Yamaha TDM 850 Service manual 1996-1999

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NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowledge, attempted repairs or service to this model may render if unfit to use and/or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.

PARTICULARY IMPORTANT INFORMATION
This material is distinguished by the following notation. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer.

CAUTION:
NOTE:

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HOW TO USE THIS MANUAL
MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See "Illustrated symbols") 1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page. 3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations. EXPLODED DIAGRAMS To help 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 disassembly jobs. 2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6 . The meanings of the
symbol marks are given on the next page. 4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart. 2 1 4

3 6 8

5 7

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ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 9 are printed on top right of each page and indicate the subject of each chapter. 1 2 3 4 5 6 7 8 9
General information Specifications Periodic inspections and adjustments Engine Cooling system Carburetion Chassis Electrical Troubleshooting

GEN INFO
3

SPEC
4

INSP ADJ
5 6

ENG

COOL
7

CARB
8

CHAS
9

ELEC
10

Illustrated symbols 10 to 17 are used to identify the specifications appearing in the text.
10 11 12 13 14 15 16 17

TRBL SHTG
11 12

Can be serviced with engine mounted Filling fluid Lubricant Special tool Torque Wear limit, clearance Engine speed , V, A

13

14

15

16

17

18

19

20

Illustrated symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points.
18 19 20 21 22 23

21

22

23

Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lightweight lithium soap base grease Apply molybdenum disulfide grease

24

25

Illustrated symbols 24 to 25 in the exploded diagrams indicate where to apply a locking agent 24 and when to install new parts 25 .
24 Apply locking agent (LOCTITE®) 25 Replace