Yamaha TDM850 (1996) [96/229] Inspection and repair

Содержание

• Service manual 2
• Tt350s 2
• Caution 4
• How to use this manual 4
• Notice 4
• Particularly important information 4
• Exploded diagram 5
• Manual format 5
• Symbol marks refer to the illustration 6
• Adj 1 real 2 authentic not artificial 3 yamaha 7
• Genuine 7
• Chapter 1 10
• General information 10
• General information 11
• Machine identification 11
• Important information 12
• Special tools 13
• Special tools 14
• For chassis service 18
• For electrical components 18
• Special tools 18
• Chapter 2 20
• Insp toi adj wil 20
• Periodic inspections and adjustements 20
• Insp tol i adj wil 22
• Periodic maintenance lubrication 22
• Engine 23
• Valve clearance adjustment 23
• Valve clearance adjustment 24
• Adjustment 25
• Caution ___________________________ 25
• Insp lol i adj wl 26
• Valve clearance adjustment 26
• Exhaust 27
• Installed pad number 27
• Intake 27
• Valve clearance adjustment 27
• Valve clearance adjustment 28
• Decompression cable adjustment 29
• Insp adj 30
• Idle speed adjustment throttle cable adjustment 31
• Insp adj 31
• Air filter cleaning 32
• Caution _____________________________ 32
• Insp adj 32
• Air filter cleaning engine oil level inspection 33
• Engine oil level inspection 34
• Engine oil replacement 34
• Insp adj 34
• Caution _____________________________ 35
• Engine oil replacement 35
• Caution ____ _________________________ 36
• Engine oil replacement oil strainer cleaning 36
• Insp i adj iwll 36
• Insp adj m 37
• Oil strainer cleaning compression pressure measurement 37
• Compression pressure measurement 38
• Adj wl 39
• Chassis 39
• Fuel cock cleaning 39
• Caution _____________________________ 40
• Front brake pad inspection brake fluid level 40
• Insp qi adj 40
• Inspection front brake adjustment 40
• Insp ad 41
• Rear brake adjustment 41
• Clutch adjustment 42
• Rear brake lining inspection 42
• Clutch adjustment 43
• Clutch adjustment drive chain slack check 44
• Drive chain slack check drive chain slack adjustment drive chain lubrication 45
• Insp toi adj iwl 45
• Adj wl 46
• Drive chain lubrication steering head adjustment steering head inspection 46
• Insp tol 46
• Insp adj 1 47
• Steering head adjustment front fork oil change 47
• Front fork oil change 48
• Insp joi adj 48
• Front fork oil change front fork adjustment 49
• Front fork adjustment 50
• Insp adj iwll 50
• Adj iwl 51
• Caution ___________________________ 51
• Rear shock absorber adjustment 51
• Caution ___________________________ 52
• I adj wil 52
• Rear shock absorber adjustment 52
• Wheel bearings check cable inspection and lubrication swingarm and relay arm lubrication 53
• Adj wc 54
• Insp toi 54
• Tires check 54
• Electrical 55
• Wheels check ignition timing check 55
• Ignition timing check battery inspection 56
• Insp adj wil 56
• Adj iwl 57
• Battery inspection 57
• Brake light switch adjustment 58
• Insp toi adj 58
• Spark plug inspection 58
• Chapter 3 60
• Engine overhaul 60
• Engine overhaul 63
• Engine removal 63
• Engine removal 64
• Engine removal 65
• Engine removal 66
• Engine removal 68
• Engine disassembly 69
• Caution _____________________________ 70
• Engine disassembly 70
• Engine disassembly 71
• Caution _____________________________ 72
• Engine disassembly 72
• Engine disassembly 73
• Engine disassembly 74
• Engine disassembly 75
• Engine disassembly 76
• Engine disassembly 77
• Engine disassembly 78
• Caution _____________________________ 79
• Engine disassembly 79
• Inspection and repair 80
• Inspection and repair 81
• Engine disassembly 82
• Engine disassembly 83
• Caution _____________________________ 84
• Inspection and repair 84
• Inspection and repair 85
• Inspection and repair 86
• Inspection and repair 87
• Inspection and repair 88
• Inspection and repair 89
• Inspection and repair 90
• Inspection and repair 91
• Inspection and repair 92
• Inspection and repair 93
• Inspection and repair 94
• Inspection and repair 95
• Inspection and repair 96
• Inspection and repair 97
• Caution _____________________________ 98
• Inspection and repair 98
• Inspection and repair 99
• Inspection and repair 100
• Engine assembly and adjustment 101
• Caution _____________________________ 102
• Engine assembly and adjustment 102
• Engine assembly and adjustment 103
• Engine assembly and adjustment 104
• Engine assembly and adjustment 105
• Caution _____________________________ 106
• Engine assembly and adjustment 106
• Engine assembly and adjustment 107
• Engine assembly and adjustment 108
