Yamaha TDM850 User Manual

o.8 Safety first!
Professional mechanics are trained in safe
working procedures. However enthusiastic you
may be about getting on with the job at hand,
take the time to ensure that your safety is not put
at risk. A moment's lack of attention can result in
an accident, as can failure to observe simple
precautions.
There will always be new ways of having
accidents, and the following is not a
comprehensive list of all dangers; it is intended
rather to make you aware of the risks and to
encourage a safe approach to all work you carry
out on your bike.
Asbestos
• Certain friction, insulating, sealing and
other products - such as brake pads, clutch
linings, gaskets, etc. - contain asbestos.
Extreme care must be taken to avoid
inhalation of dust from such products since it
is hazardous to health. If in doubt, assume
that they do contain asbestos.
Fire
• Remember at all times that petrol is highly
flammable. Never smoke or have any kind of
naked flame around, when working on the
vehicle. But the risk does not end there - a
spark caused by an electrical short-circuit, by
two metal surfaces contacting each other, by
careless use of tools, or even by static
electricity built up in your body under certain
conditions, can ignite petrol vapour, which in
a confined space is highly explosive. Never
use petrol as a cleaning solvent. Use an
approved safety solvent.
• Always disconnect the battery earth terminal
before working on any part of the fuel or electrical
system, and never risk spilling fuel on to a hot
engine or exhaust.
• It is recommended that a fire extinguisher of
a type suitable for fuel and electrical fires is kept
handy in the garage or workplace at all times.
Never try to extinguish a fuel or electrical fire with
water.
Fumes
• Certain fumes are highly toxic and can
quickly cause unconsciousness and even death if
inhaled to any extent. Petrol vapour comes into
this category, as do the vapours from certain
solvents such as trichloro-ethylene. Any draining
or pouring of such volatile fluids should be done
in a well ventilated area.
• When using cleaning fluids and solvents,
read the instructions carefully. Never use
materials from unmarked containers - they may
give off poisonous vapours.
• Never run the engine of a motor vehicle in an
enclosed space such as a garage. Exhaust
fumes contain carbon monoxide which is
extremely poisonous; if you need to run the
engine, always do so in the open air or at least
have the rear of the vehicle outside the
workplace.
The battery
• Never cause a spark, or allow a naked
light near the vehicle's battery. It will normally
be giving off a certain amount of hydrogen
gas, which is highly explosive.
• Always disconnect the battery ground (earth)
terminal before working on the fuel or electrical
systems (except where noted).
• If possible, loosen the filler plugs or cover
when charging the battery from an external
source. Do not charge at an excessive rate or the
battery may burst.
• Take care when topping up, cleaning or
carrying the battery. The acid electrolyte,
evenwhen diluted, is very corrosive and should
not be allowed to contact the eyes or skin.
Always wear rubber gloves and goggles or a face
shield. If you ever need to prepare electrolyte
yourself, always add the acid slowly to the water;
never add the water to the acid.
Electricity
• When using an electric power tool, inspection
light etc., always ensure that the appliance is
correctly connected to its plug and that, where
necessary, it is properly grounded (earthed). Do
not use such appliances 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 electric shock can result from
touching certain parts of the electrical system,
such as the spark plug wires (HT leads), when
the engine is running or being cranked,
particularly if components are damp or the
insulation is defective. Where an electronic
ignition system is used, the secondary (HT)
voltage is much higher and could prove fatal.
Remember...
.X Don't start the engine without first ascer-
taining that the transmission is in neutral. X
Don't suddenly remove the pressure cap from
a hot cooling system - cover it with a cloth and
release the pressure gradually first, or you may
get scalded by escaping coolant. X Don't
attempt to drain oil until you are sure it has
cooled sufficiently to avoid scalding you.
X Don't grasp any part of the engine or
exhaust system without first ascertaining that it
is cool enough not to burn you. X Don't allow
brake fluid or antifreeze to contact the
machine's paintwork or plastic components.
X Don't siphon toxic liquids such as fuel,
hydraulic fluid or antifreeze by mouth, or allow
them to remain on your skin. X Dont inhale
dust - it may be injurious to health (see
Asbestos heading). X Dont allow any spilled oil
or grease to remain on the floor - wipe it up
right away, before someone slips on it. X Don't
use ill-fitting spanners or other tools which may
slip and cause injury. X Dont lift a heavy
component which may be beyond your
capability - get assistance.
X Don't rush to finish a job or take
unverified short cuts.
X Don't allow children or animals in or
around an unattended vehicle.
X Don't inflate a tyre above the
recommended pressure. Apart from
overstressing the carcass, in extreme cases
the tyre may blow off forcibly.
• Do ensure that the machine is supported
securely at all times. This is especially
important when the machine is blocked up
to aid wheel or fork removal.
</ Do take care when attempting to loosen a
stubborn nut or bolt. It is generally better to pull
on a spanner, rather than push, so that if you
slip, you fall away from the machine rather
than onto it.
• Do wear eye protection when using power
tools such as drill, sander, bench grinder etc.
• Do use a barrier cream on your hands prior
to undertaking dirty jobs - it will protect your
skin from infection as well as making the dirt
easier to remove afterwards; but make sure
your hands aren't left slippery. Note that long-
term contact with used engine oil can be a
health hazard.
• Do keep loose clothing (cuffs, ties etc. and
long hair) well out of the way of moving
mechanical parts.
• Do remove rings, wristwatch etc., before
working on the vehicle - especially the
electrical system.
• Do keep your work area tidy - it is only too
easy to fall over articles left lying around.
• Do exercise caution when compressing
springs for removal or installation. Ensure that
the tension is applied and released in a
controlled manner, using suitable tools which
preclude the possibility of the spring escaping
violently.
• Do ensure that any lifting tackle used has a
safe working load rating adequate for the job.
• Do get someone to check periodically that
all is well, when working alone on the vehicle.
• Do carry out work in a logical sequence and
check that everything is correctly assembled
and tightened afterwards.
• Do remember that your vehicle's safety
affects that of yourself and others. If in doubt
on any point, get professional advice. • If in
spite of following these precautions, you are
unfortunate enough to injure yourself, seek
medical attention as soon as possible.
Scaned by Stalker

