Yamaha TDM850 1996 User manual

EB000000
TDM850 ’96
SERVICE MANUAL
1996 by Yamaha Motor Co., Ltd.
First edition, March 1996
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.

WARNING
CAUTION:
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 as-
sumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles have a
basicunderstandingofthemechanicalconceptsandproceduresinherentinmotorcyclerepairtechnology.
Withoutsuchknowledge,attemptedrepairsorservicetothismodelmayrenderifunfittouseand/orunsafe.
YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveallmodelsmanufacturedbyYamaha.Modifi-
cationsand significant changes in specificationsor procedures will be forwardedto 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!
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.
NOTE: A NOTE provides key information to make procedures easier or clearer.

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EB002000 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.
2ndtitle 2 :Thistitleindicatesthesectionofthechapterandonlyappearsonthefirstpageofeachsection.
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
Tohelp identify parts and clarify procedure steps, there are exploded diagramsatthestartofeachremoval
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. Anexplanationofjobsandnotesispresentedinaneasy-to-readwaybytheuseofsymbolmarks 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. Forjobs requiringmoreinformation,thestep-by-step formatsupplements 8 aregiveninaddition tothe
exploded diagram and the job instruction chart.

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24 25
2321
19 2018
16 1715
1413
11 12
10
GEN
INFO SPEC
ENG
CARB
ELECCHAS
COOL
INSP
ADJ
TRBL
SHTG
EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 9 are printed on top
rightofeachpageandindicatethesubjectofeach
chapter.
1General information
2Specifications
3Periodic inspections and adjustments
4Engine
5Cooling system
6Carburetion
7Chassis
8Electrical
9Troubleshooting
Illustrated symbols 10 to 17 are used to identify
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 Ω, V, A
Illustrated symbols 18 to 23 in the exploded dia-
gramsindicatethetypes of lubricants and lubrica-
tion points.
18 Apply engine oil
19 Apply gear oil
20 Apply molybdenum disulfide oil
21 Apply wheel bearing grease
22 Apply lightweight lithium soap base grease
23 Apply molybdenum disulfide grease
Illustrated symbols 24 to 25 in the exploded dia-
grams indicate where to apply a locking agent 24
and when to install new parts 25 .
24 Apply locking agent (LOCTITE)
25 Replace

GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENT
ENGINE OVERHAUL
COOLING SYSTEM
CARBURETION
CHASSIS
ELECTRICAL
TROUBLESHOOTING
GEN
INFO 1
SPEC 2
3
ENG 4
COOL 5
CARB 6
CHAS 7
ELEC 8
TRBL
SHTG 9
INSP
ADJ
INDEX

GEN
INFO
1

GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRAME SERIAL NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SERIAL NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODEL LABEL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALL REPLACEMENT PARTS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS, AND O-RINGS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS/PLATES AND COTTER PINS 1-3. . . . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING OF CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOW TO USE THE CONVERSION TABLE 1-5. . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .