Yamaha TDM850 1996 User Manual

Details for identifying the motorcycle's VIN, engine serial number, and model label.

Covers preparation for removal, replacement parts, gaskets, oil seals, O-rings, lock washers, circlips.

Guidance on inspecting and cleaning electrical connectors for stains, rust, and moisture.

Instructions on converting metric unit data to imperial unit data using a provided table.

Lists special tools required for tune-up and assembly with their part numbers and uses.

Provides overall dimensions, engine type, displacement, lubrication, and oil capacity details.

Details specifications for engine components like cylinder head, camshaft, valve clearance, and piston.

Specifies torque values for standard fasteners with ISO pitch threads.

Lists lubrication points for the engine and the recommended lubricant types.

Diagrams and instructions for routing various cables and hoses throughout the motorcycle.

Table outlining routine maintenance and lubrication intervals for various vehicle components.

Procedures for removing and installing cowlings, seat, tail cover, and fuel tank components.

Instructions for removing and installing the air filter case assembly.

Covers engine-related inspections and adjustments like valve clearance, carburetor sync, and oil level.

Details inspections and adjustments for chassis components like brakes, steering, and suspension.

Covers inspection and maintenance of electrical components including battery, fuses, and switches.

Procedure for disconnecting and connecting electrical leads for engine assembly.

Detailed instructions for removal, inspection, and installation of the camshaft and related parts.

Procedures for removing, inspecting, and installing the cylinder head, including warp limit measurement.

Steps for removal, inspection, and installation of valves, springs, and related components.

Detailed guide for cylinder and piston removal, inspection, and installation procedures.

Instructions for clutch removal, inspection of plates, springs, and installation.

Procedure for removing and installing the left crankcase cover and related components.

Inspection and installation procedures for the shift shaft, pawls, and related parts.

Covers stator coil, A.C. magneto, and starter wheel gear removal, inspection, and installation.

Details on oil pump cover, driven gears, and oil pump removal, inspection, and installation.

Comprehensive guide to crankshaft removal, inspection, assembly, and installation.

Procedures for transmission, shift cam, and shift fork removal, inspection, and installation.

Instructions for radiator removal, inspection of core, fan, hoses, and cap pressure.

Details on thermostatic valve assembly, inspection, and installation procedures.

Procedures for water pump removal, inspection, and installation of impeller and housing.

Covers carburetor assembly, disassembly, and adjustment procedures.

Guidance on measuring and adjusting carburetor fuel levels using a fuel level gauge.

Procedures for adjusting and inspecting the throttle position sensor (TPS) for proper operation.

Instructions for front wheel and brake disc removal, assembly, and static balance adjustment.

Covers rear wheel, brake disc, and driven sprocket removal and inspection procedures.

Detailed procedures for front and rear brake pad replacement, caliper service, and fluid checks.

Covers front fork removal, disassembly, inspection, assembly, and installation.

Instructions for handlebar removal, inspection, installation, and adjustment of controls.

Procedures for lower bracket removal, steering head inspection, and installation of bearings.

Guidance on removal, handling, and disposal of the rear shock absorber.

Covers swingarm and drive chain removal, inspection, lubrication, and free play checks.

Diagram showing the location and identification of key electrical components on the motorcycle.

Instructions for testing switch continuity using a pocket tester and interpreting switch charts.

Circuit diagram and troubleshooting guide for ignition system failures like no spark.

Circuit diagram and troubleshooting procedures for the electric starting system.

Troubleshooting guide for charging system issues, including battery, stator coil, and wiring checks.

Circuit diagram and troubleshooting for lighting issues like headlights, taillights, and indicators not working.

Circuit diagram and troubleshooting for signal system problems, including horn and flasher lights.

Circuit diagram and troubleshooting for cooling system issues like fan motor and temperature meter.

Information on TPS self-diagnosis and circuit diagram for troubleshooting.

Lists potential causes for starting failures related to fuel, electrical, and compression systems.

Identifies causes for poor idle speed performance related to carburetor and electrical systems.

Lists potential causes for poor performance at medium and high speeds.

Troubleshooting for issues like hard shifting, stuck shift pedals, and jump-out gears.

Diagnoses for clutch slipping or dragging due to cable adjustment, springs, or oil issues.

Identifies causes of engine overheating related to ignition, fuel, cooling, and brake systems.

Troubleshooting for poor braking effect, including worn pads, discs, and fluid issues.

Addresses oil leaks and malfunctions in the front fork assembly.

Lists causes for instable handling related to handlebars, steering, swingarm, tires, and wheels.

Troubleshooting for lighting and signal issues like dark headlights, non-blinking flashers, and inoperative horn.