Yamaha TDM850 (2000) manual

PRINTED IN JAPAN 2000 · 9 - 0.4 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . 4TX-28199-E5 OWNER’S MANUAL TDM850[...]

H_5KS_Toc0.fm Page 2 Monday, August 21, 2000 11:11 AM[...]

EAU03338 INTRODUCTION W elcome to the Y amaha world of motorcycling! As the owner of a TDM850, y ou are benefiting from Y amaha’ s vast e x perience and new est technolog y regarding the design and manuf acture of high-quality products, which hav e ear ned Y amaha a reputation f or dependability . Please tak e the time to read this manual thoroug[...]

EAU00005 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! W ARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a pers[...]

IMPORTANT MANUAL INFORMATION EW000002 W ARNING @ PLEASE READ THIS MANUAL CAREFUL LY AND COMPLETELY BE FORE OPERATING THIS MOTORCYCLE. @ E_4tx.book Page 2 Wednesday, October 4, 200 0 4:28 PM[...]

IMPORTANT MANUAL INFORMATION EAU03337 TDM850 OWNER’S MANUAL © 2000 by Yamaha Motor Co., Ltd. 1st Edition, August 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan. E_4tx.book Page 3 Wednesday, October 4, 200 0 4:28 PM[...]

TABLE OF CONTENTS 1 GIVE SAFETY THE RIGHT OF W A Y 1 2 DESCRIPTION 2 3 INSTR UMENT AND CONTROL FUNCTIONS 3 4 PRE-OPERA TION CHECKS 4 5 OPERA TION AND IMPORT ANT RIDING P OINTS 5 6 PERIODIC MAINTENANCE AND MINOR REP AIR 6 7 MO T ORCYCLE CARE AND ST ORA GE 7 8 SPECIFICA TIONS 8 9 CONSUMER I NFORMA TION 9 INDEX EAU00009 E_4tx.book Page 1 Wednesday, Oc[...]

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GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF W A Y .................. ................ .............. 1-1 E_4tx.book Page 1 Wednesday, October 4, 200 0 4:28 PM[...]

1 1-1 EAU00021 1 - GIVE SAFETY THE RIGHT OF WAY Motorcycles are fascinating vehicles, which can give you an u nsurpassed feeling of powe r and freedom. Howeve r, they also impose cert ain limits, which you must accept; even th e best motorcycle does not ignore the laws of physics. Regular care and maintenance are essent ial for preserving value and[...]

DESCRIPTION 2 Left view ............... ................ ............. ................ ................ ................ . 2-1 Right view ................... ................ ................ ................. ............ ........... 2-2 Controls and instrumen ts .. ................ ................ ................ ................ . 2-3 E_4tx.b[...]

2-1 2 EAU00026 2 - DESCRIPTION Left view 1. Coolant reservoir (page 6-12) 2. Helmet holder (page 3-11) 3. Seat lock (page 3-11) 4. Shock absorber assembly spring preload adjusting nut (fine adjustment) (page 3-15) 5. Shock absorber assembly damping force adjusting dial (page 3-16) E_4tx.book Page 1 Wednesday, October 4, 200 0 4:28 PM[...]

DESCRIPTION 2-2 2 Right view 6. Luggage strap holders (page 3-17) 7. Shock absorber assembly spring preload adjusting lever (coarse adjustment) (page 3-15) 8. Fuses (page 6-35) 9. Engine oil level check window (page 6-9) 10. Front fork spring preload adjusting bolt (page 3-13) 11. Front fork damping force adjust ing screw (page 3-14) E_4tx.book Pag[...]

DESCRIPTION 2-3 2 Controls and instruments 1. Clutch lever (page 3-7) 2. Left handlebar switches (page 3-5) 3. Starter (choke) lever (page 3-10) 4. Speedometer unit (page 3-3) 5. Main switch/steering lock (page 3-1) 6. Tachometer (page 3-4) 7. Fuel gauge (page 3-5) 8. Right handlebar switches (page 3-6) 9. Throttle grip (page 6-19) 10. Brake lever [...]

