YAMAHA TDM 850-4TX GUIDE.pdf

4TX-28199-E4

OWNER’S MANUAL

TDM850

00001 INTRODUCTION

maha’s vast experience in andcture of high-quality products,bility.

ghly, so as to enjoy all yourot only instruct you in how toso in how to safeguard yourself

elp to keep your motorcycle inestions, do not hesitate to con-

nt rides. So, remember to put

E_4tx_Intro0.fm Page 1 Saturday, October 16, 1999 9:35 AM

EAU

Welcome to the Yamaha world of motorcycling!

As the owner of a TDM850, you are benefiting from Yanewest technology for the design and the manufawhich have earned Yamaha a reputation for dependa

Please take the time to read this manual thorouTDM850’s advantages. The owner’s manual does noperate, inspect and maintain your motorcycle, but aland others from trouble and injury.

In addition, the many tips given in this manual will hthe best possible condition. If you have any further qutact your Yamaha dealer.

The Yamaha team wishes you many safe and pleasasafety first!

EAU00005PORTANT MANUAL INFORMATION

ticularly important information is distinguished in this manual by the following notations:

ERT! YOUR SAFETY IS

E_4tx_Info0.fm Page 1 Saturday, October 16, 1999 9:35 AM

IM

Par

re injury or death to theing the motorcycle.

to avoid damage to the

learer.

torcycle and should remain

d quality. Therefore, whilelable at the time of printing, this manual. If there is anydealer.

C

N

The Safety Alert Symbol meaINVOLVED!

WARNING Failure to follow WARNING imotorcycle operator, a bystand

AUTION: A CAUTION indicates specialmotorcycle.

OTE: A NOTE provides key informati

NOTE:@

● This manual should be considwith it even if the motorcycle

● Yamaha continually seeks adthis manual contains the mosthere may be minor discrepanquestion concerning this man

@

ns ATTENTION! BECOME AL

nstructions could result in seveer or a person inspecting or repair

precautions that must be taken

on to make procedures easier or c

ered a permanent part of this mois subsequently sold.vancements in product design ant current product information avaicies between your motorcycle andual, please consult your Yamaha

IMPORTANT MANUAL INFORMATIONEW000002

INGAD THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATINGRCYCLE.


WARN@

PLEASE RETHIS MOTO@

IMPORTANT MANUAL INFORMATION

© 1991st

All rightunauthopermissi

i


EAU00008

TDM850OWNER’S MANUAL

9 by Yamaha Motor Co., Ltd. Edition, September 1999s reserved. Any reprinting orrized use without the writtenon of Yamaha Motor Co., Ltd.s expressly prohibited.

Printed in Japan.

LE OF CONTENTS

WAY 1

2

FUNCTIONS 3

4

T RIDING POINTS 5

D MINOR REPAIR 6

ORAGE 7

8

9

EAU00009

E_4tx_Toc0.

TAB

1 GIVE SAFETY THE RIGHT OF

2 DESCRIPTION

3 INSTRUMENT AND CONTROL

4 PRE-OPERATION CHECKS

5 OPERATION AND IMPORTAN

6 PERIODIC MAINTENANCE AN

7 MOTORCYCLE CARE AND ST

8 SPECIFICATIONS

9 CONSUMER INFORMATION

fm Page 1 Saturday, October 16, 1999 9:35 AM

INDEX

E_4tx_Toc0.fm Page 2 Saturday, October 16, 1999 9:35 AM

GIVE SAFETY THE RIGHT OF WAY

1

GIVE SAFETY THE RIGHT OF WAY................................................. 1-1

E_4tx_LabelTOC.fm Page 1 Saturday, October 16, 1999 9:35 AM

1

EAU00021

nsurpassed feeling of power andt accept; even the best motorcycle

E_4tx_Label.fm Page 1 Saturday, October 16, 1999 9:35 AM

motorcycle’s value and operatinge for the rider: good performanceedication, drugs and alcohol is, ofrs - must always be at their mentallcohol, there is a tendency to take

eat belts are for car drivers and made of leather or tear-resistantves and a properly fitting helmet.relessness. Though full-coverage and protection, motorcyclists willrisk of going too fast and are apt tohe good motorcyclist rides safely, caused by others.

1-1

1-GIVE SAFETY THE RIGHT OF WAY

Motorcycles are fascinating vehicles, which can give you an ufreedom. However, they also impose certain limits, which you musdoes not ignore the laws of physics.

Regular care and maintenance are essential for preserving yourcondition. Moreover, what is true for the motorcycle is also trudepends on being in good shape. Riding under the influence of mcourse, out of the question. Motorcycle riders - more than car driveand physical best. Under the influence of even small amounts of adangerous risks.

Protective clothing is as essential for the motorcycle rider as spassengers. Always wear a complete motorcycle suit (whethersynthetic materials with protectors), sturdy boots, motorcycle gloOptimum protective wear, however, should not encourage cahelmets and suits, in particular, create an illusion of total safetyalways be vulnerable. Riders who lack critical self-control run the take chances. This is even more dangerous in wet weather. Tpredictably and defensively - avoiding all dangers, including those

Enjoy your ride!

Give safety the right of way

DESCRIPTION

2

Left view ............................................................................................. 2-1Right view........................................................................................... 2-2Controls/Instruments .......................................................................... 2-3

E_4tx_DescriptionTOC.fm Page 1 Saturday, October 16, 1999 9:35 AM

2

EAU00026

E_4tx_Description.fm Page 1 Saturday, October 16, 1999 9:36 AM

2-DE

Lef

1.2.3.4.

5.

2-1

SCRIPTION

t view

Coolant reservoir tank (page 6-10)Helmet holder (page 3-13)Seat lock (page 3-12)Rear shock absorber spring preload adjusting nut (for fine adjustment) (page 3-15)Rear shock absorber damping force adjusting knob (page 3-16)

DESCRIPTION

2

R

67

89

1011


2-2

ight view

. Luggage strap holders (page 3-17)

. Rear shock absorber spring preload adjusting lever (for coarse adjustment) (page 3-15)

. Fuses (page 6-29)

. Engine oil level check window (page 6-8)

. Front fork spring preload adjusting bolt (page 3-14)

. Front fork damping force adjusting screw (page 3-14)

DE

2

Co

12.13.14.15.16.

(page 3-4)(page 3-5)(page 6-16)(page 3-9)


SCRIPTION

2-3

ntrols/Instruments

Clutch lever (page 3-8)Handlebar switches (page 3-6)Starter (choke) “ ” (page 3-7)Speedometer (page 3-3)Main switch/steering lock (page 3-1)

17. Tachometer18. Fuel gauge19. Throttle grip20. Front brake lever

3

INSTRUMENT AND CONTROL FUNCTIONS

Main switch/steering lock......................................3-1Indicator lights ......................................................3-2Speedometer ........................................................3-3Tachometer ...........................................................3-4Diagnosis device...................................................3-5Antitheft alarm (optional) ......................................3-5Fuel gauge............................................................3-5Handlebar switches ..............................................3-6Starter (choke) “ ”..............................................3-7Clutch lever ...........................................................3-8Shift pedal.............................................................3-8Front brake lever ...................................................3-9

Rear brake pedal.................................................. 3-9Fuel tank cap ..................................................... 3-10Fuel .................................................................... 3-11Fuel tank breather hose (for Germany only) ...... 3-12Seat.................................................................... 3-12Helmet holder..................................................... 3-13Storage compartment ........................................ 3-13Front fork adjustment ......................................... 3-14Rear shock absorber adjustment ....................... 3-15Luggage strap holders ....................................... 3-17Sidestand ........................................................... 3-17Sidestand/clutch switch operation check............ 3-17

E_4tx_FunctionsTOC.fm Page 1 Saturday, October 16, 1999 9:36 AM

3

EAU00027

E_4tx_Functions.fm Page 1 Saturday, October 16, 1999 9:36 AM

3-IN

EW000016

WARNINGer turn the key to “OFF” orCK” when the motorcycle isving. The electrical circuits willswitched off which may result in of control or an accident. Be

e the motorcycle is stopped be- turning the key to “OFF” orCK”.

ushurn

MaTheanddes

ONEleengbe r

OFAll Thetion

3-1

STRUMENT AND CONTROL FUNCTIONS

EAU00029*

in switch/steering lock main switch controls the ignition lighting systems. Its operation iscribed below.

EAU00036

ctrical circuits are switched on. Theine can be started. The key cannotemoved in this position.

EAU00038

Felectrical circuits are switched off. key can be removed in this posi-.

EAU00040

LOCKThe steering is locked in this positionand all electrical circuits are switchedoff. The key can be removed in this po-sition.To lock the steering, turn the handle-bars all the way to the left. While push-ing the key into the main switch, turn itfrom “OFF” to “LOCK” and remove it.To release the lock, turn the key to“OFF” while pushing.

@

Nev“LOmobe losssurfore“LO@

1. P2. T

NTROL FUNCTIONS

3

ThanoncaTothDeddi

EAU00063

gh beam indicator light “ ”is indicator comes on when theadlight high beam is used.

EAU01707

olant temperature indicator light”

is indicator light comes on when thegine overheats. If the light comes on,p the engine immediately and allow

e engine to cool. To check that the in-ator light is working properly:

● Turn the engine stop switch to“ ” and the main switch to “ON”.

● Put the transmission in neutral orapply the clutch lever.

● Push the start switch.the indicator light does not come onile pushing the start switch, have amaha dealer inspect the electricalcuit.

EC000002

AUTION:hen the engine is overheated, dot continue riding.


INSTRUMENT AND CO

3-2

EAU00048

(Parking)e steering is locked in this position,d the taillight and auxiliary light come but all other circuits are off. The keyn be removed in this position. use the parking position, first lock

e steering, then turn the key to “ ”.o not use this position for an extend- length of time as the battery may

scharge.

EAU00056

Indicator lightsEAU00058

Turn indicator lights “ ” / “ ”The corresponding indicator flasheswhen the turn switch is moved to theleft or right.

EAU00061

Neutral indicator light “ ”This indicator comes on when thetransmission is in neutral.

