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EB001000
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha 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 Yamaha motorcycles has
a basic understanding of the mechanical ideas and the procedures of motorcycles repair. Repairs at-
tempted by anyone without this knowledge are likely to render the motorcycles unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant
changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear
in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT 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!
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 motor-
cycle.
A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
CAUTION:
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.
2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each section.
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
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal
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. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the
exploded diagram and the job instruction chart.
1
4
2
3
8
6
5
7
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EB003000
1
3
5
2
ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 9 are printed on top
right of each page and indicate the subject of each
chapter.
GEN
SPEC
INFO
General information
Specifications
Periodic inspection and adjustment
Engine
1
2
3
4
5
6
7
8
9
4
INSP
ADJ
ENG
Cooling system
Carburetion
6
Chassis
COOL
CARB
Electrical
Troubleshooting
7
8
CHAS
ELEC
Illustrated symbols 10 to 17 are used to identify the
specifications appearing in the text.
10
9
10 Can be serviced with engine mounted
11 Filling fluid
TRBL
SHTG
12 Lubricant
11
12
14
17
20
23
25
13 Special tool
14 Torque
15 Wear limit, clearance
16 Engine speed
17 Ω, V, A
13
15
18
21
24
18
23
in the exploded dia-
Illustrated symbols
to
16
19
22
grams indicate the types 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
24
25
in the exploded dia-
Illustrated symbols
to
24
grams indicate where to apply a locking agent
25
and when to install new parts
.
24 Apply locking agent (LOCTITE )
25 replace
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CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . 1
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PERIODIC INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 13
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . . 13
SEAT, TAIL COVER AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SEAT, TAIL COVER AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . 15
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CARBURETOR SYNCHRONIZATION . . . . . . . . . . . . . . . . . . . . . . . . 16
ENGINE OIL LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FUEL LINE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTRUMENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
COMBINATION METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SIGNAL SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FUEL PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
FUEL PUMP CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
TDM850 ’99WIRING DIAGRAM
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GEN
INFO
MOTORCYCLE IDENTIFICATION
EB100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION 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.
–1–
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SPEC
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Standard
Model:
TDM850
4TX4
Model code:
Basic weight (With oil and full fuel tank):
232 kg
Carburetor:
Type/quantity
Manufacturer
BDSR38/2
MIKUNI
Transmission
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission type
Spur gear
67/39 (1.718)
Chain drive
43/16 (2.688)
Constant mesh 5-speed
Left foot operation
37/14 (2.643)
37/19 (1.947)
30/20 (1.500)
27/23 (1.174)
27/28 (0.964)
Operation
Gear ratio
1st
2nd
3rd
4th
5th
Bulb wattage quantity
Meter light
Indicator lights
Neutral
12V 2 W 3
14 V 1.4 W 1
14 V 1.4 W 2
14 V 1.4 W 1
12 V 2 W 1
Turn
High beam
Fuel
Water tempere
14 V 1.4 W 1
–2–
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SPEC
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Item
Standard
Limit
Clutch:
Clutch spring free length
Quantity
50 mm
6
48 mm
SSS
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
Valve seat size
Starter jet 1
Starter jet 2
Throttle valve size
Fuel level
4TX4 40
#147.5
#65
#1: 6DJP17 #2: 6CL1
P-O
#87.5
#120
1.0
#17.5
0.8
0.9
0.8
2.0
1.5
#32.5
0.9
#95
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
4.4 X 5.4 mm
Engine idle speed
Intake vacuum
1050 X 1250 r/min
36.0 X 38.7 kPa (270 X 290 mmHg)
Fuel pump:
Type
Electrical type
SSS
SSS
SSS
Model/manufacturer
Output pressure
4TX/MITSUBISHI
7 kPa (0.07 kgf/cm2, 0.07 bar)
CHASSIS
Tightening
torque
Item
Thread size
Remarks
Nm
mSkgf
Fuel sender and fuel tank
Fuel pump and bracket
Bracket and frame
M5
M6
M6
3.8
6.5
6.5
0.38
0.65
0.65
–3–
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SPEC
MAINTENANCE SPECIFICATIONS
ELECTRICAL
Item
Standard
Limit
Charging system:
Type
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
180 A
4.2 X 4.6 Ω at 20_C
SSS
SSS
SSS
Fuel sender:
Model/manufacturer
resistance
4TX/NIPPON/SEIKI
SSS
SSS
SSS
full
empty
4 X 10Ω
90 X 100Ω
Fuel pump relay:
Model/manufacturer
Coil winding resistance
G8R-30Y-B/OMRON
225 Ω ± 10%
SSS
SSS
Hazard relay:
Model/manufacturer
Coil winding resistance
4KM-00/MATSUSHITA
72 X 88 Ω at 20_C
SSS
SSS
Circuit breakers:
Type
Amperage for individual circuits
Main fuse
Fuse
SSS
30 A 1
15 A 1
15 A 1
10 A 1
10 A 1
7.5 A 1
5 A 1
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Headlight fuse
Signal system fuse
Ignition fuse
Fuse (position light and hazard)
Radiator fan fuse
Back up
Reserve fuse
Reserve fuse
Reserve fuse
15 A 1
10 A 1
5 A 1
–4–
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SPEC
CABLE ROUTING
CABLE ROUTING
1 Throttle cable 1
2 Right handlebar switch lead
3 Brake hose
16 Ignition coil (left) lead
17 Ignition coil (right) lead
18 Negative lead
G Align the brake hose white mark to
the mark of bracket.
