shut if off Fuel tank XTZ models Removal 14 Make sure the fuel filler cap is secure and both fuel...

Page 111: ...hem as necessary if available If any of the components are worn or damaged beyond repair and are not available individually a new tap must be fitted On 1991 to 1998 TDM models note which hose fits whe...

Page 112: ...necessary 4 3b Air filter housing bolt arrowed XTZ models 5 Idle fuel air mixture adjustment general information 1 Due to the increased emphasis on controlling exhaust emissions certain governmental r...

Page 113: ...arburettor cleaner a supply of clean rags some means of blowing out the carburettor passages and a clean place to work It is recommended that only one carburettor be overhauled at a time to avoid mixi...

Page 114: ...of removal noting the following a Check for cracks or splits in the cylinder head intake rubbers and renew them if necessary b Make sure the carburettors are fully engaged with the intake rubbers and...

Page 115: ...burettor body noting how it fits see illustration Remove the O ring and discard it as a new one must be used If required withdraw the float pivot pin and remove the float and needle valve then unhook...

Page 116: ...IjS Difficult suitable for experienced DIY Q mechanic Very difficult suitable for expert DIY 2j or professional 2 Specifications General information Cylinder numbering Left 1 Right 2 Spark plugs see...

Page 117: ...lable any failure of the system can be traced to failure of a system component or a simple wiring fault Of the two possibilities the latter is by far the most likely In the event of failure check the...

Page 118: ...ce can be measured with a multimeter If the coil is undamaged and if the resistance readings are as specified at the beginning of the Chapter it is probably capable of proper operation although note t...

Page 119: ...ake sure the wiring connectors and HT leads are securely connected Pick up coil check and replacement Check 1 On TDM and TRX models remove the seat and on XTZ models remove the left hand side cover se...

Page 120: ...er is a I I mark The static timing mark with which this should align is the notch in the threads for the inspection plug on the alternator cover see illustration 6 Connect the timing light to the no 1...

Page 121: ...of the sensor as described below 6 If the sensor is suspected of being faulty take it to a Yamaha dealer for further testing If it is confirmed to be faulty it must be renewed the sensor is a sealed u...

Page 122: ...ead bearings lubrication see Chapter 1 Steering stem removal and installation 8 Suspension adjustments 12 Suspension check see Chapter 1 Swingarm inspection and bearing replacement 14 Swingarm removal...

Page 123: ...r holder clamp bolts XTZ models 20 Nm Handlebar retaining bolt TRX models 23 Nm Handlebar holder positioning bolt TRX models 10 Nm Handlebar holder clamp bolt TRX models 17 Nm Fork clamp bolts TDM and...

Page 124: ...noting how the return spring end locates in the bracket see illustration For easier access to the nut first unscrew the two bolts securing the bracket and remove it see illustration The footrest rubbe...

Page 125: ...de of the pedal shaft then remove the split pin from the clevis pin securing the master cylinder pushrod to the bracket see illustration Remove the clevis pin and separate the pushrod from the bracket...

Page 126: ...auxiliary stand 2 On TDM and XTZ models unhook the stand springs then counter hold the pivot bolt and unscrew the nut on the inside of the bracket see illustration Withdraw the pivot bolt and remove t...

Page 127: ...cap from the holder positioning bolt then unscrew the bolt see illustration Slacken the handlebar holder clamp bolt then ease the handlebar holder up and off the fork Installation 8 Installation is th...

Page 128: ...or on TRX models to the collar and the contact areas between the lever and its bracket and to the clutch cable nipple Adjust the clutch cable freeplay see Chapter 1 Front brake lever 12 On XTZ models...

Page 129: ...rks up through the bottom yoke then install the wiring ties where appropriate onto the forks see illustration 6 6b Slide the forks up into the top yoke Check that the amount of protrusion of the fork...