HiThhe

Co“Thenstothdic

If whYacir

C@

Wno@

1. Left turn indicator light “ ”2. Neutral indicator light “ ”3. High beam indicator light “ ”4. Coolant temperature indicator light “ ”5. Right turn indicator light “ ”6. Fuel indicator light “ ”

IN

3

FueWhproon.tanTo ing

●

●

●

If thwhYacirc

ometer and trip meter modes the trip meters to estimate how far can ride on a tank of fuel.en set to “ODO”, the motorcycle’sl mileage is indicated.en set to “TRIP 1” or “TRIP 2”, thetorcycle’s mileage since the tripter was last reset is indicated. Use trip meter to estimate how far you ride on a tank of fuel. This informa- will enable you to plan fuel stops in future.



3-3

EAU01666

l indicator light “ ”en the fuel level drops below ap-ximately 3,1 L, this light will come When this light comes on, fill thek at the first opportunity.check that the indicator light is work- properly:

Turn the engine stop switch to“ ” and the main switch to “ON”.Put the transmission in neutral orapply the clutch lever.Push the start switch.

e indicator light does not come onile pushing the start switch, have amaha dealer inspect the electricaluit.

EAU01667*

SpeedometerThis speedometer is equipped with:

● an odometer● two trip odometers● a clock

OdUseyouWhtotaWhmomethecantionthe

1. “SELECT” button2. “RESET” button

NTROL FUNCTIONS

3

SePubean“Tor“O“C

RTobypuon

CTom“RToodbu

EAU00101

chometeris model is equipped with an electric

chometer so the rider can monitor thegine speed and keep it within theal power range.

EC000003

AUTION: not operate in the red zone.d zone: 8,000 r/min and above

Tachometer


INSTRUMENT AND CO

3-4

lecting a modesh the “SELECT” button to changetween the odometer mode “ODO”d the trip odometer modes “TRIP 1”,RIP 2” and “CLOCK” in the followingder:DO” → “TRIP 1” → “TRIP 2” →LOCK” → “ODO”

esetting a trip meter reset a trip odometer to 0.0, select it pushing the “SELECT” button andsh the “RESET” button for at leaste second.

lock mode change the display to the clock

ode, push both the “SELECT” andESET” buttons. change the display back to theometer mode, push the “SELECT”tton.

To set the clock1. Push both the “SELECT” and

“RESET” buttons for at least twoseconds.

2. When the hour digits start flashing,push the “RESET” button to setthe hours.

3. Push the “SELECT” button tochange the minutes.

4. When the minute digits start flash-ing, push the “RESET” button toset the minutes.

5. Push the “SELECT” button to startthe clock.

NOTE:@

After setting the clock, be sure to pushthe “SELECT” button before turning themain switch to “OFF”, otherwise theclock will not be set. @

TaThtaenide

C@

DoRe@

1.

IN

3

DiaThisissorIf scuiplaCB-61

If thaboYa

CA@

To to cas pla@

EAU00110

el gauges model is equipped with an electricl gauge so the rider can monitor thel level in the fuel tank. When thedle indicates “E” (Empty), aboutL remain in the fuel tank.

uel gauge



3-5

EAU00103

gnosis devices model is equipped with a diagno- device for the Throttle Position Sen- (T.P.S.) circuit.ome trouble should occur in the cir-t, the tachometer will repeatedly dis-y as follows:E

e tachometer displays as describedve, take your motorcycle to a

maha dealer for repair.EC000004

UTION:prevent engine damage, be sureonsult a Yamaha dealer as soonpossible if the tachometer dis-ys a repeated change in r/min.

EAU00109

Antitheft alarm (optional)An antitheft alarm can be equipped tothis motorcycle. Consult your Yamahadealer to obtain and install the alarm.

FuThifuefuenee3.1

0 r/min for 3 seconds.

3,000 r/min for 2.5 sec-onds.

Current en-gine r/min for 3 seconds.

1. F

NTROL FUNCTIONS

3

H

PaPrlig

DTube

EAU00144

zard switch “ ”e hazard switch should be turned onder emergency or hazardous condi-ns. All turn signal lights will flash si-ultaneously when this switch isrned on with the main switch in theN” or “ ” position.

EC000006

AUTION:e battery can discharge from ex-

nded use, making it difficult to op-ate the starter.

TE:rn on the hazard switch to warn oth-

drivers if your motorcycle must bepped where it might be a traffic haz-

d.

1.2.3.4.5.


INSTRUMENT AND CO

3-6

EAU00118

andlebar switchesEAU00120

ss switch “PASS”ess the switch to operate the passinght.

EAU00121

immer switchrn the switch to “ ” for the higham and to “ ” for the low beam.

EAU00127

Turn signal switchTo signal a right-hand turn, push theswitch to “ ”. To signal a left-handturn, push the switch to “ ”. Once theswitch is released it will return to thecenter position. To cancel the signal,push the switch in after it has returnedto the center position.

EAU00129

Horn switch “ ”Press the switch to sound the horn.

HaThuntiomtu“O

C@

Thteer@

NO@

Tuerstoar@

Pass switch “PASS”Dimmer switchTurn signal switchHorn switch “ ”Hazard switch “ ”

IN

3

EnThevicwhtrouTurginsw

LigTurturnand“

EAU02976

rter (choke) “ ”rting a cold engine requires a richerfuel mixture. A separate starter cir- supplies this mixture.ve in direction a to turn on therter (choke).ve in direction b to turn off therter (choke).

1. E2. L3. S

tarter (choke) “ ”



3-7

EAU00138

gine stop switch engine stop switch is a safety de-

e for use in an emergency such asen the motorcycle overturns or ifble occurs in the throttle system.n the switch to “ ” to start the en-e. In case of emergency, turn theitch to “ ” to stop the engine.

EAU00134*

hts switchning the light switch to “ ”,s on the auxiliary light, meter lights taillight. Turning the light switch to”, turns the headlight on also.

EAU00143

Start switch “ ”The starter motor cranks the enginewhen pushing the start switch.

EC000005

CAUTION:@

See starting instructions prior tostarting the engine. @

StaStaair-cuitMostaMosta

ngine stop switchights switchtart switch “ ”

1. S

NTROL FUNCTIONS

3

CThhaoflehareThreatceci

1.


INSTRUMENT AND CO

3-8

EAU00152

lutch levere clutch lever is located on the leftndlebar, and the ignition circuit cut-

f system is incorporated in the clutchver holder. Pull the clutch lever to thendlebar to disengage the clutch, andlease the lever to engage the clutch.e lever should be pulled rapidly and

leased slowly for smooth clutch oper-ion. (Refer to the engine starting pro-dures for a description of the ignition

rcuit cut-off system.)

EAU00157

Shift pedalThis motorcycle is equipped with a con-stant-mesh 5-speed transmission.The shift pedal is located on the leftside of the engine and is used in com-bination with the clutch when shifting.

Clutch lever 1. Shift pedal

IN

3

FroTherighposTo ver

EAU00162

ar brake pedal rear brake pedal is on the right of the motorcycle. Press down on

brake pedal to apply the rear brake.

1. Ba. L

ear brake pedal



3-9

EAU00160

nt brake lever front brake lever is located on thet handlebar and is equipped with aition adjuster.activate the front brake, pull the le- toward the handlebar.

To adjust the front brake lever position,turn the adjusting nut while pulling thelever forward. Make sure the mark “ ”on the adjusting nut is aligned with themark “ ” on the lever.

ReThesidethe

rake lever position adjusterever distance

1. Adjusting nut2. Proper position

1. R

NTROL FUNCTIONS

3

FToOtubeop

ToPukecotio

1.2.


INSTRUMENT AND CO

3-10

EAU02935

uel tank cap open

pen the lock cover. Insert the key andrn it 1/4 turn clockwise. The lock will released and the cap can beened.

closesh the tank cap into position with they inserted. To remove the key, turn itunterclockwise to the original posi-n. Then, close the lock cover.

NOTE:@

This tank cap cannot be closed unlessthe key is in the lock. The key cannotbe removed if the cap is not lockedproperly. @

EW000023

WARNING@

Be sure the cap is properly installedand locked in place before riding themotorcycle. @

Lock coverOpen

IN

3

FuMatanthetion

@

Dospinottomflowexp@

TE:nocking or pinging occurs, use a dif-nt brand of gasoline or higher oc-

e grade.

1. F2. F



3-11

EAU01183

elke sure there is sufficient fuel in thek. Fill the fuel tank to the bottom of filler tube as shown in the illustra-.

EW000130

WARNING not overfill the fuel tank. Avoidlling fuel on the hot engine. Do fill the fuel tank above the bot- of the filler tube or it may over- when the fuel heats up later andands.

EAU00186

CAUTION:@

● Always wipe off spilled fuel im-mediately with a dry and cleansoft cloth. Fuel may deterioratepainted surfaces or plasticparts.

● (For Germany only)The fuel tank cap equipped onGerman models is specially de-signed. Always use the correctcap whenever replacement isnecessary.

@

EAU00191

NO@

If kferetan@

iller tubeuel level

Recommended fuel:Regular unleaded gasoline with a research octane number of 91 or higher.

Fuel tank capacity:Total:

20 LReserve:

3.1 L

NTROL FUNCTIONS

3

F(fThbrcy

installsert the projections on the front of theat into the seat holders. Then pushwn on the seat.

TE:ake sure that the seat is securely fit-d.

1. Projection (× 2)Seat holder (× 2)


INSTRUMENT AND CO

3-12

EAU00196

uel tank breather hose or Germany only)is model is equipped with a fuel tankeather hose. Before using this motor-cle, be sure to:● Check hose connection.● Check hose for cracks or damage.

Replace if damaged.● Make sure the end of the hose is

not blocked. Clean it if necessary.

EAU01726

SeatTo removeInsert the key in the lock and turn itclockwise.

ToInsedo

NO@

Mte@

Fuel tank breather hose 1. Open 1.2.

IN

3

HeTheReon the

@

Nemejecpos@

en storing this Owner’s manual orer documents in the compartment,sure to put them in a vinyl bag soy do not get wet. When washing thetorcycle, be careful not to flood thispartment with water.

1. H -LOCK (optional)trap (× 2)



3-13

EAU00263

lmet holder helmet holder is under the seat.

move the seat and hook the helmetthe helmet holder. Then, reinstall seat and lock it.