3 INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lo ck ..... ................ ................ 3-1 Indicator a nd warnin g lights ............. ................ ... 3-2 Speedometer unit ................ ................ ................ 3-3 T achometer .... ................ ................ ................ ...... 3-4 Self-diagnos is de vice[...]

3-1 3 EAU00027 3 - INSTRUMENT AND CONTROL FUNCTIONS EAU00029 Main switch/steering lock The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU00036 ON All electrical systems are supplied with power, and the engine can be started. The key cannot be rem[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-2 3 EAU01590 (Parking) The steering is locked, and the taillight and auxiliary light are on, but all other electrical systems are off. The key can be removed. The steering must be locked befor e the key can be turned to “ ”. ECA00043 CAUTION: _ Do not use the parking position for an extended length of time, ot[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-3 3 EAU03680 Fuel level warning light “ ” This warning light comes on when the fuel level drops below approximately 3.1 L. When this occurs, refuel as soon as possible. The electrical circuit of the warning light can be checked according to the fol- lowing procedure. 1. Set the engine stop switch to “ ” an[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-4 3 To set the clock 1. Push both the “SELECT” and “RESET” buttons for at least two seconds. 2. When the hour digits st art flashing, push the “RESET” button to set the hours. 3. Push the “SELECT” button to change the minutes. 4. When the minute digits start flash- ing, push the “RESET” button [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-5 3 EAU00109 Anti-theft alarm (optional) This motorcycle can be equipped with an optional anti-theft alarm by a Yamaha dealer. Contact a Yamaha dealer for more information. EAU00110 Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank. The needle moves towards “E” (Empty) as t he fuel level [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-6 3 EAU00127 Turn signal switch To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the cen- ter position. To cancel the turn signal lights, push the switch in after it has re- turned to the center position. EAU0012[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-7 3 EAU00152 Clutch lever The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward t he handle- bar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation. The clutch lever is equipped with a cl[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-8 3 The brake lever is equipped with a po- sition adjusting nut. To adjust the dis- tance between the brake lever and the handlebar grip, turn the adju sting nut while holding the lever pushed away from the handlebar grip. Make sure that the mark “ ” on th e adjusting nut is aligned with the mark “ ” on th[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-9 3 EAU02935 Fuel tank cap To open the fuel tank cap Open the fuel tank cap lock cover, in- sert the key into the lock, and then turn it 1/4 turn clockwise. The lock will be re- leased and the fuel tank cap can be opened. To close the fuel tank cap 1. Push the fuel tank cap into posi- tion with the key inserted in[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-10 3 EAU00186 CAUTION: _ ● Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate paint- ed surfaces or plastic parts. ● For Germany only: Whenever replacement is necessary, use a fuel tank cap of the same spe- cial design as the original. _ EAU00191 NO TE: _ If knocking (o[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-11 3 EAU01726 Seat To remove the seat 1. Insert the key into the seat lock, and then turn it clockwise. 2. Pull the seat off. To install the seat 1. Insert the projections on the front of the seat into the seat holders as shown. 2. Push the rear of the seat down to lock it in place. 3. Remove the key. NO TE: @ Mak[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-12 3 EW000030 W ARNING @ Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident. @ To release the helmet from the hel - met holder Remove the seat, remove the helmet from the helmet holder, and then install the seat. EAU01688 Stora[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-13 3 EAU01728 Adjusting the front fork The front fork is equipped with spring preload adjusting bolts and damping force adjusting screws. EW000035 W ARNING @ Always adjust both fork legs equal- ly, otherwise poor handling and loss of stability may result. @ Spring preload To increase the spring preload and thereby[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-14 3 Damping force To increase the damping force and thereby harden the damping, turn the adjusting screw on each fork leg in di- rection a . To decrease the damping force and thereby soften the damping, turn the adjusting screw on each fork leg in direction b . CI-02E EC000015 CAUTION: @ Never attempt to turn an [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-15 3 EAU03834 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust- ing lever and adjusting nut and a damp- ing force adjusting dial. EC000015 CAUTION: _ Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. _ Spring preload Coar[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-16 3 NO TE: _ The spring preload setting is deter - mined by measuring distance A, shown in the illustration. The shor ter distance A is, the lower the spring preload; the longer distance A is, the higher the spring preload. _ 3. Tighten the locknut to the speci- fied torque. EC000018 CAUTION: _ Always tighten the[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-17 3 EAU00315 W ARNING @ This shock absorber contains high- ly pressurized nitrogen gas. For proper handling, read and under- stand the following information be- fore handling the shock absorber. The manufacturer cannot be held re- sponsible for property damage or personal injury that may result from improper hand[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-18 3 EW000044 W ARNING @ The motorcycle must not be ridden with the sidestand down, or if the sidestand cannot be properly moved up (or does not stay up), oth- erwise the sidestand could contact the ground and distract the opera- tor, resulting in a possible loss of control. Yamaha’s ignition circuit cut-off sys[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-19 3 CD-01E With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to “ ”. 3. Turn the key to “ON”. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycl e sho[...]

