Yamaha TDM850 Owner'S Manual Download Page 1

Page: 1 / 110

PRINTED IN JAPAN
2000

0.4

(E)

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

4TX-28199-E5

OWNER’S MANUAL

TDM850

Summary of Contents for TDM850

Page 1: ...4TX 28199 E5 OWNER S MANUAL TDM850 ...

Page 2: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 3: ...o enjoy all advantages of your TDM850 The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and oth ers from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha deale...

Page 4: ... be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product informat...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE E_4tx book Page 2 Wednesday October 4 2000 4 28 PM ...

Page 6: ...NUAL 2000 by Yamaha Motor Co Ltd 1st Edition August 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan E_4tx book Page 3 Wednesday October 4 2000 4 28 PM ...

Page 7: ...ENT AND CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX EAU00009 E_4tx book Page 1 Wednesday October 4 2000 4 28 PM ...

Page 8: ...E_4tx book Page 2 Wednesday October 4 2000 4 28 PM ...

Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF WAY 1 1 E_4tx book Page 1 Wednesday October 4 2000 4 28 PM ...

Page 10: ... even small amounts of alcohol there is a tendency to take dangerous risks Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers Always wear a complete motorcycle suit whether made of leather or tear resistant synthetic materials with protectors sturdy boots motorcycle gloves and a properly fitting helmet Optimum protective wear however shoul...

Page 11: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 E_4tx book Page 1 Wednesday October 4 2000 4 28 PM ...

Page 12: ...ir page 6 12 2 Helmet holder page 3 11 3 Seat lock page 3 11 4 Shock absorber assembly spring preload adjusting nut fine adjustment page 3 15 5 Shock absorber assembly damping force adjusting dial page 3 16 E_4tx book Page 1 Wednesday October 4 2000 4 28 PM ...

Page 13: ...sembly spring preload adjusting lever coarse adjustment page 3 15 8 Fuses page 6 35 9 Engine oil level check window page 6 9 10 Front fork spring preload adjusting bolt page 3 13 11 Front fork damping force adjusting screw page 3 14 E_4tx book Page 2 Wednesday October 4 2000 4 28 PM ...

Page 14: ...hes page 3 5 3 Starter choke lever page 3 10 4 Speedometer unit page 3 3 5 Main switch steering lock page 3 1 6 Tachometer page 3 4 7 Fuel gauge page 3 5 8 Right handlebar switches page 3 6 9 Throttle grip page 6 19 10 Brake lever page 3 7 E_4tx book Page 3 Wednesday October 4 2000 4 28 PM ...

Page 15: ... 3 5 Clutch lever 3 7 Shift pedal 3 7 Brake lever 3 7 Brake pedal 3 8 Fuel tank cap 3 9 Fuel 3 9 Fuel tank breather hose for Germany only 3 10 Starter choke lever 3 10 Seat 3 11 Helmet holder 3 11 Storage compartment 3 12 Adjusting the front fork 3 13 Adjusting the shock absorber assembly 3 15 Luggage strap holders 3 17 Sidestand 3 17 Ignition circuit cut off system 3 18 E_4tx book Page 1 Wednesda...

Page 16: ...d and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it EW000016 WARNING Never turn the key to OFF or LOCK while the motorcycle is movin...

Page 17: ...ight comes on when the high beam of the headlight is switched on EAU01707 Coolant temperature warning light This warning light comes on when the engine overheats When this occurs stop the engine immediately and allow the engine to cool The electrical circuit of the warning light can be checked according to the fol lowing procedure 1 Set the engine stop switch to and turn the key to ON 2 Shift the ...

Page 18: ...ws the to tal distance traveled two tripmeters which show the distance traveled since they were last set to zero a clock Odometer and tripmeter modes Pushing the SELECT button switches the display between the odometer mode ODO and the tripmeter modes TRIP 1 TRIP 2 and CLOCK in the following order ODO TRIP 1 TRIP 2 CLOCK ODO To reset a tripmeter select it by push ing the SELECT button and then push...

Page 19: ... keep it within the ideal power range EC000003 CAUTION Do not operate the engine in the ta chometer red zone Red zone 8 000 r min and above EAU00103 Self diagnosis device This model is equipped with a self di agnosis device for the throttle position sensor circuit If the throttle position sensor circuit is defective the tachometer will repeat edly display the following error code CB 10E If the tac...