EW000030

WARNINGver ride with a helmet in the hel-t holder. The helmet may hit ob-ts, causing loss of control andsibly an accident.

EAU01688

Storage compartmentThis compartment is designed to storea genuine Yamaha U-LOCK. (Otherlocks may not fit.) Be sure the lock is fastened securelywith the straps when storing it in thecompartment.To prevent losing the straps, be sure tosecure them even when a U-LOCK isnot being stored in the compartment.

Whothbe themocom

elmet holder 1. U-LOCK (optional)2. Strap

1. U2. S

NTROL FUNCTIONS

3

FThpr

@

Alsacast@

justing damping forcern the adjusting screw in direction a

increase damping force and in direc-n b to decrease damping force.9E

EC000015

AUTION:ver attempt to turn an adjusteryond the maximum or minimumtting.

1.2.3.

Damping force adjusting screw

Minimum (soft) 5 clicks out*

Standard 4 clicks out*

aximum (hard) 0 click out*

rom the fully turned-in position


INSTRUMENT AND CO

3-14

EAU01728

ront fork adjustmente front fork is equipped with spring

eload and damping force adjusters.EW000038

WARNINGways adjust each fork leg to theme setting. Uneven adjustmentn cause poor handling and loss ofability.

Adjusting spring preloadTurn the adjusting bolt in direction a to in-crease spring preload and in direction bto decrease spring preload.CI-18E

AdTutotioCI-2

C@

Nebese@

Spring preload adjusting boltAdjusting positionStandard setting

Soft Standard Hard

Adjusting position

1 2 3 4 5

1.

M

* F

IN

3

ReadThitwodam

SpCoUskit solsen

1. A istance “A”

pring preload:Minimum (soft):

Distance “A” = 59 mmStandard:

Distance “A” = 61 mmMaximum (hard):

Distance “A” = 63 mm



3-15

EAU01768*

ar shock absorber justments shock absorber is equipped with spring preload adjusters and oneping force adjuster.

ring preloadarse adjustment (top)e the special tool in the owner’s toolto turn the lever to “S” when ridingo and to “H” when riding with a pas-ger.

Fine adjustment (bottom)Proceed as follows to suit road condi-tions and the rider’s preference.

1. Loosen the locknut.2. Turn the adjusting nut in direction a

to increase spring preload and in di-rection b to decrease spring pre-load.

djusting lever 1. Locknut2. Adjusting nut

a. D

S

NTROL FUNCTIONS

3

3

C@

Althth@

EAU00315

WARNINGis shock absorber contains high-pressurized nitrogen gas. Readd understand the following infor-ation before handling the shocksorber. The manufacturer cannot held responsible for propertymage or personal injury that maysult from improper handling.● Do not tamper with or attempt to

open the cylinder assembly.● Do not subject the shock ab-

sorber to an open flame or otherhigh heat source. This maycause the unit to explode due toexcessive gas pressure.

● Do not deform or damage thecylinder in any way. Cylinderdamage will result in poordamping performance.

● Take your shock absorber to aYamaha dealer for any service.


INSTRUMENT AND CO

3-16

. Tighten the locknut to the speci-fied torque.

EC000018

AUTION:ways tighten the locknut againste spring adjusting nut and tightene locknut to the specified torque.

Damping force adjustmentTurn the adjusting knob in direction ato increase damping force and in direc-tion b to decrease damping force.CI-29E

EC000015

CAUTION:@

Never attempt to turn an adjusterbeyond the maximum or minimumsetting. @

@

Thly anmabbedare

@

Tightening torque:Locknut:

70 Nm (7.0 m·kg)

1. Adjusting knob

Minimum (soft) 20 clicks out*

Standard 10 clicks out*

Maximum (hard) 0 click out*

* From the fully turned-in position

IN

3

LuThebelcances

EAU00331

estand/clutch switch eration checkck the operation of the sidestand

tch and clutch switch against the in-ation below.

E

1. L

RN THE MAIN SWITCH TO “ON” D THE ENGINE STOP SWITCH TO ”.

ANSMISSION IS IN GEAR AND ESTAND IS UP.

LL IN CLUTCH LEVER AND SH THE START SWITCH.

GINE WILL START.

UTCH SWITCH IS OK.



3-17

EAU00324

ggage strap holdersre are four luggage strap holders

ow the passenger seat, two of which be turned outward for easier ac-s.

EAU00330

SidestandThis model is equipped with an ignitioncircuit cut-off system. The motorcyclemust not be ridden when the sidestandis down. The sidestand is located onthe left side of the frame. (Refer topage 5-1 for an explanation of this sys-tem.)

EW000044

WARNING@

This motorcycle must not be operat-ed with the sidestand in the downposition. If the stand is not properlyretracted, it could contact theground and distract the operator, re-sulting in a possible loss of control.Yamaha has designed into thismotorcycle a lockout system to as-sist the operator in fulfilling the re-sponsibility of retracting thesidestand. Please check carefullythe operating instructions listed be-low and if there is any indication of amalfunction, return the motorcycleto a Yamaha dealer immediately forrepair. @

SidopCheswiformCD-11

uggage strap holder (× 4)

TUAN“

TRSID

PUPU

EN

CL

NTROL FUNCTIONS

3

CD-11E

@

If su@

S

E

S


INSTRUMENT AND CO

3-18

EW000045

WARNINGimproper operation is noted, con-lt a Yamaha dealer immediately.

IDESTAND IS DOWN.

NGINE WILL STALL.

IDESTAND SWITCH IS OK.

PRE-OPERATION CHECKS

4

Pre-operation check list...................................................................... 4-1

E_4tx_PreopTOC.fm Page 1 Saturday, October 16, 1999 9:36 AM

4

EAU01114

al functions can start to deterioratelements). Any damage, fluid leak ort, in addition to a thorough visual in-

E_4tx_Preop.fm Page 1 Saturday, October 16, 1999 9:36 AM

4-PR

Owquicloss

EAU00340

PAGE

3-9, 6-20 ~ 6-23

3-8, 6-19 ~ 6-20

6-16, 6-25

6-8 ~ 6-10

6-10

6-23 ~ 6-24

6-17 ~ 6-19, 6-28

6-24 ~ 6-25

6-25

spe

Fro

Re

Clu

Th

En

Co

Dri

Wh

Co

Brasha

4-1

E-OPERATION CHECKS

ners are personally responsible for their vehicle’s condition. Your motorcycle’s vitkly and unexpectedly, even if it remains unused (for instance, if it is exposed to the e of tire pressure could have serious consequences. Therefore, it is very important thaction, you check the following points before each ride.

PRE-OPERATION CHECK LIST

ITEM CHECKS

nt brake • Check operation, fluid level and brake fluid leakage.• Fill with DOT 4 brake fluid if necessary.

ar brake • Check operation, fluid level and brake fluid leakage.• Fill with DOT 4 brake fluid if necessary.

tch • Check operation, condition and free play.• Adjust if necessary.

rottle grip and housing • Check for smooth operation.• Lubricate if necessary.

gine oil • Check oil level.• Fill with oil if necessary.

olant reservoir tank • Check coolant level.• Fill with coolant if necessary.

ve chain • Check chain slack and condition.• Adjust if necessary.

eels and tires • Check tire pressure, wear and damage.

ntrol and meter cables • Check for smooth operation. • Lubricate if necessary.

ke and shift pedal fts

• Check for smooth operation. • Lubricate if necessary.

PERATION CHECKS

4

NPr spection can be thoroughly accom-pl e involved.

If nd repaired before operatingth

Bp 6-25

S 6-26

C ed. —

Ls 6-30 ~ 6-32

F 3-11

PAGE


PRE-O

4-2

OTE:e-operation checks should be made each time the motorcycle is used. Such an inished in a very short time; and the added safety it assures is more than worth the tim

WARNINGany item in the PRE-OPERATION CHECK is not working properly, have it inspected ae motorcycle.

rake and clutch lever ivots

• Check for smooth operation. • Lubricate if necessary.

idestand pivot • Check for smooth operation. • Lubricate if necessary.

hassis fasteners • Make sure that all nuts, bolts and screws are properly tighten• Tighten if necessary.

ights, signals and witches • Check for proper operation.

uel • Check fuel level.• Fill with fuel if necessary.

ITEM CHECKS

OPERATION AND IMPORTANT RIDING POINTS

5

Starting the engine............................................................................. 5-1Starting a warm engine ...................................................................... 5-4Shifting ............................................................................................... 5-4Tips for reducing fuel consumption .................................................... 5-5Engine break-in .................................................................................. 5-5Parking ............................................................................................... 5-6

E_4tx_OperationTOC.fm Page 1 Saturday, October 16, 1999 9:37 AM

5

EAU00372

E_4tx_Operation.fm Page 1 Saturday, October 16, 1999 9:37 AM

5-OP

@

●

●

●

@

5-1

ERATION AND IMPORTANT RIDING POINTSEAU00373

WARNINGBefore riding this motorcycle,become thoroughly familiarwith all operating controls andtheir functions. Consult aYamaha dealer regarding anycontrol or function that you donot thoroughly understand.Never start your engine or let itrun for any length of time in aclosed area. The exhaust fumesare poisonous and can causeloss of consciousness anddeath within a short time. Al-ways operate your motorcyclein an area with adequate ventila-tion.Before starting out, always besure the sidestand is up. Failureto retract the sidestand com-pletely can result in a seriousaccident when you try to turn acorner.

EAU01665*

Starting the engine

NOTE:@

This motorcycle is equipped with an ig-nition circuit cut-off system. The enginecan be started only under one of thefollowing conditions:

● The transmission is in neutral.● The sidestand is up, the transmis-

sion is in gear and the clutch is dis-engaged.

The motorcycle must not be riddenwhen the sidestand is down. @

EW000054

WARNING@

Before going through the followingsteps, check the function of thesidestand switch and clutch switch.(Refer to page 3-17.) @

ANT RIDING POINTS

5

CF-28E

IN GEAR AND

H LEVER AND PUSH THE GINE WILL START.

BE RIDDEN.


OPERATION AND IMPORT

5-2

TURN THE MAIN SWITCH TO “ON” AND THE ENGINE STOP SWITCH TO “ ”.

IF TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN,

PUSH THE START SWITCH.ENGINE WILL START.

RETRACT THE SIDESTAND AND PUT TRANSMISSION IN GEAR.