H Fasten the brake hose with a plas-
tic band and cut the end of band.
4 Clutch cable
5 Main switch lead
6 Left handlebar switch lead
7 Horn lead
A Fasten the right handlebar switch I Pass the speed sensor lead be-
lead with a plastic band.
B Fasten the handlebar switch lead
with a plastic band.
tween throttle cable and clutch
cable and fasten to the frame head
pipe.
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
C 50 mm
D Fasten the horn lead with a plastic
band.
E 60 mm
F Set the clamp within 10 mm from
the upper end of protector.
J Pass the wireharness and hoses
under the frame.
K Fasten the coolant reservoir hose
with a plastic band.
–5–
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SPEC
CABLE ROUTING
L Fasten the meter lead and headlight lead with a plas- P Fasten the wireharness with a plastic band.
tic band.
Q Fasten the wireharness and ignition coil (left) lead
with a plastic band.
M Fasten the wireharness with a plastic band.
N Fasten the wireharness, right handlebar switch lead R 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.
main switch lead fan motor lead with a plastic band.
S Set the ignition coil at the mark upward.
T Protector is under the coupler.
–6–
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SPEC
CABLE ROUTING
1 Front flasher light (left) lead
2 Main switch lead
3 Starter cable 1
4 Left handlebar switch lead
5 Spark plug lead
6 Carburetor breather hose
7 Fuel hose
8 Coolant reservoir hose
9 Sidestand switch lead
10 Neutral switch lead
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 frame pipe.
C Route the starter cable through ra-
diator hose upward and spark plug
lead rear side and in front of air fil-
ter case breather hose. Route the
spark plug lead to the outside of
the carburetor starter bracket and
carburetor heater hose.
–7–
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SPEC
CABLE ROUTING
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.
J Clamp the speed sensor lead to the outer tube with a
holder.
K Clamp the speed sensor lead along the brake hose
(three position).
L Connect the coupler and insert the protector. Set the
protector between crosstube and fuel pump.
M Fasten the coolant reservoir hose, A.C. magneto
lead, neutral switch lead and sidestand switch lead.
H Routetheairfiltercasebreatherhoseovertheidlead-
just bracket.
I Routetheairfiltercasebreatherhosetotheoutsideof
the carburetor heater hose and route the carburetor
heater hose to the inside of the air filter case breather
hose.
–8–
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SPEC
CABLE ROUTING
1 Battery negative lead
2 Battery positive lead
3 Starter motor lead
4 Fuel sender lead
17 Vacuum hose (#1)
18 Vacuum hose (#2)
19 Coolant reservoir breather hose
20 Carburetor breather hose
21 Rear brake switch lead
D Fasten the carburetor air vent hose.
E Route the carburetor breather
hoses, vacuum hose (#1) down
ward and vacuum hose (#2) up-
ward through the guide.
5 Fuel tank drain hose
6 Fuel tank breather hose (for DEU) 22 CYCLELOCK lead
7 Water hose
F Route the vacuum hose (#1) inside,
vacuum hose (#2) outside through
8 Spark plug lead
9 Clutch cable
A Route the battery positive lead
the guide.
and battery negative lead through G Fasten the coolant reservoir hose.
10 Brake hose
11 Throttle cable
the clamp.
H Fasten the wireharness right han-
dlebar switch lead meter lead and
headlight lead with a clamp.
I Route the relay lead through the
outside of wireharness.
B Fasten the wireharness Coolant
breather hose and flasher relay
lead.
C Route the carburetor breather
hoses through the engine clamp.
12 Right handlebar switch lead
13 Headlight lead
14 Meter light lead
15 Speed sensor lead
16 Carburetor heater hose
–9–
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SPEC
CABLE ROUTING
J Fasten the right handlebar switch lead and speed S Route the brake switch lead through the guide.
sensor lead with a clamp. T Fasten the wireharness, rear flasher lead with a clamp.
K Fastenthethrottlecableandspeedsensorleadwitha U Fasten the wireharness with a clamp.
clamp.
V Fasten the coolant reservoir breather hose with a clamp.