Page 20: ...uel level decreases When the needle reaches E approximately 3 1 L of fuel remain in the fuel tank If this occurs refuel as soon as possible NOTE Do not allow the fuel tank to empty it self completely EAU00118 Handlebar switches EAU00120 Pass switch PASS Press this switch to flash the headlight EAU00121 Dimmer switch Set this switch to for the high beam and to for the low beam 1 Fuel gauge 1 Pass s...

Page 21: ... warn other drivers when your motorcycle is stopped where it might be a traffic hazard EC000006 CAUTION _ Do not use the hazard light for an ex tended length of time otherwise the battery may discharge _ EAU00138 Engine stop switch Set this switch to to stop the en gine in case of an emergency such as when the motorcycle overturns or when the throttle cable is stuck EAU00134 Light switch Set this ...

Page 22: ...age 3 18 for an explanation of the ig nition circuit cut off system EAU00157 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on this motorcycle EAU00160 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull th...

Page 23: ...holding the lever pushed away from the handlebar grip Make sure that the mark on the adjusting nut is aligned with the mark on the brake lever EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Brake lever position adjusting nut 2 Properly aligned marks 1 Brake pedal E_4tx book Page 8 Wednesday October 4 2000 4 28 PM ...

Page 24: ...cover NOTE The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked EWA00025 WARNING Make sure that the fuel tank cap is properly closed before riding EAU03753 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown EW000130 WARNING _ Do not over...

Page 25: ...e fuel tank breather hose connection Check the fuel tank breather hose for cracks or damage and replace it if damaged Make sure that the end of the fuel tank breather hose is not blocked and clean it if necessary EAU02976 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Mo...

Page 26: ...n 2 Push the rear of the seat down to lock it in place 3 Remove the key NOTE Make sure that the seat is properly se cured before riding EAU00263 Helmet holder The helmet holder is located under the seat To secure a helmet to the helmet holder 1 Remove the seat 2 Attach the helmet to the helmet holder and then securely install the seat 1 Seat lock 2 Unlock 1 Projection 2 2 Seat holder 2 1 Helmet ho...

Page 27: ...ed to hold a genuine Yamaha U LOCK Other locks may not fit When placing a U LOCK in the storage compartment securely fasten it with the straps When the U LOCK is not in the storage com partment be sure to secure the straps to prevent losing them When storing the owner s manual or other documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When wa...

Page 28: ... preload and thereby harden the suspension turn the adjusting bolt on each fork leg in di rection a To decrease the spring pre load and thereby soften the suspension turn the adjusting bolt on each fork leg in direction b NOTE Align the appropriate groove on the ad justing mechanism with the top of the front fork cap bolt CI 10E 1 Spring preload adjusting bolt 2 Current setting 3 Standard setting ...

Page 29: ...ber of clicks of a damping force adjusting mechanism may not exactly match the above spec ifications due to small differences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary 1 Damping forc...

Page 30: ...top of the shock absorber assembly to SOFT For riding with a passenger move the adjusting lever to HARD NOTE _ Use the special tool included in the owner s tool kit to make the adjust ment _ Fine adjustment 1 Loosen the locknut 2 To increase the spring preload and thereby harden the suspen sion turn the adjusting nut at the bottom of the shock absorber as sembly in direction a To de crease the spr...

Page 31: ... _ Damping force To increase the damping force and thereby harden the damping turn the adjusting dial in direction a To de crease the damping force and thereby soften the damping turn the adjusting dial in direction b CI 04E a Distance A Spring preload Minimum soft Distance A 59 mm Standard Distance A 61 mm Maximum hard Distance A 63 mm Tightening torque Locknut 40 Nm 4 0 m kg 1 Damping force adju...

Page 32: ...Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always have a Yamaha dealer service the shock absorber EAU00324 Luggage strap holders There are four luggage strap holders below the passenger seat two of which can be turned out for easier access EAU00330 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower...

Page 33: ...nction properly EAU03720 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch lever is pulled but the sid...

Page 34: ...e clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle shoul...

Page 35: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_4tx book Page 1 Wednesday October 4 2000 4 28 PM ...