IF TRANSMISSION ISSIDESTAND IS UP,

PULL IN THE CLUTCSTART SWITCH. EN

MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN

O

5

1.

CA@

If tchethe@

2.

NO@

WhneutheYa@

3.

4.

After starting the engine, move thestarter (choke) to the halfway posi-tion.

TE: maximum engine life, never accel-te hard with a cold engine!

After the engine is warm, turn offthe starter (choke) completely.

TE: engine is warm when it responds

mally to the throttle with the starteroke) turned off.


PERATION AND IMPORTANT RIDING POINTS

5-3

Turn the main switch to “ON” andthe engine stop switch to “ ”.

EC000035

UTION:he fuel indicator light comes on,ck the fuel level. If necessary, fill tank with fuel.

Shift the transmission into neutral.

TE:en the transmission is in neutral, thetral indicator light should be on. If

light does not come on, ask amaha dealer to inspect it.

Turn on the starter (choke) andcompletely close the throttle grip.Start the engine by pushing thestart switch.

NOTE:@

If the engine fails to start, release thestart switch, wait a few seconds, thentry again. Each attempt should be asshort as possible to preserve the bat-tery. Do not crank the engine morethan 10 seconds on any one attempt. @

ECA00022

CAUTION:@

The coolant temperature indicatorlight and the fuel indicator lightshould come on when the startswitch is pushed and should go offwhen the start switch is released. Ifthe coolant temperature indicatorlight remains on, immediately stopthe engine and have a Yamaha deal-er check the monitoring circuits. Ifthe fuel indicator light remains on,add sufficient fuel. @

5.

NO@

Forera@

6.

NO@

Thenor(ch@

ANT RIDING POINTS

5

SThw

C@

Seprth@

EC000048

AUTION:● Do not coast for long periods

with the engine off, and do nottow the motorcycle a long dis-tance. Even with gears in neu-tral, the transmission is onlyproperly lubricated when theengine is running. Inadequatelubrication may damage thetransmission.

● Always use the clutch whenchanging gears. The engine,transmission, and driveline arenot designed to withstand theshock of forced shifting and canbe damaged by shifting withoutusing the clutch.



5-4

EAU01258

tarting a warm enginee starter (choke) is not required

hen the engine is warm.EC000046

AUTION:e the “Engine break-in” section

ior to operating the motorcycle fore first time.

EAU00423

ShiftingThe transmission lets you control theamount of power you have available ata given speed for starting, accelerating,climbing hills, etc. The use of the shiftpedal is shown in the illustration.To shift into neutral, depress the shiftpedal repeatedly until it reaches theend of its travel, then raise the pedalslightly.

C@

@

1. Shift pedalN. Neutral

O

5

TipcoYodepridired

●

●

●

●

●

EAU00440

150 kmid operation above 5,000 r/min.p the engine and let it cool for 5 tominutes after every hour of opera-. Vary the speed of the motorcycle time to time. Do not operate it at

set throttle position.

~ 500 kmid prolonged operation above

00 r/min. Rev the motorcycle freelyugh the gears, but do not use fullttle at any time.

~ 1,000 kmid prolonged full throttle operation.id cruising speeds in excess of

00 r/min.EC000052

UTION:r 1,000 km of operation, be sureeplace the engine oil and oil fil-


PERATION AND IMPORTANT RIDING POINTS

5-5

EAU00424

s for reducing fuel nsumptionur motorcycle’s fuel consumptionends to a large extent on your

ng style. The following tips can helpuce fuel consumption:

Warm up the engine before riding.Turn off the starter (choke) assoon as possible.Shift up swiftly and avoid high en-gine speeds during acceleration.Do not double-clutch or rev the en-gine while shifting down and avoidhigh engine speeds with no loadon the engine.Turn off the engine instead of let-ting it idle for an extended lengthof time, i.e. in traffic jams, at trafficlights or railroad crossings.

EAU00436

Engine break-inThere is never a more important periodin the life of your motorcycle than theperiod between zero and 1,000 km. Forthis reason we ask that you carefullyread the following material. Becausethe engine is brand new, you must notput an excessive load on it for the first1,000 km. The various parts in the en-gine wear and polish themselves to thecorrect operating clearances. Duringthis period, prolonged full throttle oper-ation, or any condition which might re-sult in excessive heating of the engine,must be avoided.

0 ~AvoSto10 tionfromone

150Avo6,0throthro

500AvoAvo7,0

CA@

Afteto rter.@

ANT RIDING POINTS

5

1,Fu

C@

@



5-6

000 km and beyondll throttle can be used.

EC000053

AUTION:● Never let engine speeds enter

the red zone.● If any engine trouble should oc-

cur during the break-in period,consult a Yamaha dealer imme-diately.

EAU00457

ParkingWhen parking the motorcycle, stop theengine and remove the ignition key.Turn the fuel cock to “OFF” wheneverstopping the engine.

EW000058

WARNING@

The exhaust system is hot. Park themotorcycle in a place where pedes-trians or children are not likely totouch the motorcycle. Do not parkthe motorcycle on a slope or softground; the motorcycle may over-turn. @

6

PERIODIC MAINTENANCE AND MINOR REPAIR

Tool kit...................................................................6-1Periodic maintenance and lubrication...................6-2Cowling and panel removal and installation..........6-5Cowlings A and B .................................................6-5Panels A and B .....................................................6-6Spark plugs...........................................................6-6Engine oil ..............................................................6-8Cooling system ...................................................6-10Changing the coolant..........................................6-11Air filter ...............................................................6-13Carburetor adjustment ........................................6-15Idle speed adjustment ........................................6-15Throttle cable free play inspection ......................6-16Valve clearance adjustment ................................6-16Tires....................................................................6-17Clutch lever free play adjustment........................6-19Rear brake pedal height adjustment...................6-20Brake light switch adjustment .............................6-21Checking the front and rear brake pads..............6-21Inspecting the brake fluid level............................6-22Brake fluid replacement ......................................6-23

Drive chain slack check...................................... 6-23Drive chain slack adjustment ............................. 6-23Drive chain lubrication........................................ 6-24Cable inspection and lubrication ........................ 6-24Throttle cable and grip lubrication...................... 6-25Brake and shift pedal lubrication ........................ 6-25Brake and clutch lever lubrication ...................... 6-25Sidestand lubrication.......................................... 6-26Rear suspension lubrication............................... 6-26Front fork inspection........................................... 6-27Steering inspection ............................................ 6-27Wheel bearings .................................................. 6-28Battery................................................................ 6-28Fuse replacement .............................................. 6-29Headlight bulb replacement ............................... 6-30Tail/brake light bulb replacement........................ 6-31Turn signal light bulb replacement...................... 6-32Troubleshooting.................................................. 6-32Troubleshooting chart......................................... 6-33Engine overheating ............................................ 6-34

E_4tx_PeriodicTOC.fm Page 1 Saturday, October 16, 1999 9:37 AM

6

EAU00462

TE:ou do not have necessary tools re-red during a service operation, take

E_4tx_Periodic.fm Page 1 Saturday, October 16, 1999 9:37 AM

6-PE

Perbric

r motorcycle to a Yamaha dealer forvice.

EW000063

WARNINGdifications to this motorcycle notroved by Yamaha may cause of performance, and render itafe for use. Consult a Yamahaler before attempting any chang-

the posmoandbe geninteCOTERTIOUATHATIMTERROof mandlow

@

If ycycdon@

6-1

RIODIC MAINTENANCE AND MINOR REPAIREAU00464

iodic inspection, adjustment and lu-ation will keep your motorcycle insafest and most efficient conditionsible. Safety is an obligation of thetorcycle owner. The maintenance lubrication schedule chart shouldconsidered strictly as a guide toeral maintenance and lubricationrvals. YOU MUST TAKE INTONSIDERATION THAT WEATHER,RAIN, GEOGRAPHICAL LOCA-

NS, AND A VARIETY OF INDIVID-L USES ALL TEND TO DEMAND

T EACH OWNER ALTER THISE SCHEDULE TO SHORTER IN-VALS TO MATCH THE ENVI-

NMENT. The most important pointsotorcycle inspection, adjustment,

lubrication are explained in the fol-ing pages.

EW000060

WARNINGou are not familiar with motor-le service, this work should bee by a Yamaha dealer.

EAU01299

Tool kitThe tool kit is located inside the storagecompartment under the seat. (Seepage 3-12 for seat opening proce-dures.) The tools provided in the own-er’s tool kit are to assist you in theperformance of periodic maintenance.However, some other tools such as atorque wrench are also necessary toperform the maintenance correctly.The service information included in thismanual is intended to provide you, theowner, with the necessary informationfor completing some of your own pre-ventive maintenance and minor re-pairs.

NO@

If yquiyouser@

@

Moapplossunsdeaes.@

1. Tool kit

AND MINOR REPAIR

6

EAU00473

IONCP

N INITIAL(1,000 km)

EVERY

6,000 km or

6 months(whichevercomes first)

12,000 km or


1 √ √

2 √

3 √ √ √

4 Every 42,000 km or 42 months (whichever comes first)

5 √ √

6 √ √ √

7 √ √ √

8 √ √ √

9 √ √

10 √ √

11 √ √


PERIODIC MAINTENANCE

6-2

PERIODIC MAINTENANCE AND LUBRICAT-01E

O. ITEM CHECKS AND MAINTENANCE JOBS

* Fuel line • Check fuel hoses for cracks or damage. • Replace if necessary.

* Fuel filter • Check condition. • Replace if necessary.

Spark plugs • Check condition. • Clean, regap or replace if necessary.

* Valves • Check valve clearance. • Adjust if necessary.

Air filter • Clean or replace if necessary.

Clutch • Check operation. • Adjust or replace cable.

* Front brake

• Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 6-4.)

• Correct accordingly.• Replace brake pads if necessary.

* Rear brake

• Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 6-4.)

• Correct accordingly.• Replace brake pads if necessary.

* Wheels • Check balance, runout and for damage. • Rebalance or replace if necessary.

* Tires

• Check tread depth and for damage.• Replace if necessary.• Check air pressure.• Correct if necessary.

* Wheel bearings • Check bearing for looseness or damage. • Replace if necessary.