Page 130: ...der see illustration 3 If the fork top bolt was not slackened with the fork in situ carefully clamp the fork tube in a vice equipped with soft jaws taking care not to overtighten or score its surface...

Page 131: ...against the damper rod seat Take care not to do this forcibly or the seat may be damaged Then pull the tube sharply outwards until the bottom bush strikes the top bush Repeat this operation until the...

Page 132: ...l seal washer with its flat side facing up see illustration Either use the Yamaha service tool or a suitable piece of tubing to tap the bush fully into place the tubing must be slightly larger in diam...

Page 133: ...tion Fit the spring seat with its shouldered side fitting down into the top of the spring see illustration 7 6 28 Fit a new O ring onto the fork top bolt Thread the pre load adjuster with the top bolt...

Page 134: ...op 38 Invert the fork and withdraw the damper rod from inside the fork tube see illustration If required slide the rebound spring off the damper rod 39 Carefully prise out the dust seal from the top o...

Page 135: ...er 56 Clamp the slider upright in a soft jawed vice using the brake caliper mounting lugs taking care not to overtighten and damage them Pull the fork tube out of the slider as far as possible then in...

Page 136: ...ork tube and bottom bush 7 59 Front fork components XTZ models 7 Damper rod and rebound spring 8 Damper rod seat 9 Dust seal 10 Retaining clip 11 Oil seal 12 Washer 13 Top bush 14 Slider 15 Oil drain...

Page 137: ...l the top bush and slide it down over the tube see illustration 7 22a Press the bush squarely into its recess in the slider as far as possible then install the oil seal washer see illustration 7 22b E...

Page 138: ...rvoir remains upright and so that no strain is placed on the hydraulic hoses 6 On TDM and TRX models remove the tabbed lockwasher noting how it fits then unscrew and remove the locknut using either a...

Page 139: ...9 Steering head bearings inspection and replacement Inspection 1 Remove the steering stem see Section 8 9 6 Drawbolt arrangement for fitting steering stem bearing outer races 1 Long bolt or threaded...

Page 140: ...lace the machine on an auxiliary stand Position a support under the rear wheel so that it does not drop when the shock absorber is removed but also making sure that the weight of the machine is off th...

Page 141: ...spect the damper rod for signs of bending pitting and oil leakage see illustration 13 Inspect the pivot hardware at the top and bottom of the shock for wear or damage and release the hose from its cli...

Page 142: ...inkage arm noting which way round it fits Inspection 6 Withdraw the inner sleeves and lever out the grease seals from the linkage arm and swingarm noting their different sizes see Illustrations Thorou...

Page 143: ...s spring pre load is adjusted using a suitable spanner on the adjuster flats on the top of the forks see illustration The amount of pre load is indicated by lines on the adjuster There are five lines...

Page 144: ...ecified refer to Section 14 3 On TDM models unscrew the bolt which secures the caliper bracket to the swingarm and remove the bracket see Chapter 7 f Q r h rt J r Measurement A 12 10b and according to...

Page 145: ...Inspect all components for wear or damage as described in Section 14 Installation 13 If removed install the chain slider and tighten its bolt s securely see illustration 13 11 14 Remove the cap and w...

Page 146: ...closely looking for obvious signs of wear such as heavy scoring and cracks or distortion due to accident damage Any damaged or worn component must be renewed 3 Check the swingarm pivot bolt for strai...

Page 147: ...hicknesses The shims should be fitted between the cap and washer if two shims are required fit one on each side whereas if only one shim is required fit this on the right hand side 11 Press the grease...

Page 148: ...venient place to work on Obtain a new soft link never attempt to reuse an old link 14 Install the new soft link complete with an O ring on each of its pins through the chain ends from the inside of th...

Page 149: ...ckwasher then fit the nut with its recessed side facing in and tighten it to the torque setting specified at the beginning of the Chapter using the method employed on removal to prevent the sprocket f...