Page 36: ...eakage 6 9 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 11 6 13 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 25 6 26 Rear brake Check operatio...

Page 37: ...es Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 19 6 22 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 30 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 31 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 ...

Page 38: ...E_4tx book Page 3 Wednesday October 4 2000 4 28 PM ...

Page 39: ...5 Starting a cold engine 5 1 Starting a warm engine 5 2 Shifting 5 3 Recommended shift points for Switzerland only 5 3 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 E_4tx book Page 1 Wednesday October 4 2000 4 28 PM ...

Page 40: ...tarting one of the following conditions must be met The transmission is in the neutral position The transmission is in gear with the clutch lever pulled and the sidestand up EW000054 WARNING _ Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 19 Never ride with the sidestand down _ 1 Turn the key to ON and make sur...

Page 41: ... mains on after starting stop the engine and then check the fuel level If necessary refuel as soon as possible and then check the warning light again If the warning light does not come on when pushing the start switch or if it does not go off af ter starting with sufficient fuel have a Yamaha dealer check the electrical circuit _ 5 After starting the engine move the starter choke lever back halfwa...

Page 42: ...motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting EAU02941 Recommended shift points for Switzerland only The recommended shift p...

Page 43: ...m For this rea son you should read the following ma terial carefully Since the engine is brand new do not put an excessive load on it for the first 1 000 km The various parts in the en gine wear and polish themselves to the correct operating clearances During this period prolonged full throttle oper ation or any condition that might result in engine overheating must be avoided EAU00440 0 150 km Av...

Page 44: ...If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle EAU00460 Parking When parking stop the engine and then remove the key from the main switch EW000058 WARNING Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft grou...

Page 45: ... the brake fluid level 6 25 Changing the brake fluid 6 26 Drive chain slack 6 27 Lubricating the drive chain 6 29 Checking and lubricating the cables 6 29 Checking and lubricating the throttle grip and cable 6 30 Checking and lubricating the brake and shift pedals 6 30 Checking and lubricating the brake and clutch levers 6 31 Checking and lubricating the sidestand 6 31 Lubricating the rear suspens...

Page 46: ...cycle maintenance work have a Yamaha dealer do it for you EAU01299 Owner s tool kit The owner s tool kit is located inside the storage compartment under the seat See page 3 11 for seat removal procedures The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever ad...

Page 47: ...ANCE JOB ODOMETER READING 1 000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust Every 40 000 km 5 Air filter element Clean Replace 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on...

Page 48: ...y 1 000 km and after washing the motorcycle or riding in the rain 15 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20 000 km 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Sidestand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage ...

Page 49: ...s every four years and if cracked or damaged _ 22 Carburetors Check starter choke operation Adjust engine idling speed and synchronization 23 Engine oil Change 24 Engine oil filter element Replace 25 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 26 Front and rear brake switches Check operation 27 Moving parts and cables Lubricate 28 Lights signals and swit...

Page 50: ...hapter Refer to this section each time a cowling or panel needs to be re moved and installed EAU03494 Cowlings A and B To remove one of the cowlings Remove the cowling screws and then pull the cowling off as shown To install the cowling Place the cowling in the original posi tion and then install the screws 1 Cowling A 2 Panel A 1 Cowling B 2 Panel B 1 Screw 3 E_4tx book Page 5 Wednesday October 4...

Page 51: ...r cowl ing removal and installation procedures 2 Remove the seat See page 3 11 for seat removal and installation procedures 3 Remove the screw and then take the panel off To install the panel 1 Place the panel in the original po sition and then install the screw 2 Install the seat and the cowling 1 Screw E_4tx book Page 6 Wednesday October 4 2000 4 28 PM ...

Page 52: ...shown with the spark plug wrench includ ed in the owner s tool kit To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the motorcycle is ridden normally 2 Check that all spark plugs installed in the engine have the same color NOTE If any spark plug shows a distinctly dif ferent color the engine c...

Page 53: ...all the spark plug with the spark plug wrench and then tight en it to the specified torque NOTE If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible 4 Install the spark plug cap 5 Install the cowling a Spark plug gap Spark plug ...

Page 54: ...e engine warm it up for 15 minutes and then turn it off 3 Check the oil level through the check window located on the right side of the engine oil tank NOTE The engine oil tank is located be hind the cylinders The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correc...