PE

6

12 √ √

13 Every 500 km and after washing themotorcycle or riding in the rain

14 √ √

15 √ √

16 √ √

17 √ √ √

18 √ √

19 √ √

20 √ √

21 √ √ √

22 √ √ √

23 √ √

NO INITIAL(1,000 km)

EVERY

6,000 km or


12,000 km or



RIODIC MAINTENANCE AND MINOR REPAIR

6-3

* Swingarm

• Check swingarm pivoting point for play.• Correct if necessary. • Lubricate with molybdenum disulfide grease every 24,000 km

or 24 months (whichever comes first).

Drive chain• Check chain slack.• Adjust if necessary. Make sure that the rear wheel is properly aligned.• Clean and lubricate.

* Steering bearings

• Check bearing play and steering for roughness.• Correct accordingly. • Lubricate with lithium soap base grease every 24,000 km


* Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened.• Tighten if necessary.

Sidestand • Check operation.• Lubricate and repair if necessary.

* Sidestand switch • Check operation. • Replace if necessary.

* Front fork • Check operation and for oil leakage. • Correct accordingly.

*Rear shock absorber assembly

• Check operation and shock absorber for oil leakage. • Replace shock absorber assembly if necessary.

*Rear shock absorber assembly pivoting points

• Check operation. • Lubricate with molybdenum disulfide grease every 24,000 km


* Carburetors • Check engine idling speed, synchronization and starter operation. • Adjust if necessary.

Engine oil• Check oil level and vehicle for oil leakage. • Correct if necessary.• Change. (Warm engine before draining.)

Engine oil filter element • Replace.

. ITEM CHECKS AND MAINTENANCE JOBS

AND MINOR REPAIR

6

* S aler.EAU02970*

N@

y areas.

rake fluid. Check the brake fluid level

er every two years.

@

24 √ √

N INITIAL(1,000 km)

EVERY

6,000 km or


12,000 km or




6-4

ince these items require special tools, data and technical skills, they should be serviced by a Yamaha de

OTE:● The air filter needs more frequent service if you are riding in unusually wet or dust● Hydraulic brake system

• When disassembling the master cylinder or caliper cylinder, always replace the bregularly and fill as required.

• Replace the oil seals on the inner parts of the master cylinder and caliper cylind• Replace the brake hoses every four years or if cracked or damaged.

* Cooling system• Check coolant level and vehicle for coolant leakage.• Correct if necessary.• Change coolant every 24,000 km or 24 months (whichever comes first).

O. ITEM CHECKS AND MAINTENANCE JOBS

PE

6

CoanTheneeof chaa cor r

EAU00484*

wlings A and Bremove

ove the screws and pull outwardshown.

installce the cowlings in the original posi- and install the screws.

1. C2. P

crew (× 3)



6-5

EAU01139

wling and panel removal d installation cowlings and panels illustratedd to be removed to perform some

the maintenance described in thispter. Refer to this section each timeowling or panel has to be removedeinstalled.

CoTo Remas

To Plation

owling Aanel A

1. Cowling B2. Panel B

1. S

AND MINOR REPAIR

6

PTo

1

2

To1

2

spectione spark plug is an important enginemponent and is easy to inspect. Thendition of the spark plug can indicatee condition of the engine.rmally, all spark plugs from theme engine should have the samelor on the white insulator around thenter electrode. The ideal color at thisint is a medium-to-light tan color for aotorcycle that is being ridden normal- If one spark plug shows a distinctlyferent color, there could be some-ing wrong with the engine.

1. Spark plug wrench



6-6

EAU01691*

anels A and B remove. Remove the seat. (See page 3-12

for removal and installation proce-dures.)

. Remove the screw.

install. Place the panels in the original po-

sition and install the screw.. Install the seat.

EAU01668*

Spark plugsRemoval

1. Remove cowlings A and B. (Seepage 6-5 for removal and installa-tion procedures.)

2. Remove the spark plug caps.3. Use the spark plug wrench in the

tool kit to remove the spark plugsas shown.

InThcocothNosacocepomly.difth

Screw 1. Spark plug cap 1.

PE

6

Dolemcycperspawillbresioandshospe

TE: torque wrench is not available when are installing a spark plug, a goodimate of the correct torque is 1/4 to turn past finger tight. Have therk plug tightened to the specifiedue as soon as possible.

Install the spark plug caps.Install the cowling.

S

ightening torque:Spark plug:

18 Nm (1.8 m·kg)



6-7

not attempt to diagnose such prob-s yourself. Instead, take the motor-le to a Yamaha dealer. You shouldiodically remove and inspect therk plugs because heat and deposits cause any spark plug to slowlyak down and erode. If electrode ero-n becomes excessive, or if carbon other deposits are excessive, youuld replace the spark plug with thecified plug. Installation

1. Measure the electrode gap with awire thickness gauge and, if nec-essary, adjust the gap to specifica-tion.

2. Clean the gasket surface. Wipe offany grime from the threads.

3. Install the spark plugs and tightenthem to the specified torque.

NO@

If ayouest1/2spatorq@

4.5.

pecified spark plug:DPR8EA-9 (NGK) or X24EPR-U9 (DENSO)

a. Spark plug gap

Spark plug gap:0.8 ~ 0.9 mm

T

AND MINOR REPAIR

6

EO

1

N@

BestA fa@

gine oil and oil filter element re-cement. Warm up the engine for a few min-

utes.. Stop the engine. Place an oil pan

under the engine and remove theoil filler cap.

. Remove the drain bolts and drainthe oil.

. Remove the oil filter cover boltsand oil filter.

1.2.3.

Engine oil drain bolt a



6-8

EAU01692

ngine oilil level inspection. Place the motorcycle on a level

place. Warm up the engine at idlefor 15 minutes.

OTE: sure the motorcycle is positioned

raight up when checking the oil level.slight tilt toward the side can result inlse readings.

2. The oil tank is located behind theengine cylinders. With the enginestopped, check the oil levelthrough the level window locatedon the right side of the oil tank.

3. The oil level should be betweenthe maximum and minimummarks. If the level is low, fill enginewith sufficient oil to raise it to thespecified level.

Enpla

1

2

3

4

Oil level windowMinimum level markMaximum level mark

1. Engine oil filler cap 1.

PE

6

5.

6.

EC000066

UTION:Do not put in any chemical addi-tives. Engine oil also lubricatesthe clutch and additives couldcause clutch slippage.Be sure no foreign material en-ters the crankcase.

1. E2. O3. O

T

ecommended oil:See page 8-1.

il quantity:Total amount:

4.2 LPeriodic oil change:

3.5 LWith oil filter replacement:

3.6 L



6-9

Install the drain bolts and tightenthem to the specified torque.

Install the new oil filter, O-ringsand the filter cover. Tighten the oilfilter cover bolts to the specifiedtorque.

NOTE:@

Make sure the O-rings are seated prop-erly. @

7. Fill engine with oil. Install the oil fill-er cap and tighten.

CA@

●

●

@

ngine oil drain bolt bil filter cover bolt (× 5)il filter cover

ightening torque:Drain bolt a:

35 Nm (3.5 m·kg)Drain bolt b:

30 Nm (3.0 m·kg)

1. Oil filter2. O-ring (× 2)

Tightening torque:Oil filter cover bolt:

10 Nm (1.0 m·kg)

R

O

AND MINOR REPAIR

6

8

9

. Install the coolant reservoir capand seat.

ECA00041

AUTION:rd water or salt water is harmful

the engine. You may use soft wa-r if you can’t get distilled water.

Coolant reservoir cap

Coolant reservoir capacity:0.3 L



6-10

. Start the engine and warm up for afew minutes. While warming up,check for oil leakage. If oil leakageis found, stop the engine immedi-ately and check for the cause.

. Stop the engine and check the oillevel.

EAU03024*

Cooling system1. Check the coolant level in the

coolant reservoir when the engineis cold as the coolant level will varywith engine temperature. Thecoolant level should be betweenthe maximum and minimummarks.

2. If the level is low, remove the seat.(See page 3-12 for seat removaland installation procedures.)

3. Remove the coolant reservoir cap,then add coolant or distilled waterto raise it to the specified level.

4

C@

Hatote@

1. Coolant reservoir2. Maximum level mark3. Minimum level mark

1.

PE

6

NO@

●

●

@

5.

Remove the water pump drain boltand cylinder drain bolt.

ater pump drain boltylinder drain bolt



6-11

TE:If water is added, have a Yamahadealer check the antifreeze con-tent of the coolant as soon as pos-sible. The radiator fan operation is com-pletely automatic. It is switched onor off according to the coolant tem-perature in the radiator.

If your motorcycle overheats, seepage 6-34 for details. EAU01176*

Changing the coolant1. Put the motorcycle on a level

place. 2. Remove cowling B. (See page 6-5

for cowling removal and installa-tion procedures.)

3. Place a container under the en-gine.

4. Remove the radiator cap stopperbolt and radiator cap.

EW000067

WARNING@

Do not remove the radiator capwhen the engine is hot. @

5.

1. Radiator cap stopper bolt2. Radiator cap

1. W2. C

AND MINOR REPAIR

6

6

7

8

9

10

ECA00041

AUTION:rd water or salt water is harmful

the engine. You may use soft wa-r if you can’t get distilled water.

. Run the engine several minutes.Stop the engine and recheck thecoolant level in the radiator. If it islow, add more coolant until itreaches the top of the radiator.

. Fill the coolant reservoir with cool-ant up to maximum level.

. Install the radiator cap, radiatorcap stopper bolt and coolant res-ervoir cap.

. Check for coolant leakage. If anyleakage is found, ask a Yamahadealer to inspect the cooling sys-tem.

1.2.3.4.



6-12

. Remove the seat. (See page 3-12for seat removal and installationprocedures.)

. Remove the coolant reservoir byremoving the bolts.

. Remove the coolant reservoirhose clamp and disconnect thehose.

. Drain the coolant from the coolantreservoir by turning it upsidedown.

. Install the hose and connect thecoolant reservoir hose clamp.

11. Drain the coolant completely andthoroughly flush the cooling sys-tem with clean tap water.

12. If the washers are damaged, re-place them. Tighten the waterpump drain bolt and cylinder drainbolt to the specified torques.