PRE-OPERATION CHECKS 4 Pre-operation check list ................. ................ ................ ................ .... 4-1 E_4tx.book Page 1 Wednesday, October 4, 200 0 4:28 PM[...]

4-1 4 EAU01114 4 - PRE-OPERATION CHECKS The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for e xample, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Th[...]

PRE-OPERATION CHECKS 4-2 4 NO TE: _ Pre-operation checks should be made each time the mot orcycle is used. Such an inspection can be accomplished in a very short time; and the added saf ety it assures is more than wort h the time involved. _ EWA00033 W ARNING _ If any item in the Pre-operation check list is not working properly, have it inspected a[...]

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OPERATION AND IMPORTANT RIDING POINTS 5 Star t ing a cold e ngine ......... ................ ................ ............. ................ . 5 -1 Star t ing a war m engine ............................. ................. ................ ....... 5-2 Shifting ...... ................ ............. ................ ................ ................ .[...]

5-1 5 EAU00372 5 - OPERATION AND IMPORTANT RIDING POINTS EAU00373 W ARNING @ ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer re- garding any control or function that you do not thoroughly un- derstand. ● Never start the engine or oper- ate it in a closed area for any length of [...]

OPERATION AND IMPORTANT RIDING POINTS 5-2 5 NO TE: _ If the engine fails t o start, release the start switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to pre- serve the battery. Do not crank the en- gine more than 10 seconds on any one attempt. _ ECA00022 CAUTION: _ ● The coolant temperature war[...]

OPERATION AND IMPORTANT RIDING POINTS 5-3 5 EAU00423 Shifting Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the il- lustration. NO TE: @ To shift the transmission into the neu- tral position, press the shift pedal down repeatedly until it rea[...]

OPERATION AND IMPORTANT RIDING POINTS 5-4 5 EAU00424 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style. Consider th e following tips to reduce fuel consumption: ● Thoroughly warm up the engine. ● Turn the starter (choke) off as soon as possible. ● Shift up swiftly, and avoid high e n- gine speeds during [...]

OPERATION AND IMPORTANT RIDING POINTS 5-5 5 EC000052* CAUTION: @ After 1,000 km of operation, the en- gine oil must be changed and the oil filter element replaced. @ 1,000 km and beyond The vehicle can now be operated nor- mally. EC000053 CAUTION: @ ● Keep the engine speed out of the tachometer red zone. ● If any engine trouble should oc- cur d[...]

6 PERIODIC MAINTENANCE AND MINOR REPAIR Owner’ s too l kit .............. ................ ................ ...... 6-1 P er iodic maintenance and lub rication char t ........ . 6-2 Removing and installing co wlings and panels ..... 6-5 Checking the spar k plugs .... ................ ................ 6-7 Engine oil and oil filter elem ent ........[...]