L Route the coolant reservoir hose through the outside W To the engine.
of clutch cable.
M Fasten the wireharness, right handlebar switch lead,
meter lead and headlight lead with a clamp.
N Route the clutch cable through the guide of stay.
O Route the coolant reservoir breather hose, fuel tank
drain hose, carburetor breather hose through the guide.
P Route the carburetor breather hoses through the clamp.
Q Route the fuel tank drain hose, fuel tank breather
hose through the hole of the frame bracket.
R Route the coolant reservoir breather hose, fuel tank
breather hoseand fuel tank drain hose through the guide.
–10–
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SPEC
CABLE ROUTING
1 Head light lead
2 Wireharness
3 Meter light lead
4 Throttle cable
5 Throttle stop screw cable
6 Vacuum hose (#2)
7 Vacuum hose (#1)
8 Fuel tank breather hose
9 Fuel hose
12 Fuel tank drain hose
13 Fuel hose
14 Fuel sender lead
A Fasten the meter lead, headlight
lead wireharness with a clamp.
B Fasten the wireharness, coolant
reservoir hose with a clamp.
C Fasten the fuel hose with a clamp.
D Route the starter relay lead and
fuel sender lead through the guide
of bracket.
E Connect the coupler and insert the
protector.
F Fasten the taillight lead to the tail-
light bracket above left taillight with
a clamp and end of clamp is down-
ward.
15 Starter motor lead
16 Battery positive lead
17 Battery negative lead
18 Coolant reservoir breather hose
19 Coolant reservoir hose
20 Fuel hose
21 Carburetor breather hose
22 Cylinder head breather hose
23 Air filter case breather hose
10 Carburetor air vent hose
11 Carburetor breather hose
G 50 mm
–11–
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SPEC
CABLE ROUTING
H Fasten the carburetor breather hose and see the N To head light.
hose mark. O To auxiliary light.
I In order to carburetor breather hose, idle adjust cable P To meter.
coolant breather hose from downward. Q Fasten the meter lead, headlight lead with a clamp.
J Route the air filter drain hose to outside of throttle posi- R Fasten the meter lead, headlight lead and right flash-
tion sensor lead.
K Fasten the wireharness with a clamp.
L To left flasher.
er lead connecter with a clamp.
S To right flasher.
T Fasten the meter lead, headlight lead, relay assembly
lead and right flasher lead with a clamp.
M Fasten the headlight lead with a clamp.
–12–
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INTRODUCTION/
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
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 life. The need for costly overhaul work will be greatly reduced. This information applies to
vehicles already in service as well as new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
EVERY
6,000 km
or
12,000 km
or
INITIAL
(1,000 km)
NO.
ITEM
CHECKS AND MAINTENANCE JOBS
6 months
(whichever
12 months
(whichever
comes first) comes first)
S Check fuel hoses for cracks or damage.
S Replace if necessary.
1
2
3
*
Fuel line
√
√
√
√
√
S Check condition.
*
Fuel filter
S Replace if necessary.
S Check condition.
Spark plugs
√
S Clean, regap or replace if necessary.
S Check valve clearance.
Every 42,000 km or 42 months
(whichever comes first)
4
5
6
*
Valves
Air filter
Clutch
S Adjust if necessary.
S Clean or replace if necessary.
√
√
√
S Check operation.
√
√
√
√
S Adjust or replace cable.
S Check operation, fluid level and vehicle for fluid leakage.
S Correct accordingly.
7
*
Front brake
√
S Replace brake pads if necessary.
S Check operation, fluid level and vehicle for fluid leakage.
8
9
*
*
Rear brake
Wheels
√
√
√
√
S Correct accordingly.
√
S Replace brake pads if necessary.
S Check balance, runout and for damage.
S Rebalance or replace if necessary.
S Check tread depth and for damage.
S Replace if necessary.
10
11
12
*
*
*
Tires
√
√
√
√
√
√
S Check air pressure.
S Correct if necessary.
S Check bearing for looseness or damage.
Wheel bearings
Swingarm
S Replace if necessary.
S Check swingram pivoting point for play.
S Correct if necessary.
S Lubricate with molybdenum disulfide grease every 24,000 km
or 24 months (whichever comes first).
S Check chain slack.
aligned.
S Clean and lubricate.
Every 500 km and after washing the
motorcycle or riding in the rain
S Adjust if necessary. Make sure that the rear wheel is properly
13
14
Drive chain
S Check bearing play and steering for roughness.
S Correct accordingly.
*
*
Steering bearings
√
√
S Lubricate with lithium soap base grease every 24,000 km or
24 months (whichever comes first).
S Make sure that all nuts, bolts and screws are properly tight ened.
S Tighten if necessary.
