FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the TDM850’97. For complete service information procedures it is necessary to use this Supplementary Service Manualtogether with the following manual.
TDM850 ’96 SERVICE MANUAL: 4TX-AE1TDM850 ’97SUPPLEMENTARYSERVICE MANUAL© 1996 by Yamaha Motor Co., Ltd.First Edition, October 1996 All rightsreserved.Any reproduction or unauthorized usewithout the written permission ofYamaha Motor Co., Ltd.is expressly prohibited.EB001000
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and theirqualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it isassumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcycles hasa basic understanding of the mechanical ideas and the procedures of motorcycle repair. Repairs attemptedby anyone without this knowledge are likely to render the motorcycle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significantchanges in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appearin 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 SAFETYIS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to themotorcycle operator, a bystander or a person inspecting or repairing the motor-cycle.
CAUTION:NOTE:
A CAUTION indicates special precautions that must be taken to avoid damage tothe motorcycle.
A NOTE provides key information to make procedures easier or clearer.
EB002000HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”.)1st title 1: This si 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 tirst 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 bycorresponding illustrations.EXPLODED DIAGRAMSTo help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removaland 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 bycircle indicates a disassembly step.3.An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6. Themeanings 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 ofparts, notes in jobs, etc.5.For jobs requiring more information, the step-by-step format supplements 8 are given in addition to theexploded diagram and the job instruction chart.21436857123456722CONTENTS
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTORCYCLE IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER. . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1111223334
CARBURETION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CARBURETOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL LEVEL ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5TDM850 ’97 WIRING DIAGRAM
–1–
–2–
–3–
–4–
CARBURETOR
CARBURETION
FUEL LEVEL ADJUSTMENT1.Measure:SFuel level a
Fuel level:
15.8 X 16.8 mm
(below the MIKUNI mark)Out of specification ! Adjust.
Adjust the float level by slightly bending the floattang 1.
Fuel level measurement and adjustmentsteps:
SPlace the motorcycle on a level surface.
SUse a garage jack under the engine to ensurethat the carburetors are positioned vertically.SConnect the fuel level gauge 2 to the drainpipe.
Fuel level gauge:
900-01312
SLoosen the drain screw.
SHold the gauge vertically next to the MIKUNImark 3.
SMeasure the fuel level a with the gauge.–5–
TDM850 ’97 WIRING DIAGRAM (EXCEPT FOR CH, A)
COLOR CODE
B. . . . . . BlackL. . . . . . Blue
Y. . . . . . Yellow
Br/W. . Brown/WhiteL/W. . . Blue/WhiteBr. . . . . BrownLg. . . . . Light greenB/L. . . . Black/BlueG/R. . . Green/RedL/Y. . . . Blue/YellowCh. . . . ChocolateO. . . . . OrangeB/R. . . . Black/RedG/W. . . Green/WhiteR/B. . . . Red/BlackDg. . . . Dark greenR. . . . . . RedB/W. . . Black/WhiteG/Y. . . Green/YellowR/W. . . Red/WhiteG. . . . . GreenSb. . . . . Sky blueB/Y. . . . Black/YellowL/B. . . . Blue/BlackR/Y. . . . Red/Yellow
Gy. . . . Gray
W. . . . . White
Br/L. . . Brown/Blue
L/R. . . . Blue/Red
1A.C. magneto/pickup coil2Rectifier/regulator3Main switch4Battery5Main fuse6Starter relay7Starter motor
8Starting circuit cut-off relay9Gear position switch10Sidestand switch
11T.P.S. (throttle position sensor)12Ignitor unit13Ignition coil14Spark plug
15Accessory coupler16Thermo unit17Meter assembly18Tachometer
19Water temperature meter20Meter light
21Neutral indicator light22High beam indicator light23Turn indicator ligh24Rear flasher light25Front flasher light26Headlight27Diode
28Auxiliary light
29Left handlebar switch30Horn switch31Horn
32Lights switch33Dimmer switch34Pass switch35Turn switch36Flasher relay37Clutch switch38Fan motor39Thermo switch40Radiator fan fuse41Tail/brake light42Headlight fuse43Rear brake switch44Signal system fuse45Right handlebar switch46Front brake switch47Engine stop switch48Start switch49Ignition fuse