6-1 6 EAU00462 6 - PERIODIC MAINTENANCE AND MINOR REPAIR EAU00464 Safety is an obligation of t he owner. Periodic inspection, adjustment and lu- brication will keep your vehicle in the safest and most efficient condition pos- sible. The most important points of in- spection, adjustment, and lubrication are explained on the following pages. The inte[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-2 6 EAU03685 Periodic maintenance and lubrication chart NO TE: _ ● The annual chec ks must be perf ormed every year , except if a kilometer-ba sed maintenance i s performed instea d. ● From 50,000 km, repeat the maint enance intervals starting from 10, 000 km. ● Items marked with an asterisk should be p[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-3 6 9 * Brake hose • Check for cracks or damage. √√√√ √ • Replace. (See NOTE on page 6-4.) Ev er y 4 y ea rs 10 * Wheels • Check runout and for damage. √√√√ 11 * Tires • Check tread depth and for damage. • Replace if necessary. • Check air pressure. • Correct if necessary. √?[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-4 6 EAU03541 NO TE: _ ● The air filter needs more frequent service if you are riding in unusually wet or dusty ar eas. ● Hydraulic brake service • Regularly check and, if necessary, correct th e brake fluid level. • Every two years replace the internal components of the brake master cylinder and calip[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-5 6 EAU01139 Removing and installing cowlings and panels The cowlings and panels shown above need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be re- moved and installed. EAU03494 Cowlings A and B To remove one of [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-6 6 EAU03317 Panels A and B To remove one of the panels 1. Remove the corresponding cowl- ing A or B. (See page 6-5 for co wl- ing removal and installation procedures.) 2. Remove the seat. (See page 3-11 for seat removal and installation procedures.) 3. Remove the screw, and then take the panel off. To instal[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-7 6 EAU01668 Checking the spark plugs The spark plugs are important engine components, which are easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plugs should be removed and checked in accordance with the periodic mainte- nance and lubrication chart. In addition, the[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-8 6 To install a spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if nec- essary, adjust the gap to specifica- tion. 2. Clean the surface of the spark plug gasket and its mating sur- face, and then wipe off any grime from the spark plug threads. 3. Install the spark plug with the spar[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-9 6 EAU01692 Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter ele- ment replaced at the intervals specified in the periodic maintenance and lubri- cation chart. To check the engine oil level 1. Place the motorcyc[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-10 6 3. Remove the engine oil tank cap and drain bolts to drain t he oil from the crankcase. NO TE: @ Skip steps 4–6 if the oil filt er element is not being replaced. @ 4. Remove the oil filter element cover by removing the bolts. 5. Remove and replace the oil filter element and O-rings. 6. Install the oil [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-11 6 8. Add the specified amount of the recommended engine oil, and then install and tighten the oil tank cap. EC000072 CAUTION: @ ● In order to prevent clutch slip- page (since the engine oil also lubricates the clutch), do not mix any chemical additives with the oil or use oils of a higher grade than “C[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-12 6 2. Check the coolant level in the coolant reservoir. NO TE: @ The coolant should be between the minimum and maximum level marks. @ 3. If the coolant is at or below the minimum level mark, remove the seat (See page 3-11 for seat re- moval and installation proce- dures.), and then open the coolant reservoi[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-13 6 NO TE: @ ● The radiator fan is automatically switched on or off according to the coolant temperature in the radia- tor. ● If the engine overheats, see page 6-45 for further instruct ions. @ EAU03300 To change the coolant 1. Place the motorcycle on a level surface and let t he engine cool if necessary[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-14 6 6. Remove the coolant drain bolt s to drain the cooling system. 7. Remove the coolant reservoir bolts. 8. Slightly move the coolant reservoir back, and then disconnect the hose at the bottom of the coolant reservoir. 9. Drain the coolant from the coolant reservoir by opening the cap, then turning the res[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-15 6 EC000080 CAUTION: @ ● If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine. ● If water has been used instead of coolant, replace it with cool- ant as soon as possible, other- wise the engine may not be suffic[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-16 6 4. Disconnect the fuel sender cou- pler. 5. Slightly lift the re ar of the fuel tank, turn the fuel cock lever to “OFF”, disconnect the fuel hose and breather hose, and then take the fuel tank off. 6. Remove the air filter case cover by removing the screws. 1. Fuel sender coupler 1. Fuel cock 2. Fuel[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-17 6 7. Pull the air filter element out. 8. Lightly tap the air filter element to remove most of the dust and dirt, and then blow the remaining dirt out with compressed air as shown. If the air filter element is damaged, replace it. 9. Insert the air filter element into the air filter case. EC000082 CAUTION: [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-18 6 EAU00630 Adjusting the carburetors The carburetors are important parts of the engine and require very sophisti- cated adjustment. Therefore, most car- buretor adjustments should be left t o a Yamaha dealer, who has the neces- sary professional knowledge and expe- rience. The adjustment described in the f[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-19 6 EAU00635 Adjusting the throttle cable free play The throttle cable free play should measure 3–5 mm at the throttle grip. Periodically check the throttle cable free play and, if necessary, have a Yamaha dealer adjust it. EAU00637 Adjusting the valve clearance The valve clearance changes with use, result[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-20 6 CE-01E CE-07E EWA00012 W ARNING _ Because loading has an enormous impact on the handling, br aking, per- formance and safety characte ristics of your motorcycle , you should keep the following precautions in mind. ● NEVER OVERLOAD THE MOTORCYCLE! Operation of an overloaded motorcycle may re- sult in ti[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-21 6 EW000079 W ARNING _ ● Have a Yamaha dealer replace excessively worn tires. Besides being illegal, operating the motorcycle with excessively worn tires decreases riding sta- bility and can lead to loss of control. ● The replacement of all wheel- and brake-related parts, includ- ing the tires, should b[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-22 6 CE-10E CE-14E