Yamaha TDM850 Specifications

General

Displacement	849 cc
Bore x Stroke	89.5 mm x 67.5 mm
Compression Ratio	10.5:1
Fuel System	Carburetor
Transmission	5-speed
Final Drive	Chain
Front Suspension	Telescopic fork
Rear Suspension	Monoshock
Front Brake	Dual disc
Rear Brake	Single disc
Rear Tire	150/70-17
Fuel Capacity	20 liters
Seat Height	825 mm
Length	2, 180 mm
Width	800 mm
Wheelbase	1, 475 mm
Engine Type	4-stroke, DOHC, parallel twin
Ignition	Digital

Summary

Safety First!

Asbestos Precautions

Extreme care must be taken to avoid inhalation of dust from asbestos-containing products.

Fire Safety Precautions

Never smoke or use naked flames around petrol; be aware of spark risks.

Fumes Safety

Information on toxic fumes from petrol and solvents; ensure good ventilation.

Battery Safety

Precautions regarding hydrogen gas from batteries, acid handling, and charging.

Electrical Safety

Ensure correct connection and grounding of electrical appliances; beware of sparks near fuel.

Identification Numbers

Frame and Engine Numbers

Locating and recording frame and engine serial numbers for theft reporting.

Buying Spare Parts

Importance of providing ID numbers for purchasing correct motorcycle parts.

Daily (Pre-Ride) Checks

Engine/Transmission Oil Level Check

Procedure for checking and topping up engine and transmission oil.

Brake Fluid Level Checks

Instructions for checking front and rear brake fluid levels.

Coolant Level Check

Procedure for checking and topping up the coolant level in the reservoir.

Tyre Checks

Guidance on checking tyre pressures, tread depth, and condition.

Routine Maintenance Schedule

Daily (Pre-ride) Checks

List of essential checks to perform before riding the motorcycle.

After Initial 600 Miles (1000 km)

Maintenance usually performed by a dealer after the first 600 miles.

Every 300 Miles (500 km)

Maintenance tasks recommended every 300 miles or 500 km.