Page 55: ...ement and O rings 6 Install the oil filter element cover by installing the bolts then tighten ing them to the specified torque NOTE Make sure that the O rings are properly seated 7 Install the engine oil drain bolts and then tighten them to the spec ified torques 1 Engine oil drain bolt A 1 Engine oil drain bolt B 2 Oil filter element cover 3 Bolt 5 1 Oil filter element 2 O ring 2 Tightening torqu...

Page 56: ...3495 Coolant The coolant level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart If the engine overheats see page 6 45 for further instructions To check the coolant level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE The coolant level must be checked on a cold ...

Page 57: ... soft tap water instead Do not use hard water or salt water since it is harmful to the engine If water has been used instead of coolant replace it with cool ant as soon as possible other wise the engine may not be sufficiently cooled and the cool ing system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze content of ...

Page 58: ...cool if necessary 2 Remove the seat See page 3 11 for seat removal and installation procedures 3 Remove cowling B and panel B See pages 6 5 and 6 6 for cowl ing and panel removal and instal lation procedures 4 Place a container under the en gine to collect the used coolant 5 Remove the radiator cap retaining bolt and the radiator cap EW000067 WARNING Never attempt to remove the radia tor cap when ...

Page 59: ...t reservoir 11 Install the coolant reservoir by placing it in the original position then installing the bolts 12 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 13 Install the coolant drain bolts and then tighten them to the specified torque NOTE Check the washers for damage and re place them if necessary 14 Pour the recommended coolant into the ra...

Page 60: ... 17 Check the coolant level in the res ervoir If necessary remove the coolant reservoir cap add coolant to the maximum level mark and then install the cap 18 Install the panel the cowling and the seat 19 Start the engine and then check the vehicle for coolant leakage If coolant is leaking have a Yamaha dealer check the cooling system EAU03496 Cleaning the air filter element The air filter element ...

Page 61: ...k turn the fuel cock lever to OFF disconnect the fuel hose and breather hose and then take the fuel tank off 6 Remove the air filter case cover by removing the screws 1 Fuel sender coupler 1 Fuel cock 2 Fuel hose 3 Fuel tank breather hose 1 Air filter case cover 2 Screw 3 E_4tx book Page 16 Wednesday October 4 2000 4 28 PM ...

Page 62: ... engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 10 Install the air filter case cover by installing the screws 11 Connect the fuel hose breather hose and fuel sender coupler turn the fuel cock lever to ON and then install the fuel tank by install ing the bolts EWA00013 WARNING Make sure that the fuel ho...

Page 63: ...Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart 1 Start the engine and warm it up for several minutes at 1 000 2 000 r min while occasionally rev ving it to 4 000 5 000 r min NOTE The engine is warm when it quickly re sponds to the throttle 2 Check the engine ...

Page 64: ...fied in the periodic maintenance and lubrication chart EAU00658 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride EW000082 WARNING _ The tire air pressure must be checked and adjusted on cold tires i e when t...

Page 65: ...ressure with regard to the load Check the tire condition and air pressure before each ride _ Tire inspection The tires must be checked before each ride If the center tread depth reaches the specified limit if the tire has a nail or glass fragments in it or if the side wall is cracked have a Yamaha dealer replace the tire immediately CE 08E NOTE _ The tire tread depth limits may differ from country...

Page 66: ...s motorcycle is equipped with cast wheels and tubeless tires with valves EW000080 WARNING _ The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the motor cycle cannot be guaranteed After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Ltd Always make sure that the valve caps are securely install...

Page 67: ...ore it is ad visable before doing any high speed riding to ride conserva tively for approximately 100 km after installing a new tire The tires must be warmed up before a high speed run Always adjust the tire air pres sure according to the operating conditions FRONT Manufacturer Size Model Bridgestone 110 80 ZR18 58W BT54F Pirelli 110 80 ZR18 58W MTR03 Michelin 110 80 ZR18 58W MACADAM 90X REAR Manu...

Page 68: ...in direction b 3 Tighten the locknut NOTE If the specified free play cannot be ob tained as described above or if the clutch does not operate correctly have a Yamaha dealer check the internal clutch mechanism EAU00712 Adjusting the brake pedal position The top of the brake pedal should be positioned approximately 29 mm below the top of the footrest as shown Peri odically check the brake pedal posi...