EAU00684 W ARNING @ This motorcycle is fitted with super- high-speed tires. Note the following points in order to make the most ef- ficient use of these tires. ● Use only the specified replace- ment tires. Other tires may run the danger of bursting at super high speeds. ● Brand-new tire[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-23 6 EAU00692 Adjusting the clutch lever free play The clutch lever free play should mea- sure 10–15 mm as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows. 1. Loosen the locknut at the clutch le- ver. 2. To increase the clutch lever free play, turn the adjusting [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-24 6 EW000109 W ARNING @ A soft or spongy feeling in the brake pedal can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system be- fore operating the motorcycle. Air in the hydraulic system will diminish the braking performance, wh[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-25 6 EAU00715 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec- ified in the periodic maintenance and lubrication chart. Each brake pad is provided with a wear indicator, which allows you to check the brake pad wear without having to disassemb[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-26 6 Observe these precaution s: ● When checking the fluid level, make sure that the top of the brake fluid reservoir is level. ● Use only the recommended quali- ty brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking perfor- mance . ● Refill with the same type of br[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-27 6 EAU00744 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. To check the drive chain slack 1. Place the motorcycle on a level surface and hold it in an upright position. NO TE: @ When checking and adjusting the drive chain slack, the motorcycle should be[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-28 6 NO TE: @ Using the alignment marks on each side of the swingarm, make sure that both adjusting nuts are in the same po- sition for proper wheel alignment. @ EC000096 CAUTION: @ Improper drive chain slack will over- load the engine as well as other vital parts of the motorcycle and can lead to chain slipp[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-29 6 EAU03006 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrica- tion chart, otherwise it will quickly wear out, especially when riding in d usty or wet areas. Service the drive chain as follow s. EC000097 CAUTION: @ T[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-30 6 EAU03209 Checking and lubricating the throttle grip and cable The operation of the throttle grip and the condition of the throttle cable should be checked before each ride, and the cable should be lubricated or replaced if necessary. NO TE: @ Since the throttle grip must be removed to access the throttle[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-31 6 EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lu- bricated if necessary. EAU03165 Checking and lubricating the sidestand The operation of the sidestand should be checked before [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-32 6 EAU00790 Lubricating the rear suspension The pivoting points of the rear suspen- sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. EAU02939 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-33 6 EAU00794 Checking the steering Worn or loose steering bearings may cause danger. Therefore, t he operation of the steering must be checked as fol- lows at the intervals specified in the pe- riodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-34 6 EAU00800 Battery This motorcycle is equipped with a sealed-type (MF) battery, which does not require any maintenance. Ther e is no need to check the electrolyte or to add distilled water. EC000101 CAUTION: @ Never attempt to remove the battery cell seals, as this would permanent- ly damage the battery. @[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-35 6 EC000102 CAUTION: @ ● Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. ● To charge a sealed-type (MF) battery, a special (constant- voltage) battery charger is re- quired. Using a conventional battery charger will damage the battery. If you do not have[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-36 6 3. T urn the key to “ ON” and turn on the electrical circuit in question to check if the device operates. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EAU03794 Replacing a headlight bulb This motorcycle is equipped with quartz bulb headlights. If a headlig[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-37 6 EC000105 CAUTION: _ Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely af- fected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-38 6 EAU03497 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. 2. Remove the defective bulb by pushing it in and turning it counter- clockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clock- wise until it stops. 4. Install the lens by in[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-39 6 EAU01579 Supporting the motorcycle Since this model is not equipped with a centerstand, follow these precautions when removing the front and rear wheel or performing other mainte- nance requiring the motorcycle to stand upright. Check that the motor- cycle is in a stable and level position before startin[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-40 6 3. Remove the brake caliper on each side by removing the bolts. ECA00046 CAUTION: @ Do not apply the brake after the brake calipers have been removed, otherwise the brake pads will be forced shut. @ 4. Pull the wheel axle out, and then remove the wheel. EAU03829 To install the front wheel 1. Lift the whe[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-41 6 EAU03830 Rear wheel To remove the rear wheel EW000122 W ARNING _ ● It is advisable to have a Yamaha dealer service the wheel. ● Securely support the motor- cycle so that there is no danger of it fa lling over. _ 1. Loosen the axle nut and the brake caliper bolts. 2. Lift the rear wheel off the ground[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-42 6 5. Loosen the locknut on each side of the swingarm. 6. Turn the drive chain slack adjust - ing nuts fully in direction a . 7. Push the wheel forwar d, and then remove the drive chain from the rear sprocket. NO TE: _ The drive chain does not need to be disassembled in order to remove and install the rear [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-43 6 EAU03087 Troubleshooting Although Yamaha motorcycles r eceive a thorough inspection before shipment from the factory, trouble may occur dur- ing operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting char[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-44 6 EAU02990 Troubleshooting charts Starting problems or poor engine performance EW000125 W ARNING @ Keep away open flames and do not smoke while checking or working on the fuel system. @ Check the fuel level in the fuel tank. 1. Fuel There is enough fuel. There is no fuel. Check the compression. Supply fuel[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-45 6 Engine overheating EW000070 W ARNING @ ● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled. ● After removing the radiator cap retaining bolt, [...]