13. Pour the recommended coolantinto the radiator until it is full.

C@

Hatote@

14

15

16

17

Coolant reservoirBoltCoolant reservoir hose clampHose

Tightening torque: Water pump and cylinder drain bolts:

10 Nm (1.0 m·kg)

Recommended antifreeze: High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines.

Antifreeze and water mixing ratio:1 : 1

Total amount:1.7 L

Coolant reservoir capacity:0.3 L

PE

6

AirThespemousu

1.

2.

3.

1. B uel cockuel hosereather hose



6-13

EAU01769*

filter air filter should be cleaned at thecified intervals. It should be cleanedre frequently if you are riding in un-ally wet or dusty areas.Remove the seat. (See page 3-12for seat removal and installationprocedures.)Remove cowlings A and B andpanels A and B. (See pages 6-5 ~6-6 for removal and installationprocedures.)Remove the fuel tank holdingbolts.

4. Disconnect the fuel sender cou-pler.

5. Lift up the rear of the fuel tankslightly, turn the fuel cock to “OFF”and disconnect the fuel hose andbreather hose. Then remove thefuel tank.

olt (× 2) 1. Fuel sender coupler 1. F2. F3. B

AND MINOR REPAIR

6

6. Tap the air filter lightly to remove

most of the dust and dirt. Blow outthe remaining dirt with com-pressed air as shown. If the air fil-ter is damaged, replace it.

. Install by reversing the removalprocedure.

EWA00013

WARNINGake sure that the fuel hose andeather hose are properly connect-, in place and not pinched. If ase is damaged, be sure to replace

1.2.



6-14

. Remove the air filter case cover byremoving the screws.

7. Remove the air filter. 8

9

@

Mbredhoit. @

Air filter case coverScrew (× 3)

1. Air filter

PE

6

CA@

●

●

@

EAU00632

speed adjustmentStart the engine and warm it up fora few minutes at approximately1,000 to 2,000 r/min. Occasionallyrev the engine to 4,000 to5,000 r/min. The engine is warmwhen it quickly responds to thethrottle.Set the idle to the specified enginespeed by adjusting the throttlestop screw. Turn the screw in di-rection a to increase enginespeed and in direction b to de-crease engine speed.

hrottle stop screw



6-15

EC000082

UTION:Make sure the air filter is prop-erly seated in the air filter case.The engine should never be runwithout the air filter installed.Excessive piston and/or cylin-der wear may result.

EAU00630

Carburetor adjustmentThe carburetors are important parts ofthe engine and require very sophisti-cated adjustment. Most adjustmentsshould be left to a Yamaha dealer whohas the professional knowledge andexperience to do so. However, the idlespeed may be adjusted by the owneras part of routine maintenance.

EC000095

CAUTION:@

The carburetors were set at theYamaha factory after many tests. Ifthey are changed, poor engine per-formance and damage may result. @

Idle1.

2.

1. T

AND MINOR REPAIR

6

N@

If obju@

EAU00637

alve clearance adjustmente correct valve clearance changesth use, resulting in improper fuel/airpply or engine noise. To prevent this,e valve clearance must be adjustedgularly. This adjustment however,ould be left to a professionalmaha service technician.



6-16

OTE:the specified idle speed cannot betained by performing the above ad-

stment, consult a Yamaha dealer.

EAU00635

Throttle cable free play inspectionThere should be a free play of 3 ~5 mm at the throttle grip. If the free playis incorrect, ask a Yamaha dealer tomake this adjustment.

VThwisuthreshYa

Standard idle speed:1,050 ~ 1,250 r/min

a. Free play

PE

6

TirTo lonthe

TireAlwsur

@

Tirechetemamtioncorride(faifor @

EW000083

WARNINGper loading of your motorcycleportant for several characteris-

of your motorcycle, such asdling, braking, performance and

ety. Do not carry loosely packeds that can shift. Securely packr heaviest items close to theter of the motorcycle, and dis-ute the weight evenly from sideide. Properly adjust the suspen- for your load, and check thedition and pressure of your tires.VER OVERLOAD YOUR MOTOR-CLE. Make sure the total weighthe cargo, rider, passenger, andessories (fairing, saddlebags,. if approved for this model) does exceed the maximum load of thetorcycle. Operation of an over-ded motorcycle could cause tire

age, an accident, or even injury.



6-17

EAU00658

esensure maximum performance,

g service and safe operation, note following:

air pressureays check and adjust the tire pres-e before operating the motorcycle.

EW000082

WARNING inflation pressure should becked and adjusted when theperature of the tire equals thebient air temperature. Tire infla- pressure must be adjusted ac-ding to total weight of cargo,r, passenger, and accessories

ring, saddlebags, etc. if approvedthis model), and vehicle speed.

CE-33E

@

Prois imticshansafitemyoucentribto ssionconNECYof taccetcnotmoloadam@

Maximum load* 203 kg

Cold tire pressure Front Rear

Up to 90 kg load*225 kPa

(2.25 kg/cm2,2.25 bar)

275 kPa(2.75 kg/cm2,

2.75 bar)

90 kg load ~ Maximum load*

225 kPa(2.25 kg/cm2,

2.25 bar)

275 kPa(2.75 kg/cm2,

2.75 bar)

High speed riding225 kPa

(2.25 kg/cm2,2.25 bar)

275 kPa(2.75 kg/cm2,

2.75 bar)

* Load is the total weight of cargo, rider, passengerand accessories.

AND MINOR REPAIR

6

TiAlthrehathYath

EW000080

WARNING● After extensive tests, the tires

mentioned below have been ap-proved by Yamaha Motor Co.,Ltd. for this model. No guaran-tee for handling characteristicscan be given if tire combina-tions other than what is ap-proved are used on thismotorcycle. The front and reartires should be of the samemanufacture and design.

● The use of tire valves and valvecores other than listed belowcould cause tire deflation dur-ing extreme high speed riding.Always use genuine parts ortheir equivalent for replace-ment.

● Be sure to install the valve capssecurely, as these are importantto prevent air pressure leakageduring extreme high speedriding.

1.a.



6-18

re inspectionways check the tires before operatinge motorcycle. If center tread depthaches the limit as shown, if the tires a nail or glass fragments in it, or if

e side wall is cracked, contact amaha dealer immediately and have

e tire replaced.

EW000095

WARNING@

Operating the motorcycle with ex-cessively worn tires decrease ridingstability and can lead to loss of con-trol. Have excessively worn tires re-placed by a Yamaha dealerimmediately. Brakes, tires, and relat-ed wheel parts replacement shouldbe left to a Yamaha Service Techni-cian. @

CE-26E

NOTE:@

These limits may be different by regula-tion from country to country. If so, con-form to the limits specified by theregulations of your own country. @

Tire informationThis motorcycle is equipped with tube-less tires, tire valves and cast wheels.

@

@

Side wallTread depth

Minimum tire tread depth (front and rear)

1.6 mm

PE

6

CE-10

CE-12

EAU00692

tch lever free play justment clutch lever free play should be ad-ed to 10 ~ 15 mm. If the free play isrrect, adjust as follows.Loosen the locknut.Turn the adjusting bolt at theclutch lever in direction a to in-crease free play or in direction bto decrease free play.Tighten the locknut.

1. T2. V3. V

FRO

Ma

Br

Pi

M

REA

Ma

Br

Pi

M

ocknutdjusting boltree play



6-19

E

E

EAU00684

WARNING@

This motorcycle is fitted with superhigh-speed running tires. The fol-lowing points must be observed inorder for you to make fully effectiveuse of these tires.

● Never fail to use the specifiedtires in tire replacement. Othertires may have a danger ofbursting at super high-speeds.

● New tires have a relatively lowgrip on the road surface untilthey have been slightly worn.Therefore, approximately 100 kmshould be traveled at normalspeed before any high-speedriding is done.

● Before any high-speed runs, thetires should be warmed-up suf-ficiently.

● Always inflate to the correct tirepressure according to the oper-ating conditions.

@

CluadThejustinco

1.2.

3.

ire valvealve corealve cap with seal

NT

nufacturer Size Type

idgestone 110/80 ZR18 (58W) BT-54F

relli 110/80 ZR18 (58W) MTR03

ichelin 110/80 ZR18 (58W) MACADAM 90X

R

nufacturer Size Type

idgestone 150/70 ZR17 (69W) BT-54R

relli 150/70 ZR17 (69W) MTR04

ichelin 150/70 ZR17 (69W) MACADAM 90X

Type

Tire valve TR412

Valve core #9000A (original)

1. L2. Ac. F

AND MINOR REPAIR

6

N@

If tareth@

EW000109

WARNINGsoft or spongy feeling in the brakedal can indicate the presence of in the brake system. This airust be removed by bleeding theake system before the motorcycleoperated. Air in the system willuse greatly diminished brakingpability and can result in loss ofntrol and an accident. Have amaha dealer inspect and bleed

e system if necessary.



6-20

OTE:proper adjustment cannot be ob-

ined or the clutch does not work cor-ctly, ask a Yamaha dealer to inspecte internal clutch mechanism.

EAU00712

Rear brake pedal height adjustmentThe top of the brake pedal should bepositioned 29 mm below the top of thefootrest. If not, ask a Yamaha dealer toadjust it.

@

A peairmbris cacacoYath@

a. Pedal height

PE

6

BrTheby jusjusjusswturnTurmaTurma

1. B2. A

ear indicator (× 2)

ear



6-21

EAU00713

ake light switch adjustment rear brake light switch is activated

the brake pedal and is properly ad-ted when the brake light comes ont before braking takes effect. To ad-t the rear brake light switch, hold theitch body so it does not rotate whileing the adjusting nut.n the adjusting nut in direction a toke the brake light come on earlier.n the adjusting nut in direction b toke the brake light come on later.

EAU00715

Checking the front and rear brake padsA wear indicator is provided on eachbrake. This indicator allows checkingof brake pad wear without disassem-bling the brake. Apply the brake andinspect the wear indicator. If the indica-tor is ALMOST in contact with the discplate, ask a Yamaha dealer to replacethe pads.

rake light switchdjusting nut

1. Wear indicator (× 2)

Front

1. W

R

AND MINOR REPAIR

6

InleInthbrBeisisO

● Be careful that water does not en-ter the master cylinder when refill-ing. Water will significantly lowerthe boiling point of the fluid andmay result in vapor lock.