Every 4000 Miles (6000 km) or 6 Months

Maintenance tasks recommended every 4000 miles or 6 months.

Every 8000 Miles (12,000 km) or 12 Months

Maintenance tasks recommended every 8000 miles or 12 months.

Every 16,000 Miles (24,000 km) or Two Years

Maintenance tasks recommended every 16,000 miles or two years.

Every 28,000 Miles (42,000 km)

Maintenance tasks recommended every 28,000 miles or 42,000 km.

Every Four Years

Maintenance tasks recommended every four years.

Non-scheduled Maintenance

Specific checks and tasks not tied to regular intervals.

Engine, Clutch, and Transmission

General Information

Overview of the engine, clutch, and transmission systems.

Camshafts and Valves

Details on camshafts, cylinder head, valves, guides, and springs.

Pistons and Rings

Information on piston dimensions, ring specifications, and clearances.

Clutch Assembly

Specifications and procedures for clutch plates, springs, and assembly.

Oil Pumps

Details on oil pumps, including removal, inspection, and installation.

Engine Removal and Installation

Procedures for removing and installing the engine from the frame.

Valve Cover Removal and Installation

Step-by-step guide for removing and installing the valve cover.

Camshafts and Followers Removal, Inspection, and Installation

Procedures for removing, inspecting, and installing camshafts and followers.

Crankcase Halves Separation and Reassembly

Detailed steps for separating and reassembling the crankcase halves.

Transmission Shafts Disassembly, Inspection and Reassembly

Procedures for disassembling, inspecting, and reassembling transmission shafts.

Cooling System

General Information and Precautions

Overview of the cooling system and essential safety warnings.

Radiator Pressure Cap Check

Procedure for checking the radiator cap's opening pressure.

Coolant Reservoir Removal and Installation

Steps for removing and installing the coolant reservoir.

Cooling Fan and Fan Switch Check

Procedure for checking and renewing the cooling fan and its switch.

Coolant Temperature Gauge and Sender Check

Checking and renewing the coolant temperature gauge and sender unit.

Thermostat Housing and Thermostat Check

Procedure for checking and renewing the thermostat and its housing.

Radiator Removal and Installation

Steps for removing and installing the radiator.

Water Pump Check, Removal, and Installation

Procedure for checking, removing, and installing the water pump.

Coolant Hoses Removal and Installation

Instructions for removing and installing coolant hoses.

Fuel and Exhaust Systems

General Information and Precautions

Overview of the fuel system and essential safety warnings.

Fuel Tank and Fuel Tap Removal and Installation

Procedures for removing and installing the fuel tank and fuel tap.

Air Filter Housing Removal and Installation

Steps for removing and installing the air filter housing.

Carburettor Overhaul - General Information

Information on common carburettor problems and when overhaul is needed.

Carburettors Removal and Installation

Procedures for removing and installing the carburettors.

Ignition System

General Information

Overview of the electronic ignition system components and function.

Ignition System Check

Procedure for checking the ignition system for faults.

Ignition HT Coils Check, Removal and Installation

Checking, removing, and installing the ignition HT coils.

Pick-up Coil Check and Replacement

Procedure for checking and replacing the pick-up coil.

Ignitor Unit Check, Removal and Installation

Checking, removing, and installing the ignitor unit.

Ignition Timing General Information and Check

Information on ignition timing and how to check it.

Throttle Position Sensor Check, Adjustment and Replacement

Checking, adjusting, and replacing the throttle position sensor.

Frame, Suspension, and Final Drive

Front Forks Specifications

Specifications for front fork oil type, capacity, level, and spring length.

Rear Suspension Specifications

Specifications for rear shock absorber spring length and swingarm dimensions.

General Frame Information

Overview of frame construction and inspection for damage.

Footrests, Brake Pedal, and Gearchange Lever Removal and Installation

Procedures for removing and installing footrests, brake pedal, and gearchange lever.

Sidestand Removal and Installation

Steps for removing and installing the sidestand.

Handlebars and Levers Removal and Installation

Procedures for removing and installing handlebars and levers.

Forks Disassembly, Inspection, and Reassembly

Detailed steps for disassembling, inspecting, and reassembling front forks.

Steering Stem Removal and Installation

Procedures for removing and installing the steering stem.