15
16
17
18
19
Chassis fasteners
Sidestand
√
√
√
√
√
√
√
√
√
√
S Check operation.
S Lubricate and repair if necessary.
S Check operation.
*
*
*
Sidestand switch
Front fork
√
S Replace if necessary.
S Check operation and for oil leakage.
S Correct accordingly.
Rear shock absorber
assembly
S Check operation and shock absorber for oil leakage.
S Replace shock absorber assembly if necessary.
Rear shock absorber
assembly pivoting
points
S Check operation.
20
*
√
√
S Lubricate with molybdenum disulfide grease every 24,000 km
or 24 months (whichever comes first).
–13–
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INSP
ADJ
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
EVERY
6,000 km
6 months
(whichever
12,000 km
12 months
(whichever
INITIAL
(1,000 km)
NO.
ITEM
CHECKS AND MAINTENANCE JOBS
comes first) comes first)
S Check engine idling speed, synchronization and starter
21
*
Carburetors
Engine oil
oper ation.
√
√
√
√
S Adjust if necessary.
S Check oil level and vehicle for oil leakage.
22
S Correct if necessary.
√
√
√
√
S Change. (Warm engine before draining.)
23
Engine oil filter
element
S Replace.
S Check coolant level and vehicle for coolant leakage.
S Correct if necessary.
*
24
Cooling system
√
√
S Change coolant every 24,000 km or 24 months (whichever
comes first).
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha
dealer.
NOTE:
S The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
S Hydraulic brake system
S When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the
brake fluid level regularly and fill as required.
S Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
S Replace the brake hoses every four years or if cracked or damaged.
–14–
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INSP
ADJ
SEAT, TAIL COVER AND FUEL TANK
SEAT, TAIL COVER AND FUEL TANK
16 Nm (1.6mSkg)
3.8 Nm (0.38mSkg)
Order
Job name/Part name
Q’ty
Remarks
Seat, tail cover and fuel tank removal
Side cowling
Seat
Taillight lead coupler
Tail cover
Side cover
Fuel hose
Remove the parts in the order below.
Refer to “COWLINGS”.
1
2
3
4
5
1
1
1
2
1
Disconnect
NOTE:
Set the fuel cock (fuel tank side) to “OFF”
before disconnecting the fuel hoses.
6
7
8
Fuel tank breather hose
Fuel tank
Fuel sender coupler
1
1
1
Disconnect
For installation, reverse the removal
procedure.
–15–
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INSP
ADJ
CARBURETOR SYNCHRONIZATION
ENGINE
CARBURETOR SYNCHRONIZATION
NOTE:
Valve clearance and idling speed should be ad-
justed properly before synchronizing the carbure-
tors.
1. Place the motorcycle on a level surface.
NOTE:
Place the motorcycle on its centerstand if a cen-
terstand is equipped. If not, place a suitable stand
under the motorcycle.
2. Remove:
S Side cowling
S Seat
S Side cover
S Fuel tank
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
3. Remove:
S Vacuum hose 1 (#1 carburetor) 1
S Vacuum hose 2 (#2 carburetor) 2
4. Attach:
S Adapters
S Vacuum gauge 1
S Engine tachometer 2
(to #1 spark plug lead)
Vacuum gauge:
90890-03094
Engine tachometer:
90890-03113
5. Start the engine and let it warm up for several
minutes.
6. Check:
S Engine idling speed
Out of specification ! Adjust.
Refer to “ENGINE IDLING SPEED ADJUST-
MENT”.
Engine idling speed:
1,050 X 1,250 r/min
–16–
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INSP
ADJ
CARBURETOR SYNCHRONIZATION
7. Adjust:
S Carburetor synchronization
Adjustment steps:
S Synchronize carburetor #1 to carburetor #2 by
turning synchronizing screw 1 until both
gauges read the same.
S Race the engine for less than a second, two or
three times and check the synchronization
again.
Intake vacuum at idle speed:
36.0 – 38.7 kPa (270 – 290 mm Hg)
NOTE:
The difference between both carburetors should
be 0.67 kPa (5 mm Hg) or less.
8. Check:
S Engine idling speed
Out of specification ! Adjust.
9. Stop the engine and detach the measuring
equipment.
10. Adjust:
S Throttle cable free play
Refer to “THROTTLE CABLE FREE PLAY AD-
JUSTMENT”.
Free play:
3 – 5 mm
At throttle grip flange
11. Install:
S Fuel tank
S Side cover
S Seat
S Side cowling
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
–17–
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INSP
ADJ
ENGINE OIL LEVEL INSPECTION
ENGINE OIL LEVEL INSPECTION
NOTE:
Position the motorcycle straight up when inspect-
ing the oil level.
1. Place the motorcycle on a level surface.
NOTE:
S After idling the engine a few minutes.
The summer season is about 5 minutes and the
winter season is about 15 minutes.
