Yamaha 4TX-AE3 manual

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FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the TDM850 ’99. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. TDM850 ’96 SERVICE MANUAL: 4TX-AE1 TDM850 ’97 SUPPLEMENT AR Y SERVICE MANUAL: 4TX-AE2 TDM850[...]

NOTE: CAUTION: EB001000 NOTICE This manual was produced by the Y amaha Motor Company primarily for use by Y amaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Y amaha motorcycles has a basic un[...]

1 2 4 6 5 7 3 8 EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZA TION 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. 2nd title 2 : This title indicates the section of the chapter and only appea[...]

22 1 3 5 7 9 2 4 8 6 24 25 23 21 19 20 18 16 17 15 14 13 11 12 10 GEN INFO SPEC ENG CARB ELEC CHAS COOL INSP ADJ TRBL SHTG EB003000 ILLUSTRA TED SYMBOLS Illustrated symbols 1 to 9 are printed on top right of each page and indicate the subject of each chapter . 1 General information 2 Specifications 3 Periodic inspection and adjustment 4 Engine 5 Co[...]

CONTENTS GENERAL INFORMA TION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOTORCYCLE IDENTIFICA TION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICA TION NUMBER 1 . . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL 1 . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

–1– MOTORCYCLE IDENTIFICA TION GEN INFO EB100000 GENERAL INFORMA TION MOTORCYCLE IDENTIFICA TION VEHICLE IDENTIFICA TION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head. MODEL LABEL The model label 1 is affixed to the frame. This in- formation will be needed to order spare parts.[...]

–2– GENERAL SPECIFICA TIONS SPEC SPECIFICA TIONS GENERAL SPECIFICA TIONS Item Standard Model: TDM850 Model code: 4TX4 Basic weight (With oil and full fuel tank): 232 kg Carburetor: T ype / quantity Manufacturer BDSR38 / 2 MIKUNI T ransmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio T[...]

–3– MAINTENANCE SPECIFICA TIONS SPEC MAINTENANCE SPECIFICA TIONS ENGINE Item Standard Limit Clutch: Clutch spring free length Quantity 50 mm 6 48 mm  Carburetor: I.D. mark Main jet Main air jet Jet needle Needle jet Pilot air jet 1 Pilot air jet 2 Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Pilot screw V alve seat size Starter je[...]

–4– MAINTENANCE SPECIFICA TIONS SPEC ELECTRICAL Item Standard Limit Charging system: T ype Model / manufacturer Nominal output Stator coil resistance A.C. magneto TLN252 / DENSO 14 V 25 A at 5,000 r / min 0.23 X 0.35 Ω at 20 _ C/W - W SSS SSS SSS SSS Starter relay: Model / manufacturer Amperage rating Coil winding resistance MS5F-421 / JIDECO[...]

–5– 1 Throttle cable 1 2 Right handlebar switch lead 3 Brake hose 4 Clutch cable 5 Main switch lead 6 Left handlebar switch lead 7 Horn lead 8 Starter cable 9 Speed sensor lead 10 Coolant reservoir hose 11 Headlight lead 12 Meter light lead 13 Thermo unit lead 14 Thermo switch lead 15 Fan motor lead CABLE ROUTING SPEC 16 Ignition coil (left) le[...]

–6– CABLE ROUTING SPEC L Fasten the meter lead and headlight lead with a plas- tic band. M Fasten the wireharness with a plastic band. N Fasten the wireharness, right handlebar switch lead meter lead and headlight lead with a plastic band. O Connect the coupler and insert to the protector . P Fasten the wireharness with a plastic band. Q Fasten[...]

–7– 11 A.C. magneto lead 12 Air filter case breather hose 13 Carburetor heater hose 14 Starter cable 2 15 Thermo switch lead 16 Brake hose 17 Speed sensor lead 18 Wire harness 19 Flasher relay lead 20 Fuel pump lead A Fasten the left handlebar switch lead and main switch lead with a plastic band. B Route the wireharness to the rear- side of the[...]

–8– D Fasten the rear flasher light (left) lead. E Fasten the sidestand switch lead neutral switch lead and A.C. magneto lead. F Route the sidestand switch lead and air filter case breather hose to the inside of the engine cover . G Fasten the sidestand switch lead to the air filter case breather hose. H Route the air filter case breather hose [...]

–9– 1 Battery negative lead 2 Battery positive lead 3 Starter motor lead 4 Fuel sender lead 5 Fuel tank drain hose 6 Fuel tank breather hose (for DEU) 7 W ater hose 8 Spark plug lead 9 Clutch cable 10 Brake hose 11 Throttle cable 12 Right handlebar switch lead 13 Headlight lead 14 Meter light lead 15 Speed sensor lead 16 Carburetor heater hose [...]