Page 150: ...see illustration Note the spacer inside the coupling it should be a tight fit but remove it if it is likely to drop out Check the coupling for cracks or any obvious signs of damage Also check the spro...

Page 151: ...pection and installation 13 Wheels alignment check 10 Wheels inspection and repair 9 Degrees of difficulty Easy suitable for k novice with little R expenence gjg Fairly easy suitable k for beginner wi...

Page 152: ...ke master cylinder bolts TDM and TRX models 23 Nm XTZ models 20 Nm Brake caliper bleed valves 6 Nm Front wheel axle TDM models 58 Nm TRX models 65 Nm Front wheel axle clamp bolt TDM models 19Nm TRX mo...

Page 153: ...emove the pad cover from the top of the caliper see illustration Remove the pad pin retaining clips then withdraw the pad pins from the caliper noting how they locate against the pad spring see illust...

Page 154: ...lly using a fine wire brush which is completely free of oil and grease to remove all traces of road dirt and corrosion Using a pointed instrument clean out the grooves in the friction material and dig...

Page 155: ...oint to the outside of the caliper see illustration Apply the specified grease see Step 9 to the slider pins on the bracket and slide the bracket into the caliper see 1 A fcji 2 9c Apply the recommend...

Page 156: ...clean brake fluid only on the internal parts Brake cleaner or denatured alcohol can be used on external parts Removal 1 On XTZ models if removing the rear brake caliper unscrew the bolts securing the...

Page 157: ...ing used take great care not to damage the caliper bores 8 Remove and discard the piston seals in the same way 9 Clean the pistons and bores with clean brake fluid If compressed air is available use i...

Page 158: ...could become warped Set the wheel on wood blocks so the disc doesn t support the weight of the wheel 5 Mark the relationship of the disc to the wheel so it can be installed in the same position Unscr...

Page 159: ...o the bracket then release the clamp securing the reservoir hose to the union on the master cylinder see illustrations Remove the reservoir cap and lift off the diaphragm plate and the rubber diaphrag...

Page 160: ...tch see Chapter 9 24 Attach the master cylinder to the handlebar and where marked fit the clamp with its UP mark facing up aligning the top mating surfaces of the clamp with the punch mark on the hand...

Page 161: ...town carefully and place the open end in a lean container The objective is to prevent wcessive loss of brake fluid fluid spills and lystem contamination 1 Remove the split pin and washer from the ile...

Page 162: ...the banjo bolt to the specified torque setting see illustrations 6 5a and b 24 Secure the fluid reservoir to the frame with its retaining bolt see illustrations 6 4a b and c Ensure that the hose is co...

Page 163: ...ing and the lever will move toward the handlebar or the pedal will move down 9 Retighten the bleed valve then release the brake lever or pedal gradually Repeat the process until no air bubbles are vis...

Page 164: ...d and pull it tight so that it is roughly parallel to the floor Slowly bring the string into contact with the front sidewall of the rear tyre then turn the front wheel until it is parallel with the st...

Page 165: ...rest on a disc the disc could become warped Set the wheel on wood blocks so the disc doesn t support the weight of the wheel or keep it upright 8 Check the axle for straightness by rolling it on a fl...

Page 166: ...e brake pedal with the calipers removed On TDM models slacken the caliper bracket bolt on the swingarm see illustration 3 Where fitted remove the split pin from the axle nut on the end of the axle see...

Page 167: ...isc 13 3b then lever out the retainer plate and remove the drive plate arrowed see Section 3 Tighten the caliper mounting bolts to the specified torque setting On XTZ models install the caliper shield...

Page 168: ...ring driver or a suitable socket to drive it into place if necessary see illustration 14 Clean off all grease from the brake discs using acetone or brake system cleaner then install the wheel see Sect...

Page 169: ...contact the outer race of the bearing drive it in until it is completely seated see illustration 13 10 30 Apply a smear of grease to the lips of the new seal and press it into the coupling using 13 2...

