Yamaha TDM850 User manual

OWNER'S MANUAL
TDM850
3VD-28199-El

cAAOOIW
TDM850
OWNER'S MANUAL
©1994 by Yamaha Motor Co., Ltd.
1st Edition, July 1994
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
INTRODUCTION
Congratulations on your purchase of the
Yamaha TDM850. This model is the result
of Yamaha's vast experience in the production
of fine sporting, touring, and pacesetting rac¬
ing machines. It represents the high degree of
craftsmanship and reliability that have made
Yamaha a leader in these fields.
This manual will give you an understanding of
the operation, inspection, and basic main¬
tenance of this motorcycle. If you have any
questions about the operation or maintenance
of your motorcycle, please consult a Yamaha
dealer.

EAAICHXI
Particularly important information is distin¬
guished in this manual by the following no¬
tations:
&
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS IN¬
VOLVED!
A WARNING
Failure to follow WARNING instructions could
result in severe injury or death to the motor¬
cycle operator, a bystander or a person inspect¬
ing or repairing the motorcycle.
CAUTION:
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.
OJJOOOOO
NOTE. _
This manual should be considered a permanent
part of this motorcycle and should remain with
it even if the motorcycle is subsequently sold.
HJUI3BOO
NOTE: _
Yamaha continually seeks advancements in
product design and quality. Therefore, while
this manual contains the most current product
information available at the time of printing,
there may be minor discrepancies between
your machine and this manual. If there is any
question concerning this manual, please con¬
sult your Yamaha dealer.
tujanoo
A WARNING
PLEASE READ THIS MANUAL CAREFUL¬
LY AND COMPLETELY BEFORE OPERAT¬
ING THIS MOTORCYCLE.

CONTENTS
~HINK OF YOUR SAFETY.1-1
DESCRIPTION.2-1
■ OTORCYCLE IDENTIFICATION .3-1
Identification numbers record.3-1
Frame serial number.3-2
Engine serial number.3-2
20NTR0L FUNCTIONS.4-1
Main switch.4-1
Indicator lights.4-2
Speedometer.4-2
Tachometer .4-3
Engine temperature gauge.4-3
Handlebar switches.4-4
Headlight beam variation.4-6
Clutch lever.4-7
Shift pedal.4-7
Front brake lever.4-8
Rear brake pedal.4-8
Fuel tank cap.4-8
Fuel cock.4-9
Starter knob (CHOKE).4-10
Steering lock. .4-10
Seat.4-11
Helmet holder.4-13
Side cowl/upper cowl.4-13
Front fork.4-14
Rear shock absorber.4-15
Sidestand.4-15
Sidestand/clutch switch
operation check.4-16
PRE-OPERATION CHECKS.5-1
Brakes.5-3
Brake fluid leakage.5-4
Clutch.5-4
Throttle grip.5-4
Engine oil.5-4
Coolant.5-5
Chain.5-6
Tires.5-6

Tubeless tires and cast wheels.5-9
Fittings/Fasteners.5-11
Lights and signals.5-11
Switches.5-11
Fuel.5-11
OPERATION AND IMPORTANT
RIDING POINTS.6-1
Starting the engine.6-2
Starting a warm engine.6-5
Shifting.6-5
Recommended shift point
{For Switzerland only).6-6
Engine break-in.6-6
Parking.6-7
PERIODIC MAINTENANCE AND
MINOR REPAIR.7-1
Tool kit.7-1
Periodic maintenance/lubrication.7-3
Torque specifications.7-5
Engine oil.7-6
Cooling system.7-10
Electric fan. 7-13
Air filter.7-14
Carburetor adjustment.7-16
Idle speed adjustment.7-16
Throttle cable adjustment.7-17
Valve clearance adjustment.7-18
Spark plug inspection.7-18
Front brake lever position
adjustment.7-20
Rear brake adjustment. .7-20
Brake light switch adjustment.7-21
Checking the front and rear
brake pads.7-21
Inspecting the brake fluid level.7-22
Brake fluid replacement.7-23
Clutch adjustment.7-24
Drive chain slack check.7-24
Drive chain slack adjustment .7-25
Drive chain lubrication...7-27
Cable inspection and lubrication.7-27
Throttle cable and grip lubrication .. .7-28
Brake and shift pedals.7-28
Brake and clutch levers.7-28