S Turn off the engine and wait a few minutes until
the oil settle.
The motor cycle is vertical.
Then check that the oil level is between the maxi-
mum and minimum marks.
S Place the motorcycle on its centerstand if a cen-
terstand is equipped. If not, place a suitable
stand under the motorcycle.
2. Inspect:
S Oil level
a
Oil level should be between the maximum
and minimum b marks.
Oil level is below the minimum mark ! Add oil
up to the proper level.
Recommended oil:
Refer to the following chart for
selection of oils which are suited
to the atmospheric temperatures.
Recommended engine oil classifica-
tion:
API STANDARD:
API “SE” or higher grade
CAUTION:
S Do not put in any chemical additives or use
a
oils with a grade of CD
higher.
S Be sure not to use oils labeled “ENERGY
CONSERVING II” b or higher. Engine oil also
lubricates the clutch and additives could
cause clutch slippage.
S Be sure no foreign material enters the crank-
case.
3. Start the engine and let it warm up for several
minutes.
4. Turn off the engine and check the oil level
again.
–18–
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INSP
ADJ
ENGINE OIL REPLACEMENT
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:
S Oil filler plug 1
4. Remove:
S Drain bolt (with gasket) 1
S Oil filter drain bolt (with gasket) 2
Drain the crankcase and oil tank of its oil.
5. If the oil filter is to be replaced during this oil
change, remove the following parts and rein-
stall them.
Replacement steps:
S Remove the oil filter cover 1 and oil filter ele-
ment 2 .
S Check the O-rings 3 , if cracked or damaged,
replace them with a new one.
S Install the oil filter element and oil filter cover.
Oil filter cover (M10):
10 Nm (1.0 mSkg)
6. Install:
S Gaskets
New
S Drain bolt
35 Nm (3.5 mSkg)
30 Nm (3.0 mSkg)
S Oil filter drain bolt
–19–
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INSP
ADJ
ENGINE OIL REPLACEMENT
7. Fill:
S Crankcase
CAUTION:
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:
Total amount:
4.2 L
Periodic oil change:
3.5 L
With oil filter replacement:
3.6 L
8. Install:
S Oil filler plug
9. Inspect:
S Engine (for oil leaks)
S Oil level
Refer to “ENGINE OIL LEVEL INSPECTION”.
–20–
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INSP
ADJ
FUEL LINE INSPECTION
FUEL LINE INSPECTION
1. Remove:
S Side cowling
S Seat
S Side cover
S Fuel tank
Refer to “COWLINGS, SEAT, TAIL COVER
AND FUEL TANK”.
2. Inspect:
S Fuel hoses 1
Cracks/Damage ! Replace.
Loose connection ! Connect properly.
NOTE:
Drain and flush the fuel tank if abrasive damage to
any components is evident.
3. Install:
S All removed parts
NOTE:
Install all removed parts in reversed order of their
removal.
–21–
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ENG
CLUTCH
CLUTCH
CLUTCH
70 Nm (7.0mSkg)
8 Nm (0.8mSkg)
Order
Job name/Part name
Clutch removal
Q’ty
Remarks
Remove the parts in the order below.
1
2
3
Clutch spring
Pressure plate
Plain washer/Bearing
Pull rod
6
1
1/1
1
4
5
6
7
Friction plate
Friction plate
Clutch plate
7
2
8
Refer to “REMOVAL”, and
“INSTALLATION”.
8
9
Clutch boss nut
Lock washer
Clutch boss
1
1
1
1
1/1
1
1
10
11
12
13
14
15
Thrust plate
Spacer/Bearing
Clutch housing
Thrust plate 2
Thrust plate 1
1
For installation, reverse the removal
procedure.
–22–
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ENG
CLUTCH
INSTALLATION
1. Install:
S friction plates
S clutch plates
CAUTION:
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.
NOTE:
S Mount friction and clutch plate alternately.
S Lubricate the friction plates with engine oil.
–23–
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ELEC
INSTRUMENT FUNCTIONS
This combination meter is equipped with the fol-
lowing.
INSTRUMENT FUNCTIONS
COMBINATION METER
S An odometer
S Two trip odometers
S A clock
Odometer and trip meters
Use the trip meters to estimate how far you can
ride on a tank of fuel.
1
2
3
4
Speedometer
Clock, odometer
Select button
Reset button
Push the Select button to change between the
odometer mode “ODO” and the trip odometer
modes “TRIP 1” and “TRIP 2” in the following or-
der:
“ODO” ! “TRIP 1” ! “TRIP 2” ! “ODO”
To reset a trip odometer to 0.0, select it by pushing
the select button and push the reset button for at
least one second.
Clock
To change the display to the clock mode, push
both the select and reset buttons.
To set the clock:
1. Push both the select and reset buttons for at
least two seconds.