MOTORCYCLE CARE AND STORAGE 7 Care .......... ................ ................ ............. ................ ................ ........... 7-1 Storage ......... ................ ................. ................ ................ ................ .... 7-4 E_4tx.book Page 1 Wednesday, October 4, 200 0 4:28 PM[...]

7-1 7 EAU03429 7 - MOTORCYCLE CARE AND STORAGE Care While the open design of a motorcycle reveals the attractiveness of the tech- nology, it also makes it more vulnera- ble. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go un- noticed on a car, however, it detracts from the overall appearance of a[...]

MOTORCYCLE CARE AND STORAGE 7-2 7 ● Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust re- movers or inhibitors, brake flu- id, antifreeze or electrolyte. ● Do not use high-pressure wa sh[...]

MOTORCYCLE CARE AND STORAGE 7-3 7 1. Clean the motorcycle with cold water and a mild detergent, after the engine has cooled down. ECA00012 CAUTION: @ Do not use warm water since it in- creases the corrosive action of the salt. @ 2. After drying the motorcycle, apply a corrosion protection spray on all metal, including chrome- and nick- el-plated, s[...]

MOTORCYCLE CARE AND STORAGE 7-4 7 ECA00013 CAUTION: @ ● Apply spray oil and wax spar- ingly and make sure to wipe off any excess. ● Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product. ● Avoid using abrasive polishing compounds as they will wear away the paint. @ NO TE: @ Consult a Yamaha dealer[...]