Page 170: ...bead is substantial and is usually beyond the capabilities of an individual working with normal tyre levers Additionally the specialist will be able to balance the wheels after tyre fitting 5 Note tha...

Page 171: ...istant will be required when removing panels to help avoid the risk of damage to paintwork Once the evident fasteners have been removed try to withdraw the panel as described but DO NOT FORCE IT if it...

Page 172: ...ke sure the tabs at the front of the seat locate correctly under and on the back of the tank Push down on the rear of the seat to engage the latch TRX models 6 Insert the ignition key into the seat lo...

Page 173: ...ustration Carefully lift one side up to clear the frame then remove the assembly along with the tail light see illustration 3 Installation is the reverse of removal TRX models 4 Remove the seats see S...

Page 174: ...UNREGISTERED VI ScanedbyStalker UNREGISTERED VI...

Page 175: ...uired remove the single screw securing the side trim panel and remove the panel noting how it locates onto the lug on the frame 5 Installation is the reverse of removal XTZ models 6 Remove the seven s...

Page 176: ...ectly and securely connected 1996 on TDM models Removal 4 Remove the fairing side panels see Section 4 Remove the three screws securing the instrument cluster cover and remove the cover and the foam d...

Page 177: ...the nuts securing the rear view mirrors to the fairing bracket and remove the mirrors along with the rubber pads see illustrations 11 Disconnect the headlight auxiliary light and turn signal wiring c...

Page 178: ...val 1 On 1991 to 1995 TDM models unscrew the knurled ring securing the speedometer to the drive housing on the front wheel then detach 3 2b Mudguard mounting bolts arrowed TRX models 6 2c On are XTZ m...

Page 179: ...placement 22 Starter circuit cut off relay check and replacement 25 Starter motor disassembly inspection and reassembly 29 Starter motor removal and installation 28 Starter relay check and replacement...

Page 180: ...7 5A Fan 7 5A XTZ models Main 30A Fan 10A Bulbs Headlight 1991 to 1995 TDM models 35 35W halogen x 2 1996 on TDM models 55W halogen H3 x 2 TRX models 60 55W halogen x 1 XTZ models 35 35W halogen x 2 A...

Page 181: ...ons or a blown fuse Prior to any electrical fault finding always visually check the condition of the fuse wires and connections in the problem circuit Intermittent failures can be especially frustrati...

Page 182: ...tery negative ve terminal When fully charged there should be more than 12 5 volts present If the voltage falls below 12 5 volts the battery must be removed disconnecting the negative ve terminal first...

Page 183: ...this happens remove the corrosion with a wire brush or emery paper then spray the fuse end and terminals with electrical contact cleaner 6 Lighting system check 1 The battery provides power for operat...

Page 184: ...to the headlight bulb s remove the fairing on TDM models and the relevant fairing side panel on XTZ models see Chapter 8 2 Disconnect the relevant wiring connector from the back of the headlight assem...

Page 185: ...8 3a Unscrew the nut on each side A and the central nut on the bottom B and auxiliary light Check the headlight aim see Chapter 1 9 Brake tail light bulb f renewal 1 On TDM models remove the seat see...

Page 186: ...ash in the other direction Check the bulbs and the sockets see Section 12 3 The relay is mounted under the seat on TDM and TRX models and behind the fairing on XTZ models see illustrations Remove the...

Page 187: ...lder Do not overtighten the screw as the lens or threads could be damaged 13 Turn signal assemblies removal and installation k Removal 1 Disconnect the turn signal wiring connectors On the front turn...

Page 188: ...e connector with the ignition ON connector halves remain joined If there s no voltage present check the wire between the switch and the ignition switch see the wiring diagrams at the end of this Chapt...

Page 189: ...Removal 1 Remove the fairing see Chapter 8 On TRX models remove the fuel tank and air filter housing for best access to the wiring connectors see Chapter 4 On XTZ models release the clips on the inst...