Page 69: ...nt EAU00713 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direc...

Page 70: ...the wear indicator almost touches the brake disc have a Yamaha dealer replace the brake pads as a set EAU03776 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly caus ing it to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake flu id level may indicate worn brake p...

Page 71: ...ck Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to gradually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU03238 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the perio...

Page 72: ...te the tight est portion of the drive chain and then measure the drive chain slack as shown 4 If the drive chain slack is incorrect adjust it as follows EAU00765 To adjust the drive chain slack 1 Loosen the axle nut and the brake caliper bracket bolt 2 Loosen the chain puller locknut at each end of the swingarm 3 To tighten the drive chain turn the adjusting nut at each end of the swingarm in dire...

Page 73: ...ne as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 4 Tighten the locknuts and then tighten the axle nut and the brake caliper bracket bolt to the specified torques 1 Bolt 2 Brake caliper bracket Tightening torques Axle nut 110 Nm 11 0 m kg Brake caliper bracket bolt 35 Nm...

Page 74: ...2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant ECA00052 CAUTION Do not use engine oil or any other lubricants for the drive chain as they may contain substances that could damage the O rings EAU02962 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and ...

Page 75: ...d then apply several drops of oil to the cable end allowing it to trickle into the sheath 3 Connect the throttle cable and then grease the inside of the throt tle grip housing 4 Grease the metal to metal contact surface of the throttle grip and then install the grip by installing the screws EAU03370 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals sho...

Page 76: ...ting the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary EW000113 WARNING If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grea...

Page 77: ... EW000115 WARNING Securely support the motorcycle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the motorcycle on a level surface and hold it in an upright position 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds sm...

Page 78: ...support the motorcycle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steer ing EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion char...

Page 79: ...t medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the batt...

Page 80: ...d installation proce dures If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage EC000103 CAUTION _ Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire _ 1 Headlight fuse 2 S...

Page 81: ...lb burns out replace it as follows 1 Remove the headlight bulb cover and then disconnect the headlight couplers 2 Unhook the headlight bulb holder and then remove the defective bulb EW000119 WARNING _ Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down _ 3 Place a new bulb into position and then secure it...

Page 82: ... install the bulb cover 5 Have a Yamaha dealer adjust the headlight beam if necessary EAU01623 Replacing the tail brake light bulb 1 Remove the tail brake light lens by removing the screws 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws...

Page 83: ...ulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw ECA00065 CAUTION Do not overtighten the screw other wise the lens may break 1 Screw 2 Turn signal light lens 1 Turn signal light bulb E_4tx book Page 38 Wednesday October 4 2000 4 28 PM ...

Page 84: ...der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm EAU03498 Front wheel To remove the front wh...

Page 85: ...er the front wheel so that it is on the ground 4 Install the brake calipers by install ing the bolts NOTE _ Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs _ 5 Tighten the wheel axle the front wheel axle pinch bolt and the brake caliper bolts to the specified torques 6 Push down hard on the handlebar several times to check for ...

Page 86: ...rake caliper bolts 2 Lift the rear wheel off the ground according to the procedure on page 6 39 3 Loosen the brake caliper bracket bolt 4 Remove the brake caliper by re moving the bolts ECA00046 CAUTION _ Do not apply the brake after the brake calipers have been removed otherwise the brake pads will be forced shut _ 1 Axle nut 2 Locknut 3 Drive chain slack adjusting nut 1 Brake caliper 2 Bolt 2 3 ...

Page 87: ...he wheel by inserting the wheel axle from the right hand side 2 Install the drive chain onto the rear sprocket and then adjust the drive chain slack See page 6 27 for drive chain slack adjustment pro cedures 3 Install the brake caliper by install ing the bolts 4 Install the axle nut and then lower the rear wheel so that it is on the ground 5 Tighten the axle nut the brake cal iper bolts and the br...

Page 88: ... troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often infer...

Page 89: ...mpression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle Operate the electric starter 4 Battery The engine turns over quickly The engine turn...

Page 90: ...hiss ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check t...

Page 91: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_4tx book Page 1 Wednesday October 4 2000 4 28 PM ...

