Yamaha TRX850H - User Manual

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Main Page

How to Use the Manual4
Illustrated Symbols5
Index6
General Information7
Motorcycle Identification8
Frame Serial Number8
Engine Serial Number8
Model Lebel8
Preparation for Removal9
Note on Gaskets, Oil Seals and O-Rings9
Note on Lock Washers/Plates and Cotter Pins10
Note on Bearings and Oil Seals10
Note on Circlips10
Checking of Connections11
How to Use the Conversion Table12
Special Tools13
Specifications16
Crankcase Tightening Sequence27
Tightening Torques30
General Torque Specifications33
Lubrication Point and Grade of Lubricant34
Lubrication Diagrams36
Cable Routing41
Periodic Inspection and Adjustment50
Periodic Maintenance/Lubrication Intervals52
Upper Cowling, Seat, Side Cover and Fuel Tank54
Air Filter Case56
Valve Clearance Adjustment57
Carburetor Synchronization64
Idling Speed Adjustment66
Throttle Cable Adjustment67
Spark Plug Inspection68
Ignition Timing Check69
Compression Pressure Measurement71
Engine Oil Level Inspection73
Engine Oil Replacement74
Clutch Adjustment76
Air Filter Cleaning76
Carburetor Joint Inspection77
Fuel Line Inspection78
Breather Hose Inspection78
Exhaust System Inspection79
Coolant Level Inspection79
Coolant Replacement80
Handling Notes for Coolant82
Cooling System Inspection83
Front Brake Adjustment84
Rear Brake Adjustment84
Brake Fluid Level Inspection86
Brake Pad Inspection87
Brake Light Switch Adjustment87
Brake Hose Inspectin88
Air Bleeding (Hydraulic Brake System)88
Drive Chain Slack Adjustment89
Drive Chain Lubrication91
Steering Head Inspection91
Front Fork Inspection93
Front Fork Adjustment94
Spring Preload94
Rear Shock Absorber Adjustment95
Rebound Damping95
Compression Damping96
Tire Inspection97
Wheel Inspection99
Cable Inspection and Lubrication99
Lever and Pedal Lubrication100
Sidestand and Rear Suspension Lubrication100
Battery Inspection101
Charging Method Using a Variable-Current (Voltage) Type Charger104
Charging Method Using a Constant-Voltage Type Charger105
Fuse Inspection106
Headlight Beam Adjustment108
Headlight Bulb Replacement108
Engine Overhaul110
Engine Assembly112
Drive Sprocket and Exhaust Pipe113
Camshaft116
Cylinder Head Cover116
Camshaft Removal118
Camshaft Inspection119
Camshaft Installation121
Cylinder Head123
Cylinder Head Inspection124
Cylinder Head Installation124
Valve and Valve Spring125
Valve and Valve Spring Removal126
Valve and Valve Spring Inspection127
Cylinder and Piston Removal133
Cylinder and Piston Inspection134
Cylinder and Piston Installation137
Clutch139
Crankcase Cover (Right) Removal139
Clutch Removal140
Clutch Inspection141
Clutch Installation142
Crankcase Cover (Left) Removal144
Shift Shaft Removal145
Shift Shaft Inspection146
Shift Shaft Installation146
AC Magneto and Starter Wheel Gear147
Stator Coil Removal147
AC Magneto and Starter Wheel Gear Removal148
AC Magneto and Starter Wheel Gear Inspection149
AC Magneto and Starter Wheel Gear Installation150
Oil Pump Cover and Oil Pump Driven Gears Removal151
Oil Pump Removal152
Oil Pump Inspection153
Oil Tank154
Oil Hose Removal154
Oil Tank Removal155
Oil Pan Removal156
Balancer Weight Removal157
Oil Pan Installation160
Crankshaft Assembly162
Crankshaft Removal162
Connecting Rod Removal163
Crankshaft Inspection165
Crankshaft Installation170
Transmission, Shift Cam and Shift Fork Removal173
Transmission, Shift Cam and Shift Fork Inspection175
Transmission, Shift Cam and Shift Fork Installation176
Cooling System178
Radiator Removal179
Radiator Inspection180
Radiator Installation181
Thermostatic Valve182
Thermostatic Assembly Removal182
Thermostatic Valve Housing Disassembly183
Thermostatic Valve Housing Inspection184
Thermostatic Valve Housing Assembly184
Water Pump Removal185
Water Pump Installation186
Carburetion187
Carburetor Assembly Removal188
Carburetor Disassembly189
Carburetor Assembly191
Fuel Level Adjustment192
TPS (Throttle Position Sensor) Adjustment and Inspection192
Chassis195
Front Wheel and Brake Discs Removal197
Front Wheel Disassembly198
Front Wheel Inspection199
Front Wheel Installation201
Static Wheel Balance Adjustment202
Rear Wheel Removal204
Brake Disc and Drive Sprocket Removal205
Rear Wheel Disassembly206
Rear Wheel Inspection207
Driven Sprocket Replacement Steps208
Front and Rear Brake209
Front Brake Pad Removal209
Rear Brake Pad Removal210
Front Brake Master Cylinder Removal214
Front Brake Master Cyinder Disassembly215
Rear Brake Master Cylinder Removal216
Rear Brake Master Cylinder Disconnection217
Master Cylinder Inspection218
Master Cylinder Assembly218
Front Brake219
Rear Brake220
Front Brake Caliper Removal222
Front Brake Caliper Disassembly223
Rear Brake Caliper Removal224
Rear Brake Caliper Disassembly225
Caliper Disassembly226
Caliper Inspection and Repair227
Caliper Assembly227
Caliper Installation228
Front Fork Removal229
Front Fork Disassembly230
Front Fork Assembly233
Front Fork Installation236
Left Handlebar Removal237
Right Handlebar Removal238
Right Handlebar Inspection239
Right Handlebar Installation239
Steering Head241
Lower Bracket Removal241
Lower Bracket Inspection243
Lower Bracket Installation244
Rear Shock Absorber and Relay Arm Removal245
Shock Absorber Disposal247
Swingarm and Drive Chain Removal248
Swingarm and Drive Chain Inspection250
Electrical252
Electrical Components Diagram253
Switch Inspection254
Switch Continuity Inspection255
Wiring Diagram258
Ignition System Troubleshooting259
Electric Starting System264
Starting Circuit Operation265
Electric Starting System Troubleshooting266
Starter Motor Removal and Disassembly270
Starter Motor Inspection and Repair271
Starter Motor Assembly272
Charging System Circuit Diagram274
Charging System Troubleshooting275
Lighting System Circuit Diagram278
Lighting System Troubleshooting279
Lighting System Check281
Signal System Circuit Diagram284
Signal System Troubleshooting286
Signal System Check287
Cooling System Circuit Diagram292
Cooling System Troubleshooting293
TPS (Throttle Position Sensor) Self Diagnosis297
Troubleshooting299
Starting Failure/Hard Starting301
Poor Idle Speed Performance302
Poor Medium and High Speed Performance302
Faulty Gear Shifting303
Clutch Slipping/Dragging303
Overheating304
Faulty Brake304
Front Fork Oil Leakage and Front Fork Malfunction304
Instable Handling305
Faulty Lighting and Signal System305

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Yamaha TRX850H Specifications

General

Brand	Yamaha
Model	TRX850H
Category	Motorcycle
Language	English

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Yamaha TRX850H - User Manual

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Yamaha TRX850H Specifications

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