2. When the hour digits start flashing, push the re-
set button to set the hours.
3. Push the select button to change the minutes.
4. When the minute digits start flashing, push the
reset button to set the minutes.
5. Push the select button to start the clock.
NOTE:
After setting the clock, be sure to push the select
button before turning the main switch to “OFF”,
otherwise the clock will not be set.
–24–
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ELEC
SIGNAL SYSTEM
EB806000
SIGNAL SYSTEM
CIRCUIT DIAGRAM
–25–
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ELEC
SIGNAL SYSTEM
Main switch
3
4
6
8
Fuse (position light and hazard)
Battery
Main fuse
22 Fuel sender
25 Fuel meter
27 Fuel level indicator light
32 Turn indicator light (left)
33 Turn indicator light (right)
34 Speed meter
35 Speed sensor
36 Front flasher light
37 Rear flasher light
44 Hazard switch
45 Turn switch
48 Flasher relay
49 Hazard relay
–26–
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ELEC
SIGNAL SYSTEM
EB806010
EB802401
TROUBLESHOOTING
2. Battery
S Any of the following fail to light: flasher
light, trun and fuel level indicator light.
S The fuel meter fails to operate.
S Check the condition of the battery.
Refer to “BATTERY INSPECTION”.
Open-circuit voltage
12.8 V or more at 20_C
Check:
1. main and signal system fuses
2. battery
S Is the battery OK?
3. main switch
YES
NO
4. wiring
(of the entire signal system)
S Clean the battery
terminals.
NOTE:
S Before troubleshooting, remove the following
S Recharge or replace
part(-s):
the battery.
1) seats
EB802411
2) fuel tank
3) air filter case
3. Main switch
4) side cowlings
5) side covers
S Troubleshoot with the following special tool(-s).
S Check the main switch for continuity.
Refer to “SWITCH INSPECTION”.
S Is the main switch OK?
Pocket tester
90890-03112
YES
NO
Repalce the main
switch.
EB802400
1. Main and signal system fuses
EB806400
S Check the main and signaling system fuses
for continuity.
4. Wiring
Refer to “FUSE INSPECTION”.
S Are the main and signaling system fusesOK?
S Check the entire signal system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the signal system’s wiring properly con-
nected and withour defects?
YES
NO
Replace the fuse(-s).
YES
NO
Properly connect or
repair the signal sys-
tem’s wiring
Check the condition
of each of the signal-
ing system’s circuits.
Refer to “SIGNAL
SISTEM CHECK.”
–27–
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ELEC
SIGNAL SYSTEM
SIGNAL SYSTEM CHECK
1. Flasher light and/or turn indicator light does
not blink.
4. Voltage
S Connect the pocket tester (DC 20 V) to the
flasher relay coupler.
1. Flasher/turn indicator light bulb and socket
Tester (+) lead ! Brown/Red terminal
Tester (–) lead ! Frame ground
1
S Check the flasher/turn indicator light bulb and
socket for continuity.
S Are the flasher/turn indicator light bulb and
socket OK?
YES
NO
Replace the flash-
er/turn indicator light
balb, socket or both.
2. Turn switch
S Turn the main switch to “ON” or “P”.
S Refer to “SWITCH INSPECTION”.
S Is the turn switch OK?
S Check for voltage (12 V) on the “Brown/Red”
lead at the flasher relay terminal.
S Is the voltage within specification.
YES
NO
YES
NO
Replace the left han-
dlebar switch.
Wiring circuit from
main switch to flasher
relay connector is
faulty, repair.
3. Voltage
S Connect the pocket tester (DC 20 V) to the
hazard relay coupler.
5. Voltage
Tester (+) lead ! Brown/Red terminal
Tester (–) lead ! Frame ground
1
S Connect the pocket tester (DC 20 V) to the
flasher relay lead.
Tester (+) lead ! Brown/White terminal
Tester (–) lead ! Frame ground
1
S Turn the main switch to “ON” or “P”.
S Check for voltage (12 V) on the “Brouwn/Red”
lead at the flasher relay terminal.
S Is the voltage within specification.
YES
NO
Wiring circuit from
main switch to hazard
relay connector is
faulty, repair.
–28–
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ELEC
SIGNAL SYSTEM
2. The fuel level indicator light fails to come on or
the fuel meter fails to operator.
S Turn the main switch to “ON” or “P”.
S Check for voltage (12 V) on the “Brouwn/White”
lead at the flasher relay terminal.
1. Fuel level indicator light bulb and socket
S Is the voltage within specification.
S Check the fuel level indicator bulb and socket
continuity.
YES
NO
S Arethefuellevelindicatorlightbulbandsock-
et OK?
Replace the flasher
relay.
YES
NO
5. Voltage
Replace the bulb
and/or socket.