Sidestand.7-28
Rear suspension.7-28
Front fork inspection .7-29
Front fork adjustment.7-30
Rear shock absorber.7-31
Rear shock absorber adjustment-7-32
Recommended combinations of the
front fork and the rear shock
absorber settings.7-35
Steering inspection.7-36
Wheel bearings.7-36
Battery.7-36
Battery maintenance.7-37
Fuse replacement.7-38
Headlight bulb replacement.7-39
Taillight bulb replacement.7-40
Front wheel removal.7-41
Front wheel installation.7-43
Rear wheel removal .7-44
Rear wheel installation.7-45
Troubleshooting.7-46
Troubleshooting chart.7-47
CLEANING AND STORAGE.8-1
A. Cleaning.8-1
B. Storage.8-2
SPECIFICATIONS.9-1
HOW TO USE THE CONVERSION
TABLE...’..10-1
WIRING DIAGRAM

{UU'bbO’J
ATHINK OF YOUR SAFETY:
Both motorcycles and mopeds are fascinating vehicles which give a tremendous feeling
of freedom to their riders.
They must be correctly maintained at all times in order to ensure optimum performance.
However, as a rider you must also ensure that your physical condition is good, and that
you are not tired, in order that you too can optimize your vehicle control. Medicines,
drugs and alcohol should not be combined with riding, especially alcohol, which in¬
creases the individual's likelihood of taking risks.
Alcohol is dangerous, even in small quantities.
Correct protective riding gear is just as much a part of motorcycling safety as the safety
belt is in the car; a good leather suit and gloves, sturdy boots and a good quality,
properly fitting crash helmet are ideal. But beware: good protective clothing can result in
the individual being lulled into a false sense of security. When this happens more risks
are taken and speeds increase... this particularly applies in wet weather.
The good motorcyclist therefore rides defensively and protectively in order to minimize
risks.

£AA5C<X0
DESCRIPTION
1. Tai/Brake light 13.
Grab bar
2. Rear flasher light 14. Shift pedal
3. Seat 15. Radiator
4. Upper cowl 16. Clutch lever
5. Auxiliary light
17. Handlebar switches
6- Front flasher light 18. Speedometer
7. Side cowl 19. Tachometer
8. Engine guard 20.
Engine temperature gauge
9. Brake pedal 21.
Throttle grip
10. Headlight
22. Brake lever
11. Fuel tank
23. Main switch
12. Helmet holder

EAA6CCO)
MOTORCYCLE
IDENTIFICATION
EAAHca:'
Identification numbers record
1. KEY IDENTIFICATION NUMBER:
2. FRAME SERIAL NUMBER:
I
3. ENGINE SERIAL NUMBER:
Your key identification number is stamped on
your key as shown in the following illustration.
Record this number in the space provided for
reference if you need a new key.
Record your frame serial number and engine
serial number in the spaces provided to assist
you in ordering spare parts from your Yamaha
dealer or for reference in case your vehicle is
stolen.
3 1

-a. 46091X1
Frame serial number
The frame serial number is stamped into the
steering head pipe.
1. Engine serial number
NOTE: _
The first three digits of these numbers are for
model identification; the remaining digits are
the unit production number. Keep a record of
these numbers for reference when ordering
parts from a Yamaha dealer.
EAA7TOC1
Engine serial number
The engine serial number is stamped into the
crankcase.

EA0OOCCO
CONTROL FUNCTIONS
EASOQlfO
Main switch
The main switch controls the ignition and light
ing systems. Its operation is described below
LOCK
CAB0C6M
Electrical circuits are switched on. The engine
can be started. The key cannot be removed in
this position.
LASX60C
OFF:
Al electrical circuits are switched off. The key
he removed in this position.
EAB00M1
LOCK:
The steering is locked in this position, and all
electrical circuits are switched off. The key can
be removed in this position. Refer to “Steer¬
ing lock" (page 4-10) for operation instructions.
EAB01201
PARKING:
The steering is locked in this position, and the
taiilight and auxiliary light come on but all
other circuits are off. The key can be removed
in this position.
EUU0CP00
NOTE: -
Always turn the main switch to “OFF" or
"LOCK" and remove the key when the motor¬
cycle is unattended.

HAB12J00
“TURN" indicator light (green):
This indicator flashes when the turn switch is
"ON".
eABiOMi
"NEUTRAL" indicator light (green):
This indicator comes on when the transmission
is in neutral.
I 6AB1OM0
Indicator lights
4
fABWW)
"HIGH BEAM" indicator light (blue):
This indicator comes on when the headlight
high beam is used.
EAB40CQ2
Speedometer
The speedometer shows riding speed. This
speedometer is equipped with an odometer and
trip odometer. The trip odometer can be reset
to "0" with the reset knob.
Use the odometer to estimate how far you can
ride on a tank of fuel before going to
"RESERVE". This information will enable you
to plan fuel stops in the future.
4 Trip odometer

