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Yamaha TDM850'99 4TX-AE3, Service Manual

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–22–

CLUTCH

ENG

Order

Job name / Part name

Q’ty

Remarks

1
2
3
4
5
6
7
8
9

10

11

12
13
14
15

Clutch removal
Clutch spring
Pressure plate
Plain washer / Bearing
Pull rod
Friction plate
Friction plate
Clutch plate
Clutch boss nut
Lock washer
Clutch boss
Thrust plate
Spacer / Bearing
Clutch housing
Thrust plate 2
Thrust plate 1

6
1

1 / 1

1
7
2
8
1
1
1
1

1 / 1

1
1
1

Remove the parts in the order below.

For installation, reverse the removal
procedure.

Refer to “REMOVAL”, and
“INSTALLATION”.

70 Nm (7.0m

kg)

8 Nm (0.8m

kg)

CLUTCH

CLUTCH

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Summary of Contents for TDM850'99 4TX-AE3

Page 1: ......

Page 2: ...this Supplementary Service Manual 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 Yam...

Page 3: ...ll its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicabl...

Page 4: ...lp identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassemb...

Page 5: ...ntify 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 V A Illustrated...

Page 6: ...CATION 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 INSPECT...

Page 7: ...RMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head MODEL LABEL The model label 1 is affixed to the...

Page 8: ...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 s...

Page 9: ...ize 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 X 5 4 mm 1050...

Page 10: ...rer resistance full empty 4TX NIPPON SEIKI 4 X 10 90 X 100 SSS SSS SSS Fuel pump relay Model manufacturer Coil winding resistance G8R 30Y B OMRON 225 10 SSS SSS Hazard relay Model manufacturer Coil wi...

Page 11: ...ad A Fasten the right handlebar switch lead with a plastic band B Fasten the handlebar switch lead with a plastic band C 50 mm D Fasten the horn lead with a plastic band E 60 mm F Set the clamp within...

Page 12: ...ead and headlight lead with a plastic band O Connect the coupler and insert to the protector P Fasten the wireharness with a plastic band Q Fasten the wireharness and ignition coil left lead with a pl...

Page 13: ...s to the rear side of the frame pipe C Route the starter cable through ra diator hose upward and spark plug lead rear side and in front of air fil ter case breather hose Route the spark plug lead to t...

Page 14: ...the idle ad just bracket I Route the air filter case breather hose to the outside of the carburetor heater hose and route the carburetor heater hose to the inside of the air filter case breather hose...

Page 15: ...lead 22 CYCLELOCK lead A Route the battery positive lead and battery negative lead through the clamp B Fasten the wireharness Coolant breather hose and flasher relay lead C Route the carburetor breath...

Page 16: ...eservoir breather hose fuel tank drain hose carburetor breather hose through the guide P Route the carburetor breather hoses through the clamp Q Route the fuel tank drain hose fuel tank breather hose...

Page 17: ...Coolant reservoir breather hose 19 Coolant reservoir hose 20 Fuel hose 21 Carburetor breather hose 22 Cylinder head breather hose 23 Air filter case breather hose A Fasten the meter lead headlight lea...

Page 18: ...rottle posi tion sensor lead K Fasten the wireharness with a clamp L To left flasher M Fasten the headlight lead with a clamp N To head light O To auxiliary light P To meter Q Fasten the meter lead he...

Page 19: ...heck operation fluid level and vehicle for fluid leakage Correct accordingly Replace brake pads if necessary 9 Wheels Check balance runout and for damage Rebalance or replace if necessary 10 Tires Che...

Page 20: ...k coolant level and vehicle for coolant leakage Correct if necessary Change coolant every 24 000 km or 24 months whichever comes first Since these items require special tools data and technical skills...

Page 21: ...pler Tail cover Side cover Fuel hose Fuel tank breather hose Fuel tank Fuel sender coupler 1 1 1 2 1 1 1 1 Remove the parts in the order below Refer to COWLINGS Disconnect Set the fuel cock fuel tank...

Page 22: ...le stand under the motorcycle 2 Remove Side cowling Seat Side cover Fuel tank Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK 3 Remove Vacuum hose 1 1 carburetor 1 Vacuum hose 2 2 carburetor 2 4 Attac...

