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 SUPPLEMENTARY SERVICE MANUAL: 4TX-AE2
TDM850 ’99
SUPPLEMENTARY
SERVICE MANUAL
1998 by Yamaha Motor Co., Ltd.
First Edition, November 1998
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd. is expressly
prohibited.
W
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.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
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. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 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.
2
1
4
3
6
8
5
7
1
2
EB003000
ILLUSTRATED 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
Cooling system
6
Carburetion
7
Chassis
8
Electrical
9
Troubleshooting
GEN
INFO
SPEC
3
4
INSP
ADJ
ENG
5
6
COOL
CARB
7
8
CHAS
ELEC
9
10
Illustrated symbols
10
to
17
are used to identify the
specifications appearing in the text.
10
Can be serviced with engine mounted
11
Filling fluid
12
Lubricant
13
Special tool
14
Torque
15
Wear limit, clearance
16
Engine speed
17
TRBL
SHTG
11
12
13
14
W
, V, A
15
16
17
Illustrated symbols
18
to
23
in the exploded dia-
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
18
19
20
21
22
23
24
25
Illustrated symbols
24
to
25
in the exploded dia-
grams indicate where to apply a locking agent
24
and when to install new parts
25
.
24
Apply locking agent (LOCTITE
)
)
25
replace