MOTORCYCLE CARE AND STORAGE 7-5 7 a. Remove the spark plug caps and spark plugs. b. Pour a teaspoonful of engine oil into each spark plug bore. c. Install the spark plug caps onto the spark plugs, and then place the spark plugs on the cylinder head so that the electrodes are ground- ed. (This will limit sparking during the next step.) d. Turn the e[...]

SPECIFICATIONS 8 Specification s ............... ................. ................ ................ ................ .... 8-1 Conv er sion table ....................... ............. ................ ................ ........... 8-5 E_4tx.book Page 1 Wednesday, October 4, 200 0 4:28 PM[...]

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SPECIFICATIONS 8-2 8 Cooling system capacity (total amount) 1.7 L Air filter Dr y type element Fuel T ype Regular unleaded gasoline Fuel tank capacity 20 L Fuel reser ve amount 3.1 L Carburetor Manuf acture r MIKUNI Model × quantity BDSR38 × 2 Spark plug Manuf acture r/model NGK / DPR8EA-9 or DENSO / X24EPR-U9 Gap 0.8–0.9 mm Clutch t ype W et, [...]

SPECIFICATIONS 8-3 8 Maximum load* 203 kg Tire air pressure (measured on cold tires) Up to 90 kg* F ront 225 kP a (2.25 kg/cm 2 , 2.25 bar) Rear 275 kPa (2.75 kg/cm 2 , 2.75 bar) 90 kg–maximum* F ront 225 kP a (2.25 kg/cm 2 , 2.25 bar) Rear 275 kPa (2.75 kg/cm 2 , 2.75 bar) High-speed riding F ront 225 kP a (2.25 kg/cm 2 , 2.25 bar) Rear 275 kPa [...]

SPECIFICATIONS 8-4 8 Electrical system Ignition system T .C.I. (digital) Charging system T ype A.C . magneto Standard output 14 V , 24 A @ 5,000 r/min Batter y Model GT12B-4 V oltage, capacity 12 V , 10 Ah Headlight type Quar tz bulb (halogen) Bulb voltage, wattage × quantity Headlight 12 V , 55 W × 2 A uxiliar y light 12 V , 5 W × 1 T ail/brake[...]

SPECIFICATIONS 8-5 8 EAU01064 Conversion table CS-02E All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data t o IMPERIAL unit data. Example METRIC MULTIPLIER IMPERIAL ** mm × 0.03937 = ** in 2 mm × 0.03937 = 0.08 in Conversion table METRIC TO IMPE RIAL Metric unit Multiplier Imperial u[...]

CONSUMER INFORMATION 9 Identificatio n numbers ...... ................ ................ ................ ................ . 9-1 K ey identification number ....... ................ ............. ................ .............. 9-1 V e hicle identifica tion number .. ................ ................ ............. .............. 9-1 Model label .....[...]

9-1 9 EAU01039 9 - CONSUMER INFORMATION EAU02944 Identification numbe rs Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. 1. KEY IDENTIFICATION NUMBER: CA-02E[...]

CONSUMER INFORMATION 9-2 9 EAU01050 Model label The model label is affixed t o the frame under the seat. (See page 3-11 for seat removal and installation procedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer. 1. Model label E_4tx.book Page 2 Wednesday,[...]

1 0- INDEX A Air fi lter elem ent, cleaning ...................... 6- 15 Anti -the ft alarm ........................................ 3-5 B Batt ery .............................. ..................... 6-34 Brake and clutch levers, checking and lubr icat ing ............................................ 6-31 Brake and shift pedals, checking and lubr [...]

INDEX Shi fting ...... .............................................. 5- 3 Shift peda l ............................................... 3- 7 Shif t poi nts (f or Switzer land o nly)............. 5- 3 Shock absorber assembly, adjusting ..... 3- 15 Sid estan d .............................................. 3-17 Sid estan d, c heck ing a nd lub ricati[...]

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H_5KS_Toc0.fm Page 2 Monday, August 21, 2000 11:11 AM[...]