Page 92: ...ctrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 CAUTION Avoid using strong acidic wheel cleaners e...

Page 93: ...or plastic may leave scratches on the wind shield Test the product on a small hidden part of the wind shield to make sure that it does not leave any marks If the wind shield is scratched use a quali ty plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebr...

Page 94: ...he thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 4 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 5 Use spray oil as a universal clean er to remove any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the m...

Page 95: ...er and humid ity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored Long term Before storing your motorcycle for several months 1 Follow all the instructions in the Care section of this chapter 2 For motorcycles equipped with a fuel cock that has an OFF posi tion Turn the fuel cock lever to OFF 3...

Page 96: ...e turning the engine over 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 7 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover...

Page 97: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 E_4tx book Page 1 Wednesday October 4 2000 4 28 PM ...

Page 98: ... ratio 10 5 1 Starting system Electric starter Lubrication system Dry sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter element replacement 3 5 L With oil filter element replacement 3 6 L Total amount dry engine 4 2 L 20 10 0 10 20 30 40 50 C SAE 10W 30 SAE 15W 40 SAE 20W 40 SAE 20W 50 SAE 10W 40 CAUTION Be sure to use motor oils ...

Page 99: ... ratio 1 718 Secondary reduction system Chain drive Secondary reduction ratio 2 688 Number of drive chain sprocket teeth front rear 16 43 Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 643 2nd 1 947 3rd 1 500 4th 1 174 5th 0 964 Chassis Frame type Diamond Caster angle 24 5 Trail 103 mm Tires Front Type Tubeless tire Size 110 80 ZR18 58W Manufacturer model Bridgestone ...

Page 100: ...2 75 kg cm2 2 75 bar Total weight of rider passenger cargo and accessories Wheels Front Type Cast wheel Size 18 MT 3 00 Rear Type Cast wheel Size 17 MT 4 00 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Telescopic fork Rear Swingarm monocross Spring shock absorber Front Coil spring oil damper Rear Co...

Page 101: ...12 V 5 W 1 Tail brake light 12 V 5 21 W 2 Turn signal light 12 V 21 W 4 Meter lighting 12 V 2 W 3 Neutral indicator light 14 V 1 4 W 1 High beam indicator light 14 V 1 4 W 1 Turn signal indicator light 14 V 1 4 W 2 Coolant temperature warning light 14 V 1 4 W 1 Fuel level warning light 12 V 2 W 1 Fuses Main fuse 30 A Headlight fuse 15 A Signaling system fuse 15 A Ignition fuse 10 A Hazard fuse 10 ...

Page 102: ...etric unit Multiplier Imperial unit Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km h 0 6214 mi h Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 L liter L liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous kg mm kg cm2 Centigrade C 55...

Page 103: ...CONSUMER INFORMATION 9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 E_4tx book Page 1 Wednesday October 4 2000 4 28 PM ...

Page 104: ...1E EAU01041 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify y...

Page 105: ... frame under the seat See page 3 11 for seat removal and installation procedures Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label E_4tx book Page 2 Wednesday October 4 2000 4 28 PM ...

Page 106: ...gine break in 5 4 Engine oil and oil filter element 6 9 Engine stop switch 3 6 F Front fork adjusting 3 13 Front fork checking 6 32 Fuel 3 9 Fuel consumption tips for reducing 5 4 Fuel gauge 3 5 Fuel level warning light 3 3 Fuel tank breather hose Germany only 3 10 Fuel tank cap 3 9 Fuses replacing 6 35 H Handlebar switches 3 5 Hazard switch 3 6 Headlight bulb replacing 6 36 Helmet holder 3 11 Hig...

Page 107: ...motorcycle 6 39 Suspension rear lubricating 6 32 T Tachometer 3 4 Tail brake light bulb replacing 6 37 Throttle cable free play adjusting 6 19 Throttle grip and cable checking and lubricating 6 30 Tires 6 19 Tool kit 6 1 Troubleshooting 6 43 Troubleshooting charts 6 44 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 38 Turn signal switch 3 6 V Valve clearance adjusting 6 19 Veh...

Page 108: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 109: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 110: ...PRINTED IN JAPAN 2000 9 0 4 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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Yamaha TDM850, Owner'S Manual

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