Yamaha TDM850 User manual

OWNER'S MANUAL
TDM850
3VD-28199-El

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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.

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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.
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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.
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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

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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.

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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

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MOTORCYCLE
IDENTIFICATION
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Identification numbers record
1. KEY IDENTIFICATION NUMBER:
2. FRAME SERIAL NUMBER:
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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

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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.
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Engine serial number
The engine serial number is stamped into the
crankcase.