S Connect the pocket tester (DC 20 V) to the
bulb socket connector.
2. Fuel sender
A Flasher lights
Turn indicator light
B
S Drain the fuel and remove the fuel sender
from the fuel tank.
At flasher light (left):
S Disconnect the fuel sender coupler from the
wire harness.
Tester (+) lead ! Chocolate lead
Tester (–) lead ! Frame ground
1
S Connect the posket tester (Ω 1) to the fuel
At flasher light (right):
sender.
Tester (+) lead ! Dark green lead
Tester (–) lead ! Frame ground
2
Tester (+) lead ! Green/Red terminal 2
1
Tester (–) lead ! Black terminal
A
B
S Check the fuel sender for continuity.
S Connect the pocket tester (Ω 1) to the fuel
sender
Tester (+) lead ! Green/Red terminal 3
1
Tester (–) lead ! Black terminal
S Measure the fuel sender resistance.
Fuel sender resistance
: 4 X 10 Ω at 20_C
4
5
S Turn the main switch to “ON” or “P”.
S Turn the turn switch to “L” or “R”.
: 90 X 100 Ω at 20_C
S Check for voltage (12 V) on the “Chocolate”
lead or “Dark green” lead at the bulb socket
connector.
S Is the voltage with in specification.
YES
NO
This circuit is good.
Wiring circuit from
turn switch to bulb
socket connector is
faulty, repair.
–29–
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ELEC
SIGNAL SYSTEM
S Set the main switch to “ON”.
S Measure the voltage (12 V).
S Is the voltage within specification?
S Is the fuel sender OK?
YES
NO
YES
NO
Replace the fuel
sender.
This circuit is OK.
The wiring circuit from
the main switch to the
meter assembly cou-
pler is faulty and must
be repaired.
3. Fuel meter
S Drainthefuelandremovethefuelsenderfrom
the fuel tank.
S Connect the fuel sender to wireharness.
1
2. The speed meter fails to operate.
1. Speed sensor
S Move the float to “UP” or “DOWN”
.
2
S Connect the pocket tester (DC 20 V) and bat-
tery (12 V)to the speed sensor coupler as
shown.
S Speed sensor coupler (speed sensor side)
S Turn the main switch to “ON”.
S Check the fuel gauge needle moves “F” or “E”.
Needle moves
Float position
“F”
“E”
1
Float “UP”
Float “DOWN” 2
YES
NO
Replace the fuel meter
4. Voltage
Connect the pocket tester (DC 20 V) to the meter
assembly coupler (wire harness side) as shown.
Tester positive probe ! Brown
1
Tester negative probe ! Green/Red
2
–30–
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ELEC
SIGNAL SYSTEM
Battery positive terminal ! red 2
Battery negative terminal ! black
3
Tester positive probe ! white
Tester negative probe ! black
1
3
S Set the main switch to “ON”.
S Elevate the front wheel and slowly rotate it.
S Does the voltage (5V) read cycle 4 times with
each, full rotation of the front wheel?
YES
NO
Replace the speed
sensor.
2. Wiring
S Check the entire wiring signal system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the signal system’s wiring properly con-
nected and with out defects?
YES
NO
Properly connect or
repair the signal sys-
tem’s wiring.
Replace the speed
meter.
–31–
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ELEC
FUEL PUMP SYSTEM
EB808000
FUEL PUMP SYSTEM
CIRCUIT DIAGRAM
–32–
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ELEC
FUEL PUMP SYSTEM
EB808010
FUEL PUMP CIRCUIT OPERATION
The ignitor unit includes the control unit for the fuel pump.
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
–33–
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ELEC
FUEL PUMP SYSTEM
EB808020
EB802401
TROUBLESHOOTING
2. Battery
_Check the condition of the battery.
The fuel pump fails to operate.
Refer to “BATTERY INSPECTION”.
Check:
1. main and ignition fuses
2. battery
Open-circuit voltage
12.8 V or more at 20 C
3. main switch
_Is the battery OK?
4. engine stop switch
5. fuel pump relay
6. fuel pump
YES
NO
7. wiring
_Clean the battery
terminals.
(the entire fuel pump system)
NOTE:
_Recharge or replace
_Before troubleshooting, remove the following
the battery.
part(-s):
EB802411
1) seat
2) fuel tank
3. Main switch
3) side cowlings
4) side covers
_Troubleshoot with the following special tool(-s).
_Check the main switch for continuity.
Refer to “SWITCH INSPECTION”.
_Is the main switch OK?
YES
NO
Pocket tester
90890-03112
Repalce the main
switch.
EB802400
1. Main and ignition fuses
EB802412
_Check the main and ignition fuses for continu-
4. Engine stop switch
ity.
Refer to “SWITCH INSPECTION”.
_Are the main and ignition fuses OK?