Page 190: ...nts 16 Instruments check replacement and bulbs Speedometer Check TRX XTZ and 1991 to 1998 TDM models 1 Special instruments are required to properly check the operation of this meter If it is believed...

Page 191: ...he cluster and lift off the front cover assembly see illustrations 16 6a b or c On 1999 TDM models remove the seven screws from the base of the cluster and separate the upper and lower covers from the...

Page 192: ...ghest position and check the meter reading 4 to 10 ohms should now be indicated If the sender unit does not produce the correct readings it must be renewed 4 Before renewing the fuel gauge or the send...

Page 193: ...3 On TDM models remove the fairing see Chapter 8 On TRX models remove the air filter housing and on XTZ models remove the fuel tank see Chapter 4 Trace the wiring harness of the switch in question bac...

Page 194: ...the wiring diagrams at the end of this Chapter Turn the ignition OFF Removal 6 Make sure the transmission is in neutral The switch is located in the left hand side of the transmission casing above the...

Page 195: ...Reconnect the wiring connector and check the operation of the sidestand switch 11 On TDM models install the seat on TRX models install the side covers and on XTZ models install the left hand side cove...

Page 196: ...starter circuit cut off relay is part of the safety circuit which prevents or stops the engine running if the transmission is in gear whilst the sidestand is down and prevents the engine from starting...

Page 197: ...lead see illustration position the lead away from the relay terminal With the ignition switch ON the engine kill switch in the RUN position the transmission in 26 3c and mounting bolt B TRX models ne...

Page 198: ...ion Slide the starter motor out from the crankcase and remove it from the machine see illustration 5 Remove the O ring on the end of the starter motor and discard it as a new one must be used Installa...

Page 199: ...llustration 4 Wrap some insulating tape around the teeth on the end of the starter motor shaft this will protect the oil seal from damage as the front cover is removed Remove the front cover from the...

Page 200: ...o not use sandpaper or emery paper After cleaning wipe away any residue with a cloth soaked in electrical system cleaner or denatured alcohol Measure the diameter of the commutator and compare It to t...

Page 201: ...t becoming entangled with the exposed brush ends 18 Insert the armature into the main housing noting that it will be forcibly drawn in by the attraction of the magnets see illustration 29 6 Remove the...

Page 202: ...y testing of the individual components Note Before beginning the checks make sure the battery is fully charged and that all system connections are clean and tight 2 Checking the output of the charging...

Page 203: ...ft hand side of the engine and disconnect it at the white connector containing the three white wires see illustrations 3 Using a multimeter set to the ohms x 1 ohmmeter scale measure the resistance be...

Page 204: ...9 Withdraw the shaft arrowed and remove the gear the position of the dowels and remove them if loose 9 Withdraw the shaft from the starter idle reduction gear and remove the gear noting how it fits se...

Page 205: ...igning the slot arrowed with the key idle reduction gear making sure it engages correctly with both the starter motor pinion and the starter clutch pinion and insert the shaft see illustration 32 9 17...

Page 206: ...fairing Remove the fairing for access see Chapter 8 On 1991 to 1995 33 3a Regulator rectifier 1991 to 1995 TDM models models remove the air filter housing for access to the wiring connector see Chapt...

Page 207: ...Wiring diagrams 9 29 _____Scaned by Stalker 5 l 6o Cxj fi I JICM...

Page 208: ...UNREGISTERED VI 9 30 Wiring diagrams UNREGISTERED VERSION 01 ONREGISTEREDVI Scaned by Stalker ONREGISTERED VERSION 0...

Page 209: ...I UNREGISTERED VI Wiring diagrams 9 31 ____ Scaned by Stalker UNREGISTERED VERSION OF PICTURE DESK...

Page 210: ...9 32 Wiring diagrams Scaned by Stalker...

Page 211: ...XTZ750 gauge Starter circuit Neutral Starter cut off relay switch rnotor...

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