● Brake fluid may deteriorate paint-ed surfaces or plastic parts. Al-ways clean up spilled fluidimmediately.

● Have a Yamaha dealer check thecause if the brake fluid level goesdown.

1.

F



6-22

EAU00731

specting the brake fluid velsufficient brake fluid may let air entere brake system, possibly causing theakes to become ineffective.fore riding, check that the brake fluid

above the minimum level and replen-h when necessary.bserve these precautions:

● When checking the fluid level,make sure the top of the mastercylinder is level by turning the han-dlebars.

● Use only the designated qualitybrake fluid. Otherwise, the rubberseals may deteriorate, causingleakage and poor brake perfor-mance.

● Refill with the same type of brakefluid. Mixing fluids may result in aharmful chemical reaction andlead to poor brake performance.

Minimum level mark

ront

1. Minimum level mark

Recommended brake fluid: DOT 4

Rear

PE

6

BrTheby Hafollmaage

●

●

EAU00765

ve chain slack adjustmentLoosen the axle nut and caliperbracket bolt.Loosen the locknuts on each sideof the swingarm. To tighten thechain, turn the adjusting nut in di-rection a. To loosen the chain,turn the adjusting nut indirection b and push the wheelforward. Turn each adjusting nutexactly the same amount to main-tain correct axle alignment. Thereare marks on each side of theswingarm. Use these marks toalign the rear wheel.

xle nutocknutdjusting nutlignment marks



6-23

EAU00742

ake fluid replacement brake fluid should be replaced only

trained Yamaha service personnel.ve the Yamaha dealer replace theowing components during periodicintenance or when they are dam-d or leaking:oil seals (every two years)brake hoses (every four years)

EAU00744

Drive chain slack check

NOTE:@

Spin the wheel several times and findthe tightest position of the chain. Checkand/or adjust the chain slack while it’sin this tightest position. @

To check the chain slack the motor-cycle must be held straight up with bothwheels on the ground and without rider.Check the slack at the position shownin the illustration. Normal slack is ap-proximately 40 ~ 50 mm. If the slackexceeds 50 mm, adjust.

Dri1.

2.

a. Chain slack 1. A2. L3. A4. A

AND MINOR REPAIR

6

C@

TothKelim@

3

EAU02962

able inspection and brication

EW000112

WARNINGmage to the outer housing of ca-s may lead to internal rusting and

erfere with the cable movement.place damaged cables as soon asssible to prevent unsafe condi-ns.

bricate the cables and cable ends. Ifcable does not operate smoothly, askYamaha dealer to replace it.

1.

Recommended lubricant:Engine oil



6-24

EC000096

AUTION:o little chain slack will overload

e engine and other vital parts.ep the slack within the specifiedits.

. After adjusting, tighten the axle nutand caliper bracket bolt to thespecified torque.

EAU03006

Drive chain lubricationThe chain consists of many parts whichwork with each other. If the chain is notmaintained properly, it will wear outquickly. Therefore, the chain must beserviced regularly. This service is es-pecially necessary when riding in dustyareas. This motorcycle is equippedwith a sealed type chain. Steam clean-ing, high-pressure washers, and sol-vents can damage the drive chain, sodo not use these for cleaning it. Useonly kerosene to clean the drive chain.Wipe it dry, and thoroughly lubricate itwith SAE 30 ~ 50W motor oil. Do notuse any other lubricants on the drivechain. They may contain solvents thatcould damage the sealed chain.

EC000097

CAUTION:@

Be sure to oil the chain after wash-ing the motorcycle or riding in therain. @

Clu

@

DableintRepotio@

Lua a

Caliper bracket bolt

Tightening torque:Axle nut:

110 Nm (11.0 m·kg)Caliper bracket bolt:

35 Nm (3.5 m·kg)

PE

6

ThlubThebe lubmocabtheputthemea s

EAU02985

ke and clutch lever ricationricate the pivoting parts.

ecommended lubricant:Engine oil



6-25

EAU00773

rottle cable and grip rication throttle twist grip assembly should

greased at the time that the cable isricated, since the grip must be re-ved to get at the end of the throttlele. After removing the screws, hold end of the cable up in the air and in several drops of lubricant. With throttle grip disassembled, coat thetal surface of the grip assembly withuitable all-purpose grease.

EAU02984

Brake and shift pedal lubricationLubricate the pivoting parts.

BralubLub


R

AND MINOR REPAIR

6

SLuanCan

@

If sm@



6-26

EAU02986

idestand lubricationbricate the sidestand pivoting pointd metal-to-metal contact surfaces.

heck that the sidestand moves upd down smoothly.

EW000113

WARNINGthe sidestand does not moveoothly, consult a Yamaha dealer.

EAU00790

Rear suspension lubricationLubricate the pivoting parts.


Recommended lubricant:Molybdenum disulfide grease

PE

6

FroVis

@

Sethe@

Chinnfrom

EAU00794

ering inspectioniodically inspect the condition of theering. Worn out or loose steeringrings may be dangerous. Place a

nd under the engine to raise thet wheel off the ground. Hold theer end of the front forks and try tove them forward and backward. If free play can be felt, ask a Yamahaler to inspect and adjust the steer-

. Inspection is easier if the frontel is removed.

EW000115

WARNINGurely support the motorcycle so

re is no danger of it falling over.



6-27

EAU02939

nt fork inspectionual check

EW000115

WARNINGcurely support the motorcycle sore is no danger of it falling over.

eck for scratches or damage on theer tube and excessive oil leakage

the front fork.Operation check

1. Place the motorcycle on a levelplace.

2. Hold the motorcycle in an uprightposition and apply the front brake.

3. Push down hard on the handle-bars several times and check if thefork rebounds smoothly.

EC000098

CAUTION:@

If any damage or unsmooth move-ment is found with the front fork,consult a Yamaha dealer. @

StePerstebeastafronlowmoanydeaingwhe

@

Secthe@

AND MINOR REPAIR

6

WIf husmsp

EW000116

WARNINGttery electrolyte is poisonous andngerous, causing severe burns,

c. It contains sulfuric acid. Avoidntact with skin, eyes or clothing.TIDOTE:

● EXTERNAL: Flush with water.● INTERNAL: Drink large quanti-

ties of water or milk. Follow withmilk of magnesia, beaten egg,or vegetable oil. Call a physi-cian immediately.

● EYES: Flush with water for15 minutes and get promptmedical attention.

tteries produce explosive gases.ep sparks, flame, cigarettes etc.,ay. Ventilate when charging oring in an enclosed space. Alwaysield your eyes when working neartteries.EP OUT OF REACH OF CHIL-EN.



6-28

EAU01144

heel bearingsthere is play in the front or rear wheelb or if the wheel does not turnoothly, have a Yamaha dealer in-ect the wheel bearings.

EAU00800

BatteryThis motorcycle is equipped with asealed-type battery. Therefore it is notnecessary to check the electrolyte or fillthe battery with distilled water.

● If the battery seems to have dis-charged, consult a Yamaha deal-er.

● If the motorcycle is equipped withoptional electrical accessories, thebattery tends to discharge morequickly, so be sure to recharge itperiodically.

EC000101

CAUTION:@

Never try to remove the sealing capsof the battery cells. The battery willbe damaged. @

@

BadaetcoAN

BaKeawusshbaKEDR@

PE

6

BaWhmofullpla

CA@

●

●

●

@

EC000103

UTION:not use fuses of higher amper- rating than those recommend-

Substitution of a fuse ofroper rating can cause extensive

ctrical system damage and pos-y a fire.

ain fusepare fuse



6-29

ttery storageen the motorcycle is not used for anth or longer, remove the battery,y charge it and store it in a cool, dryce.

EC000102

UTION:Completely recharge the bat-tery before storing. Storing adischarged battery can causepermanent battery damage.Use a battery charger designedfor a sealed-type (MF) battery.Using a conventional batterycharger will cause battery dam-age. If you do not have a sealed-type battery charger, contactyour Yamaha dealer.Always make sure the connec-tions are correct when reinstall-ing the battery.

EAU01670

Fuse replacementThe fuse boxes are located under therider seat and the main fuse case is at-tached to the starter relay.If any fuse is blown, turn off the mainswitch and the switch of the circuit inquestion. Install a new fuse of specifiedamperage. Turn on the switches andsee if the electrical device operates. Ifthe fuse immediately blows again, con-sult a Yamaha dealer.

CA@

Do ageed.impelesibl@

1. Headlight fuse2. Signaling system fuse3. Ignition fuse4. Hazard light fuse5. Odometer fuse6. Radiator fan fuse7. Spare fuse (× 4)

1. M2. S

AND MINOR REPAIR

6

. Put a new bulb into position andsecure it in place with the bulbholder.

EC000105

AUTION:oid touching the glass part of alb. Keep it free from oil; other-se, the transparency of the glass, of the bulb, and luminous flux

ll be adversely affected. If oil gets a bulb, thoroughly clean it with ath moistened with alcohol or lac-er thinner.

Connector (× 2)Bulb holder



6-30

EAU00827

Headlight bulb replacementThis motorcycle is equipped with aquartz bulb headlight. If the headlightbulb burns out, replace the bulb as fol-lows:

1. Remove the connectors and thebulb holder cover.

2. Unhook the bulb holder and re-move the defective bulb.

EW000119

WARNING@

Keep flammable products and yourhands away from a bulb while it ison, as it is hot. Do not touch a bulbuntil it cools down. @

3

C@

Avbuwilifewioncloqu@

Specified fuses:Main fuse: 30 AHeadlight fuse: 15 ASignaling system fuse: 15 AIgnition fuse: 10 AHazard light fuse: 10 AOdometer fuse: 5 ARadiator fan fuse: 7.5 A

1. Bulb holder cover 1.2.

PE

6

4.

ulb (× 2)



6-31

Install the bulb holder cover andreconnect the headlight connec-tors. If the headlight beam adjust-ment is necessary, ask a Yamahadealer to make that adjustment.

EAU01623*

Tail/brake light bulb replacement

1. Remove the screws and the lens.2. Remove the defective bulb by

pushing it inward and turning itcounterclockwise.