–10– J Fasten the right handlebar switch lead and speed sensor lead with a clamp. K Fasten the throttle cable and speed sensor lead with a clamp. L Route the coolant reservoir hose through the outside of clutch cable. M Fasten the wireharness, right handlebar switch lead, meter lead and headlight lead with a clamp. N Route the clutch cable thro[...]

–1 1– CABLE ROUTING SPEC 1 Head light lead 2 Wireharness 3 Meter light lead 4 Throttle cable 5 Throttle stop screw cable 6 V acuum hose (#2) 7 V acuum hose (#1) 8 Fuel tank breather hose 9 Fuel hose 10 Carburetor air vent hose 11 Carburetor breather hose 12 Fuel tank drain hose 13 Fuel hose 14 Fuel sender lead 15 Starter motor lead 16 Battery p[...]

–12– CABLE ROUTING SPEC H Fasten the carburetor breather hose and see the hose mark. I In order to carburetor breather hose, idle adjust cable coolant breather hose from downward. J Route the air filter drain hose to outside of throttle posi- tion sensor lead. K Fasten the wireharness with a clamp. L T o left flasher . M Fasten the headlight le[...]

–13– INTRODUCTION / PERIODIC MAINTENANCE / LUBRICA TION INTER V ALS INSP ADJ PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspection and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service lif[...]

–14– PERIODIC MAINTENANCE / LUBRICA TION INTER V ALS INSP ADJ NOTE: EVER Y NO. ITEM CHECKS AND MAINTENANCE JOBS INITIAL (1,000 km) 6,000 km 6 months (whichever comes first) 12,000 km 12 months (whichever comes first) 21 * Carburetors  Check engine idling speed, synchronization and starter oper ation.  Adjust if necessary . √ √ √ 22 [...]

–15– SEA T , T AIL COVER AND FUEL T ANK INSP ADJ Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 Seat, tail cover and fuel tank removal Side cowling Seat T aillight lead coupler T ail cover Side cover Fuel hose Fuel tank breather hose Fuel tank Fuel sender coupler 1 1 1 2 1 1 1 1 Remove the parts in the order below . Refer to “COWLI[...]

–16– CARBURET OR SYNCHRONIZA TION INSP ADJ NOTE: NOTE: ENGINE CARBURETOR SYNCHRONIZA TION V alve clearance and idling speed should be ad- justed properly before synchronizing the carbure- tors. 1. Place the motorcycle on a level surface. Place the motorcycle on its centerstand if a cen- terstand is equipped. If not, place a suitable stand under[...]

–17– CARBURET OR SYNCHRONIZA TION INSP ADJ NOTE: 7. Adjust:  Carburetor synchronization Adjustment steps:  Synchronize carburetor #1 to carburetor #2 by turning synchronizing screw 1 until both gauges read the same.  Race the engine for less than a second, two or three times and check the synchronization again. Intake vacuum at idle sp[...]

–18– ENGINE OIL LEVEL INSPECTION INSP ADJ NOTE: NOTE: CAUTION: ENGINE OIL LEVEL INSPECTION Position the motorcycle straight up when inspect- ing the oil level. 1. Place the motorcycle on a level surface.  After idling the engine a few minutes. The summer season is about 5 minutes and the winter season is about 15 minutes.  T urn off the e[...]

–19– ENGINE OIL REPLACEMENT INSP ADJ New 35 Nm (3.5 m  kg) 30 Nm (3.0 m  kg) ENGINE OIL REPLACEMENT 1. Start the engine and let it warm up for several minutes. 2. Stop the engine and place an oil pan under the drain bolt. 3. Remove:  Oil filler plug 1 4. Remove:  Drain bolt (with gasket) 1  Oil filter drain bolt (with gasket) 2 D[...]

–20– ENGINE OIL REPLACEMENT INSP ADJ CAUTION: 7. Fill:  Crankcase The engine should be filled with oil in two steps. First fill the engine with 3.2 liters of oil. Then start the engine and race it five or six times. Continue idling the engine a few min- utes. Stop the engine and fill it with oil to the specified level. Oil quantity: T otal a[...]

–21– FUEL LINE INSPECTION INSP ADJ NOTE: NOTE: FUEL LINE INSPECTION 1. Remove:  Side cowling  Seat  Side cover  Fuel tank Refer to “COWLINGS, SEA T , T AIL COVER AND FUEL T ANK”. 2. Inspect:  Fuel hoses 1 Cracks / Damage  Replace. Loose connection  Connect properly . Drain and flush the fuel tank if abrasive damage to a[...]

–22– CLUTCH ENG Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Clutch removal Clutch spring Pressure plate Plain washer / Bearing Pull rod Friction plate Friction plate Clutch plate Clutch boss nut Lock washer Clutch boss Thrust plate Spacer / Bearing Clutch housing Thrust plate 2 Thrust plate 1 6 1 1/1 1 7 2 8 1 [...]