Steering Head Bearings Inspection and Replacement

Checking and replacing steering head bearings.

Rear Shock Absorber Removal, Inspection, and Installation

Steps for removing, inspecting, and installing the rear shock absorber.

Rear Suspension Linkage Removal, Inspection and Installation

Procedures for removing, inspecting, and installing the rear suspension linkage.

Suspension Adjustments

Information on adjusting front fork spring pre-load and damping.

Swingarm Removal and Installation

Steps for removing and installing the swingarm.

Drive Chain Removal, Cleaning and Installation

Procedures for removing, cleaning, and installing the drive chain.

Sprockets Check and Replacement

Checking and replacing front and rear sprockets.

Brakes, Wheels, and Tyres

Brake System Checks

General checks for the brake system's condition and operation.

Brake Pads Replacement

Procedure for replacing worn brake pads.

Brake Discs Inspection, Removal and Installation

Checking, removing, and installing brake discs.

Front Brake Master Cylinder Removal, Overhaul and Installation

Procedures for removing, overhauling, and installing the front brake master cylinder.

Brake Calipers Removal, Overhaul and Installation

Steps for removing, overhauling, and installing brake calipers.

Brake System Bleeding

Procedure for bleeding air from the hydraulic brake system.

Wheels Inspection and Repair

General inspection of wheels and procedures for repair.

Front Wheel Bearings

Procedures for removing, inspecting, and installing front wheel bearings.

Rear Wheel Bearings

Procedures for removing, inspecting, and installing rear wheel bearings.

Sprocket Coupling Bearing

Checking and replacing the sprocket coupling bearing.

Tyres - General Information and Fitting

Information on tyre types, fitting, and maintenance.

Bodywork

General Information

Overview of bodywork parts and removal/installation precautions.

Seat Removal and Installation

Steps for removing and installing the rider and passenger seats.

Side Covers Removal and Installation

Procedures for removing and installing side covers.

Fairing Removal and Installation

Steps for removing and installing the fairing assembly.

Front Mudguard Removal and Installation

Procedures for removing and installing the front mudguard.

Electrical System

General Information

Overview of the motorcycle's 12-volt electrical system.

Electrical System Fault Finding

Guidance on troubleshooting electrical system problems.

Battery Removal, Installation, Inspection and Maintenance

Procedures for battery maintenance, checks, and replacement.

Fuses Check and Renewal

Procedure for checking and replacing fuses.

Lighting System Check

Checking the operation of headlights, tail lights, and turn signals.

Headlight Bulb and Auxiliary Light Bulb Renewal

Steps for replacing headlight and auxiliary light bulbs.

Headlight Assembly Removal and Installation

Procedures for removing and installing the headlight assembly.

Brake/tail Light Bulb Renewal

Procedure for renewing brake and tail light bulbs.

Turn Signal Circuit Check

Checking the turn signal circuit for faults.

Ignition (main) Switch Check, Removal and Installation

Checking, removing, and installing the ignition switch.

Handlebar Switches Check

Procedure for checking handlebar switches for continuity.

Handlebar Switches Removal and Installation

Steps for removing and installing handlebar switches.

Neutral Switch Check, Removal and Installation

Procedures for checking, removing, and installing the neutral switch.

Sidestand Switch Check and Replacement

Checking and replacing the sidestand switch.

Clutch Switch Check and Replacement

Checking and replacing the clutch switch.

Diode (XTZ models) Check and Replacement

Checking and replacing the diode unit on XTZ models.

Starter Circuit Cut-off Relay Check and Replacement

Checking and replacing the starter circuit cut-off relay.

Horn Check and Replacement

Procedure for checking and replacing the horn.

Starter Relay Check and Replacement

Checking and replacing the starter relay.

Starter Motor Removal and Installation

Steps for removing and installing the starter motor.

Starter Motor Disassembly, Inspection and Reassembly

Procedures for disassembling, inspecting, and reassembling the starter motor.

Charging System Testing - General Information and Precautions

Information and precautions for testing the charging system.

Charging System - Leakage and Output Test

Tests for charging system leakage and output.

Alternator Check, Removal and Installation

Checking, removing, and installing the alternator.