_Check the engine stop switch for continuity.
Refer to “SWITCH INSPECTION”.
_Is the engine stop switch OK?
YES
NO
YES
NO
Replace the fuse (-s)
Replace the right han-
dlebar switch
–34–
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ELEC
FUEL PUMP SYSTEM
5. Fuel pump relay
S Measure the fuel pump resistance.
Fuel pump resistance
S Disconnect the relay unit from the coupler.
S Connect the pocket tester (Ω 1) and battery
(12 V) to the relay unit ferminals as shown.
4 X 10 Ω at 20_C
S Is the fuel pump OK?
Battery positive terminal ! red/black
Battery negative terminal ! blue/red
1
2
YES
NO
Relpace the fuel pump.
Tester positive probe ! red/black
Tester negative probe ! blue/black
1
3
EB808401
7. Wiring
S Check the entire fuel pump system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the fuel pump system’s wiring properly con-
nected and without defects?
YES
NO
S Does the fuel pump relay have continuity be-
Replace the ignitor Prperly connect or re-
tween red/black and blue/black?
unit.
pair the fuel pump
system’s wiring.
YES
NO
Replace the relay unit
EB808400
6. Fuel pump resistance
S Disconnect the fuel pump coupler from the
wire harness.
S Connect the pocket tester (Ω 1) to the fuel
pump coupler (fuel pump side) as shown.
Tester positive probe ! black/blue
1
Tester negative probe ! black
2
–35–
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ELEC
FUEL PUMP SYSTEM
EB808410
CHECKING THE FUEL PUMP
WARNING
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 of fire.
_ If you do accidentally spill gasoline, wipe it
up immediately with dry rags.
_ If gasoline touches the engine when it is hot,
a fire may occur. Therefore, make sure that
the engine is completely cool before per-
forming the following test.
1. Check:
_ fuel pump operation
a. Fill the fuel tank.
b. Put the end of the fuel hose into an open con-
tainer.
c. Connect the battery (12 V) to the fuel pump
coupler as shown.
Battery positive lead ! blue/black 1
Battery negative lead ! black 2
d. Iffuelflowsoutofthefuelhose, thefuelpumpis
OK. If fuel does not flow, replace the fuel pump.
–36–
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1 A.C. maguneto/pickup coil
2 Rectifier/regulator
3 Main switch
TDM850 ’99 WIRING DIAGRAM
4 Fuse (position light and hazard)
5 Backup fuse (odometer)
6 Battery
7 Starter relay
8 Main fuse
9 Starter motor
10 Thermo unit
11 Fuel pump
12 Starting circuit cutoff relay
13 Fuel pump relay
14 Relay unit
15 T.P.S (throttle position sensor)
16 Gear position switch
17 Sidestand switch
18 Ignitor unit
19 Ignition coil
20 Spark plug
21 CYCLELOCK (option)
22 Fuel sender
23 Meter assembly
24 Tachometer
25 Fuel meter
26 Meter light
27 Fuel level indicator light
28 Neutral indicator light
29 Water temperature meter
30 Combination meter
31 High beam indicator light
32 Turn indicator light (left)
33 Turn indicator light (right)
34 Speed meter
35 Speed sensor
36 Front flasher light
37 Rear flasher light
38 Head light
39 Auxiliary light
40 Horn
41 Horn switch
42 Dimmer switch
43 “PASS” switch
44 Hazard switch
45 Turn switch
46 Clutch switch
47 Left handlebar switch
48 Flasher relay
49 Hazard relay
50 Fan motor
51 Thermo switch
52 Radiator fan fuse
53 Tail/brake light
54 Headlight fuse
55 Rear brake switch
56 Signal system fuse
57 Right handlebar switch
58 Front brake switch
59 Light switch
COLOR CODE
B . . . . . . Black
Br . . . . . Brown
Ch . . . . Chocolate
Dg . . . . Dark green
G . . . . . Green
Gy . . . . Gray
L . . . . . . Blue
Y . . . . . . Yellow
B/Y . . . . Black/Yellow
G/B . . . Green/Black
G/R . . . Green/Red
G/W . . . Green/White
G/Y . . . Green/Yellow
L/R . . . . Blue/Red
L/W . . . Blue/White
L/Y . . . . Blue/Yellow
R/B. . . . Red/Black
P/G . . . Red/Green
R/W . . . Red/White
R/Y. . . . Red/Yellow
Y/B . . . . Yellow/Black
60 Engine stop switch
61 Start switch
62 Ignition fuse
Lg . . . . . Light green
Or . . . . . Orange
R . . . . . . Red
Sb . . . . . Sky blue
W . . . . . White
B/L . . . . Black/Blue
Br/L . . . Brown/Blue
Br/R . . . Brown/Red
Br/W . . Brown/White
B/W . . . Black/White
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