–23– CLUTCH ENG CAUTION: NOTE: INST ALLA TION 1. Install:  friction plates  clutch plates The friction plates are made in two types. The first and last friction plates are different in ma- terial from the other ones and black on the sur- face. Assembly should be done in the correct order .  Mount friction and clutch plate alternately .[...]

–24– INSTRUMENT FUNCTIONS ELEC INSTRUMENT FUNCTIONS COMBINA TION METER Speedometer Clock, odometer Select button Reset button 1 2 3 4 NOTE: This combination meter is equipped with the fol- lowing.  An odometer  T wo trip odometers  A clock Odometer and trip meters Use the trip meters to estimate how far you can ride on a tank of fuel. [...]

–25– SIGNAL SYSTEM ELEC EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM[...]

–26– SIGNAL SYSTEM ELEC 3 Main switch 4 Fuse (position light and hazard) 6 Battery 8 Main fuse 22 Fuel sender 25 Fuel meter 27 Fuel level indicator light 32 T urn indicator light (left) 33 T urn indicator light (right) 34 Speed meter 35 Speed sensor 36 Front flasher light 37 Rear flasher light 44 Hazard switch 45 T urn switch 48 Flasher relay 4[...]

–27– EB802401 2. Battery S Check the condition of the battery . Refer to “BA TTERY INSPECTION”. Open-circuit voltage 12.8 V or more at 20 _ C S Is the battery OK? YES NO S Clean the battery terminals. S Recharge or replace the battery . EB80241 1 3. Main switch S Check the main switch for continuity . Refer to “SWITCH INSPECTION”. S Is [...]

–28– SIGNAL SYSTEM ELEC  T urn the main switch to “ON” or “P”.  Check for voltage (12 V) on the “Brouwn / Red” lead at the flasher relay terminal.  Is the voltage within specification. 1. Flasher / turn indicator light bulb and socket  Check the flasher / turn indicator light bulb and socket for continuity .  Are the [...]

–29– SIGNAL SYSTEM ELEC S Drain the fuel and remove the fuel sender from the fuel tank. S Disconnect the fuel sender coupler from the wire harness. S Connect the posket tester ( Ω 1) to the fuel sender . S T urn the main switch to “ON” or “P”. S Check for voltage (12 V) on the “Brouwn / White” lead at the flasher relay terminal. S[...]

–30– SIGNAL SYSTEM ELEC  Connect the pocket tester (DC 20 V) and bat- tery (12 V)to the speed sensor coupler as shown.  Speed sensor coupler (speed sensor side) YES NO Replace the fuel sender .  Is the fuel sender OK? 3. Fuel meter  Drain the fuel and remove the fuel sender from the fuel tank.  Connect the fuel sender to wireharn[...]

–31– SIGNAL SYSTEM ELEC Battery positive terminal  red Battery negative terminal  black T ester positive probe  white T ester negative probe  black  Set the main switch to “ON”.  Elevate the front wheel and slowly rotate it.  Does the voltage (5V) read cycle 4 times with each, full rotation of the front wheel? YES NO Re[...]

–32– FUEL PUMP SYSTEM ELEC Main switch 3 6 8 11 13 18 61 Battery Main fuse Fuel pump Fuel relay Ignitor unit Engine stop switch Ignition fuse 62 EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM[...]

–33– FUEL PUMP SYSTEM ELEC 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay 8 Fuel pump EB808010 FUEL PUMP CIRCUIT OPERA TION The ignitor unit includes the control unit for the fuel pump.[...]

–34– FUEL PUMP SYSTEM ELEC EB802401 2. Battery  Check the condition of the battery . Refer to “BA TTERY INSPECTION”. Open-circuit voltage 12.8 V or more at 20  C  Is the battery OK? YES NO  Clean the battery terminals.  Recharge or replace the battery . EB80241 1 3. Main switch  Check the main switch for continuity . Refer[...]

–35– FUEL PUMP SYSTEM ELEC 5. Fuel pump relay  Disconnect the relay unit from the coupler .  Connect the pocket tester ( Ω  1) and battery (12 V) to the relay unit ferminals as shown. Battery positive terminal  red / black Battery negative terminal  blue / red T ester positive probe  red / black T ester negative probe  bl[...]

–36– FUEL PUMP SYSTEM ELEC W ARNING EB808410 CHECKING THE FUEL PUMP Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points:  Stop the engine before refuelling.  Do not smoke and keep away from open flames, sparks or any other source [...]

COLOR CODE B Black . . . . . . Br Brown . . . . . Ch Chocolate . . . . Dg Dark green . . . . G Green . . . . . Gy Gray . . . . L Blue . . . . . . Lg Light green . . . . . Or Orange . . . . . R Red . . . . . . Sb Sky blue . . . . . W White . . . . . Y Y ellow . . . . . . B / L Black / Blue . . . . Br / L Brown / Blue . . . Br / R Brown / Red . . . B[...]