Page 23: ...chronization again Intake vacuum at idle speed 36 0 38 7 kPa 270 290 mm Hg The difference between both carburetors should be 0 67 kPa 5 mm Hg or less 8 Check Engine idling speed Out of specification A...

Page 24: ...a suitable stand under the motorcycle 2 Inspect Oil level Oil level should be between the maximum a and minimum b marks Oil level is below the minimum mark Add oil up to the proper level Recommended o...

Page 25: ...Oil filter drain bolt with gasket 2 Drain the crankcase and oil tank of its oil 5 If the oil filter is to be replaced during this oil change remove the following parts and rein stall them Replacement...

Page 26: ...il Then start the engine and race it five or six times Continue idling the engine a few min utes Stop the engine and fill it with oil to the specified level Oil quantity Total amount 4 2 L Periodic oi...

Page 27: ...Fuel tank Refer to COWLINGS SEAT TAIL COVER AND FUEL TANK 2 Inspect Fuel hoses 1 Cracks Damage Replace Loose connection Connect properly Drain and flush the fuel tank if abrasive damage to any compone...

Page 28: ...ull rod Friction plate Friction plate Clutch plate Clutch boss nut Lock washer Clutch boss Thrust plate Spacer Bearing Clutch housing Thrust plate 2 Thrust plate 1 6 1 1 1 1 7 2 8 1 1 1 1 1 1 1 1 1 Re...

Page 29: ...e friction plates are made in two types The first and last friction plates are different in ma terial from the other ones and black on the sur face Assembly should be done in the correct order Mount f...

Page 30: ...ODO To reset a trip odometer to 0 0 select it by pushing the select button and push the reset button for at least one second Clock To change the display to the clock mode push both the select and res...

Page 31: ...25 SIGNAL SYSTEM ELEC EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM...

Page 32: ...tery 8 Main fuse 22 Fuel sender 25 Fuel meter 27 Fuel level indicator light 32 Turn indicator light left 33 Turn indicator light right 34 Speed meter 35 Speed sensor 36 Front flasher light 37 Rear fla...

Page 33: ...sys tem s wiring Check the condition of each of the signal ing system s circuits Refer to SIGNAL SISTEM CHECK SIGNAL SYSTEM ELEC NOTE S Check the main and signaling system fuses for continuity Refer t...

Page 34: ...ter DC 20 V to the hazard relay coupler Tester lead Brown Red terminal Tester lead Frame ground YES NO Wiring circuit from main switch to hazard relay connector is faulty repair 4 Voltage Connect the...

Page 35: ...or P S Turn the turn switch to L or R S Check for voltage 12 V on the Chocolate lead or Dark green lead at the bulb socket connector S Is the voltage with in specification YES NO Wiring circuit from t...

Page 36: ...el meter Turn the main switch to ON Check the fuel gauge needle moves F or E Float position Needle moves Float UP F Float DOWN E 4 Voltage Connect the pocket tester DC 20 V to the meter assembly coupl...

Page 37: ...heel and slowly rotate it Does the voltage 5V read cycle 4 times with each full rotation of the front wheel YES NO Replace the speed sensor 2 Wiring Check the entire wiring signal system s wiring Refe...

Page 38: ...32 FUEL PUMP SYSTEM ELEC Main switch 3 6 8 11 13 18 61 Battery Main fuse Fuel pump Fuel relay Ignitor unit Engine stop switch Ignition fuse 62 EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM...

Page 39: ...ELEC 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay 8 Fuel pump EB808010 FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control un...

Page 40: ...Refer to SWITCH INSPECTION Is the engine stop switch OK YES NO Replace the right han dlebar switch NOTE 1 Main and ignition fuses Check the main and ignition fuses for continu ity Refer to SWITCH INS...

Page 41: ...e relay unit 6 Fuel pump resistance Disconnect the fuel pump coupler from the wire harness Connect the pocket tester 1 to the fuel pump coupler fuel pump side as shown 1 2 EB808400 Tester positive pro...

Page 42: ...ccidentally spill gasoline wipe it up immediately with dry rags If gasoline touches the engine when it is hot a fire may occur Therefore make sure that the engine is completely cool before per forming...

Page 43: ...ar position switch 17 Sidestand switch 18 Ignitor unit 19 Ignition coil 20 Spark plug 21 CYCLELOCK option 22 Fuel sender 23 Meter assembly 24 Tachometer 25 Fuel meter 26 Meter light 27 Fuel level indi...

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