HAB43200
Tachometer
This model is equipped with an electric tachom¬
eter so the rider can monitor the engine speed
and keep it within the ideal power range.
1. Tachometer 2. Red zone
EUU3M00
Do not operate in the red zone.
Red zone: 8,000 r/min and above
lmbwh
Engine temperature gauge
This gauge indicates the coolant temperature
when the main switch is ON. The engine oper¬
ating temperature will vary with changes in
weather and engine load. If the needle points
to the red zone or higher, stop your motorcy¬
cle and let the engine cool. (See page 7-10 for
details.)

t'JU3C600
When the engine is overheated, do not
continue riding.
CAB0X*
Handlebar switches:
•'LIGHTS' switch
PASS" switch
LIGHTS* (Dimmer) switch
'TURN" signal switch
HORN" switch
FNGINE STOP" switch
START" switch
EA3532>X
“PASS" switch
Press the switch to operate the passing light,
light switch should be depressed so that the
headlight gives a signal to the driver of the
other vehicle.
EAS6DKC
"LIGHTS" (Dimmer) switch
Turn the switch to "HI" for the high beam and
to "LO" for the low beam.
EAB62131
'TURN" signal switch
To signal a right-hand turn push the switch to
the right; to signal a left-hand turn push the
switch to the left. Once the switch is released
it will return to the center position. To cancel
the signal push the switch in after it has
returned to the center position.

EABQD20C
"HORN" switch
Press the switch to sound the horn.
EAB6'201
"LIGHTS" switch
Turning the light switch to "PO” turns on the
auxiliary light, taillight, and meter lights. Turn¬
ing to "ON", turns the headlight on also.

« : LIGHT "ON”
o : LIGHT "OFF'
Bulb to be used
Germany Belgium
Switzerland Portugal
Norway Greece
Denmark
Left Right
Finland
Netherlands
Austria
adlight beam variation
OTE:__
ight and left directions are those assumed from the position of a person facing the front of the
otorcycle.
46

EARfiGMI
"ENGINE STOP" switch
The engine stop switch is a safety device for
use in an emergency such as when the motor¬
cycle overturns or if trouble occurs in the throt¬
tle system. Turn the switch to "RUN" to start
the engine. In case of emergency, turn the
switch to "OFF" to stop the engine.
EAR83701
"START" switch
The starter motor cranks the engine when
pushing the starter switch.
RIII33700
See starting instructions prior to starting
the engine.
EABrtOOl
Clutch lever
The clutch lever is located on the left handle¬
bar, and the starting circuit cutoff switch is in¬
corporated in the clutch lever holder. Pull the
clutch lever to the handlebar to disengage the
clutch, and release the lever to engage the
clutch. The lever should be pulled rapidly and
released slowly for smooth clutch operation.
(Refer to the engine starting procedures for a
description of the starting circuit cutoff switch.)
EABOTOJ
Shift pedal
This motorcycle is equipped with a constant-
mesh 5-speed transmission. The shift pedal is
located on the left side of the engine and is
used in combination with the clutch when
shifting.

EA890*01
CAD90JOI
Front brake lever
The front brake lever is located on the right
handlebar. Pull it toward the handlebar to ac¬
tivate the front brake. The front brake lever is
equipped with a lever position adjuster.
Refer to page 7-20 for adjustment.
Rear brake pedal
The rear brake pedal is on the right side of the
motorcycle. Press down on the brake pedal to
apply the rear brake.
EAOX&OI
Fuel tank cap
TO OPEN:
Open the key cover. Insert the key and turn it
1/4 turn clockwise. The lock will be released
and the cap can be opened.
1. Open
4-8

TO CLOSE:
Push the tank cap into position with the key
inserted. To remove the key, turn it counter¬
clockwise to the original position. Then, close
the key cover.
EUJJ01200
NOTE: ---
This tank cap cannot be closed unless the key
is in the lock. The key cannot be removed if
the cap is not locked properly.
EUU61KO
___
Be sure the cap is properly installed and
locked in place before riding the
motorcycle.
fcAClOW
Fuel cock
The fuel cock supplies fuel from the tank to the
carburetor(s) while filtering it also. The fuel
cock has three positions:
OFF: With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.
ON: With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
49

RES: This indicates reserve. If you run out of
fuel while riding, move the lever to this
position. FILL THE TANK AT THE
FIRST OPPORTUNITY. BE SURE TO
SET THE LEVER TO "ON" AFTER
REFUELLING.
-AC20W
Starter knob (CHOKE)
Starting a cold engine requires a richer air-fuel
mixture. A separate starter circuit supplies this
mixture. Pull the starter knob out to open the
circuit for starting. When the engine has
warmed up, push the knob in to close the cir¬
cuit.
EAC3»K
Steering lock
The steering is locked when the main switch
is turned to "LOCK." To lock the steering, turn
the handlebars all the way to the left. While
pushing the key into the main switch, turn it
from "OFF” to "LOCK" and remove it. To re¬
lease the lock, turn the key to "OFF" while
pushing.
4 10