• Engine assembly and adjustment 109
• Engine assembly and adjustment 110
• Engine assembly and adjustment 111
• Engine assembly and adjustment 112
• Engine assembly and adjustment 113
• Engine assembly and adjustment 114
• Engine assembly and adjustment 115
• Engine assembly and adjustment 116
• Engine assembly and adjustment 117
• Engine assembly and adjustment 118
• Engine assembly and adjustment 119
• Engine assembly and adjustment 120
• Engine assembly and adjustment 121
• Caution _____________________________ 122
• Caution ______________________________ 122
• Engine assembly and adjustment 122
• Caution _____________________________ 123
• Engine assembly and adjustment 123
• Eng 10 124
• Engine assembly and adjustment 124
• Engine assembly and adjustment 125
• Engine assembly and adjustment 126
• Engine assembly and adjustment 127
• Engine assembly and adjustment 128
• Engine assembly and adjustment 129
• Carburetion 130
• Chapter 4 130
• Carburetion 131
• Coasting enricher 131
• Carb if 132
• Coasting enriche 132
• Carburetor 133
• Carbureto 134
• Carburetor 135
• Carbureto 136
• Carburetor 137
• Carbureto 138
• Carburetor 139
• Caution _____________________________ 139
• Carbureto 140
• Carburetor 141
• Carbureto 142
• Chapter 5 145
• Chassis 145
• Chassis 147
• Front wheel 147
• Chasg t 148
• Front whee 148
• Caution ___________________________ 149
• Caution _____________________________ 149
• Front wheel 149
• Chasg r 150
• Front whee 150
• Chas s 151
• Rear wheel 151
• Rear whee 152
• Chasgfcfe 153
• Rear wheel 153
• Rear wheel 154
• Chasefafe 155
• Front brake 155
• Front brak 156
• Caution _____________________________ 157
• Front wheel 157
• Front brake 158
• Chas 3 159
• Front brake 159
• Front brak 160
• Chasc y 161
• Front brake 161
• Front brake 162
• Chasg fe 163
• Front brake 163
• Chas 7 164
• Front fork 164
• Chas 7 165
• Front fork 165
• Chase fe 166
• Front for 166
• Chasc y 167
• Front fork 167
• Front for 168
• Front fork 169
• Снабс у 169
• Front fork 170
• Steering head 171
• Chasg t 172
• Steering hea 172
• Steering head 173
• Steering hea 174
• Chase fe 175
• Rear shock absorber 175
• Rear shock absorber monocross suspension de carbn system 175
• Caution ___________________________ 176
• Chas fe 176
• Rear shock absorbe 176
• Caution _____________________________ 177
• Rear shock absorber 177
• Rear shock absorbe 178
• Caution _____________________________ 179
• Rear shock absorber 179
• Swingarm 180
• Chasg j 182
• Swingarm 182
• Swingarm 183
• Swingarm 184
• Swingarm drive chain and sprockets 185
• Chas 3fe 186
• Drive chain and sprocket 186
• Drive chain and sprockets 186
• Drive chain and sprockets 187
• Chapter 6 electrical 188
• Elec h 188
• Elec s 189
• Electrical 189
• Circuit diagram 190
• Electrical components 191
• Elec s 193
• Ignition system 194
• Ignition system 195
• Caution _____________________________ 196
• Ignition system 196
• Ignition system 197
• Elec s 198
• Ignition system 198
• Elec 9 199
• Lighting system 200
• Lighting system 201
• Caution _____________________________ 202
• Elec s 202
• Lighting system 202
• Appx s 204
• Chapter 7 appendices 204
• Appendices 205
• Appx a 205
• General specifications 205
• Specifications 205
• Specification 206
• Specifications 207
• Appx as 208
• Maintenance specifications engine 208
• Specification 208
• Specifications 209
• Appx x s 210
• Specification 210
• Appx s 211
• Specifications 211
• Specification 212
• Specifications 213
• Specification 214
• Specifications 215
• Chassis 216
• Specification 216
• Specifications 217
• Specification 218
• Electrical 219
• Specifications 219
• Specification 220
• Appx 1 221
• Definition of units 221
• General torque specification definition of units 221
• General torque specifications 221
• Cable routing 224
• Appx x s 225
• Cable routing 225
• Cable routin 226
• Appx s 227
• Cable routing 227
• Tt350s wiring diagram 228

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INSPECTION AND REPAIR ENG 5 Inspect Pressure plate T O ring 2 Short push rod 3 Push plate 4 Plain washer 5 Locknut 6 Damage Replace 6 Measure Long push rod Roll on V block Exceeds bending limit Replace Bend Limit 0 5 mm 0 02 in 7 Measure Clutch spring free length a Out of specification Replace spring as a set Clutch spring minimum free length a 40 3 mm 1 587 in TRANSMISSION 1 Inspect Shift fork cam follower T Shift fork pawl 2 Scoring Bends Wear Replace 2 Inspect Shift cam groove Shift cam dowel and side plate Shift cam stopper plate circlip and stopper Wear Damage Replace 3 34