3. Install a new bulb by pushing it in-ward and turning it clockwise.

4. Install the lens and tighten thescrews.

EC000108

CAUTION:@

Do not over-tighten the screws asthe lens may break. @

1. Screw (× 2)2. Lens

1. B

AND MINOR REPAIR

6

Tre

12

3

4

EAU01008

oubleshootingthough Yamaha motorcycles receiverigid inspection before shipment frome factory, trouble may occur duringeration.y problem in the fuel, compression,

ignition systems can cause poorrting and loss of power. The trouble-ooting chart describes a quick, easyocedure for making checks.your motorcycle requires any repair,ing it to a Yamaha dealer. The skilledchnicians at a Yamaha dealershipve the tools, experience, and know-w to properly service your motor-cle. Use only genuine Yamaha parts your motorcycle. Imitation parts mayk like Yamaha parts, but they are of-

n inferior. Consequently, they have aorter service life and can lead to ex-nsive repair bills.

1.2.



6-32

EAU01095

urn signal light bulb placement. Remove the screw and the lens.. Remove the defective bulb by

pushing it inward and turning itcounterclockwise.

. Install a new bulb by pushing it in-ward and turning it clockwise.

. Install the lens and tighten thescrew.

TrAla thopAnorstashprIf brtehahocyonlooteshpe

ScrewLens

1. Bulb

PERIODIC

6

Troubleshootin

WARNING@

Never check the f@

Check if thin the fuel

1. Fuel

to compression check.

2. Com

Engine doesn’t start, ask a Yamaha dealer to inspect.

Engine doesn’t start, go to battery check.

Open throttle half-way and startthe engine.


Use the electric s

Remove spark pand check electr

3. Ignition

Use the electric s

4. Battery

MAINTENANCE AND MINOR REPAIR

6-33

EAU02990*

g chartEW000125

uel system while smoking or in the vicinity of an open flame.

ere is fuel tank.

Enough fuel.

No fuel.

Go to compression check.

Supply fuel. Engine doesn’t start, go

tarter.

pressionThere is compression.

No compression.

Go to ignition check.

Ask a Yamaha dealer to inspect.

lugs odes.

Wet.

Dry.

Wipe clean with dry cloth and correct spark gap or replace spark plugs.

Ask a Yamaha dealer to inspect.

tarter.

Engine turns over quickly.

Engine turns over slowly.

Battery good.

Check connections orrecharge.

AND MINOR REPAIR

6

EEW000070

@

D id and steam may be blownou s. Wait until the engine hasco a towel over the radiator capan esidual pressure to escape.W kwise and remove it. @

N@

If vided that it is changed to the recom-m@

ge.

age.Ask a Yamaha dealer to inspect and repair the cooling system.

Add coolant. (See NOTE.)

e. If the engine overheats again, ask a o inspect and repair the cooling system.



6-34

ngine overheating

WARNINGo not remove the radiator cap when the engine and radiator are hot. Scalding hot flut under pressure, which could cause serious injury. Open the radiator cap as followoled. Remove the radiator cap stopper by removing the screw. Place a thick rag like d slowly rotate the cap counterclockwise to the detent. This procedure allows any rhen the hissing sound has stopped, press down on the cap while turning countercloc

OTE:it is difficult to get the recommended coolant, tap water can be temporarily used, proended coolant as soon as possible.

Wait until the engine has cooled.

Check the coolant level in the reservoir tank and/or radiator.

Level is OK.

Level is low, check the cooling system for leakage.

No leaka

Leak

Restart the enginYamaha dealer t

MOTORCYCLE CARE AND STORAGE

7

Care ................................................................................................... 7-1Storage............................................................................................... 7-4

E_4tx_CleaningTOC.fm Page 1 Saturday, October 16, 1999 9:38 AM

7

EAU01517

aningr normal useove dirt with warm water, a neutral

E_4tx_Cleaning.fm Page 1 Saturday, October 16, 1999 9:38 AM

7-MO

CaThemot

ergent and a soft clean sponge,n rinse with plenty of clean water. a tooth or bottle brush for hard-to-

ch parts. Tougher dirt and insects come off more easily if the area isered with a wet cloth for a few min-s before cleaning.

ble.areWhunntracpromotandovecle all thatand

7-1

TORCYCLE CARE AND STORAGE

re exposure of its technology makes aorcycle charming but also vulnera- Although high-quality components used, they are not all rust-resistant.ile a rusty exhaust pipe may remainoticed on a car, it does look unat-tive on a motorcycle. Frequent andper care, however, will keep yourorcycle looking good, extend its life maintain its performance. More-r, the warranty states that the vehi-must be properly taken care of. Forthese reasons, it is recommended you observe the following cleaning storing precautions.

Before cleaning1. Cover up the muffler outlets with

plastic bags.2. Make sure that all caps and covers

as well as all electrical couplersand connectors, including thespark plug caps, are tightly in-stalled.

3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply such prod-ucts onto seals, gaskets, sprock-ets, the drive chain and wheelaxles. Always rinse the dirt anddegreaser off with water.

CleAfteRemdettheUsereawillcovute

ARE AND STORAGE

7

C@

● For motorcycles equipped witha windshield: Do not use strongcleaners or hard sponges asthey will cause dulling orscratching. Some cleaningcompounds for plastic mayleave scratches on the wind-shield. Test the product on asmall hidden part of the wind-shield to make sure they do notleave any marks. If the wind-shield is scratched, use a quali-ty plastic polishing compoundafter washing.

ter riding in the rain, near the sea or salt-sprayed roadsnce sea salt or salt sprayed on theads in the winter are extremely corro-e in combination with water, carryt the following steps after each ridethe rain, near the sea or on salt-rayed roads. (Salt sprayed in thenter may remain on the roads wello spring.)


MOTORCYCLE C

7-2

ECA00010

AUTION:● Avoid using strong acidic wheel

cleaners, especially on spokedwheels. If you do use suchproducts for hard-to-removedirt, do not leave it on any long-er than instructed, then thor-oughly rinse it off with water,immediately dry the area andapply a corrosion protectionspray.

● Improper cleaning can damagewindshields, cowlings, panelsand other plastic parts. Useonly a soft, clean cloth orsponge with mild detergent andwater to clean plastic.

● Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abrasivecleaning products, solvent orthinner, fuel (gasoline), rust re-movers or inhibitors, brake flu-id, antifreeze or electrolyte.

● Do not use high-pressure wash-ers or steam-jet cleaners sincethey cause water seepage anddeterioration in the following ar-eas: seals (of wheel bearings,swingarm bearings, forks andbrakes), electric components(couplers, connectors, instru-ments, switches and lights),breather hoses and vents.

@

AfonSirosivouin spwiint

M

7

1.

CA@

Docresal@

2.

EWA00001

WARNINGke sure that there is no oil or waxthe brakes and tires. If neces-y, clean the brake discs and lin-s with a regular brake discner or acetone, and wash the

s with warm water and mild soap.n, carefully test the motorcycle

its braking performance and cor-ing behavior.


OTORCYCLE CARE AND STORAGE

7-3

Clean your motorcycle with coldwater and soap after the enginehas cooled down.

ECA00012

UTION: not use warm water since it in-ases the corrosive action of thet.

Be sure to apply a corrosion pro-tection spray on all (even chrome-and nickel-plated) metal surfacesto prevent corrosion.

After cleaning1. Dry the motorcycle with a chamois

or an absorbing cloth.2. Immediately dry the drive chain

and lubricate it to prevent it fromrusting.

3. Use a chrome polish to shinechrome, aluminum and stainless-steel parts, including the exhaustsystem. (Even the thermally in-duced discoloring of stainless-steel exhaust systems can be re-moved through polishing.)

4. To prevent corrosion, it is recom-mended to apply a corrosion pro-tection spray on all (even chrome-and nickel-plated) metal surfaces.

5. Use spray oil as a universal clean-er to remove any remaining dirt.

6. Touch up minor paint damagecaused by stones, etc.

7. Wax all painted surfaces.8. Let the motorcycle dry completely

before storing it or covering it.

@

Maon saringcleatireThefor ner@

ARE AND STORAGE

7

C@

@

N@

Cw@

ng-termfore storing your motorcycle forveral months:. Follow all the instructions in the

“Care” section of this chapter.. Drain the carburetor float cham-

bers by loosening the drain bolts;this will prevent fuel deposits frombuilding up. Pour the drained fuelinto the fuel tank.

. Only for motorcycles equippedwith a fuel cock which has an“OFF” position: Turn the fuel cockto “OFF”.

. Fill up the fuel tank and add fuelstabilizer (if available) to preventthe fuel tank from rusting and thefuel from deteriorating.

. Perform the following steps to pro-tect the cylinders, piston rings, etc.from corrosion.


MOTORCYCLE C

7-4

ECA00013

AUTION:● Apply spray oil and wax spar-

ingly and wipe off any excess.● Never apply oil or wax on rub-

ber and plastic parts, but treatthem with a suitable care prod-uct.

● Avoid using abrasive polishingcompounds as they wear awaythe paint.

OTE:onsult a Yamaha dealer for advice onhat products to use.

StorageShort-termAlways store your motorcycle in a cool,dry place and, if necessary, protect itagainst dust with a porous cover.

ECA00014

CAUTION:@

● Storing the motorcycle in apoorly ventilated room or cover-ing it with a tarp while it is stillwet will allow water and humidi-ty to seep in and cause rust.

● To prevent corrosion, avoiddamp cellars, stables (becauseof the presence of ammonia)and areas where strong chemi-cals are stored.

@

LoBese

1

2

3

4

5

M

7

a

b

c

d

e

@

Whsurtrodfrom@

Remove the battery and fullycharge it. Store it in a cool, dryplace and recharge it once amonth. Do not store the battery inan excessively cold or warm place(less than 0 °C or more than30 °C). For more information, see“Battery storage” in the chapter“PERIODIC MAINTENANCE ANDMINOR REPAIRS”.

TE:ke any necessary repairs beforering the motorcycle.


OTORCYCLE CARE AND STORAGE

7-5

. Remove the spark plug caps andspark plugs.

. Pour a teaspoonful of engine oilinto each spark plug bore.

. Install the spark plug caps onto thespark plugs and place the sparkplugs on the cylinder head so thatthe electrodes are grounded. (Thiswill limit sparking during the nextstep.)

. Turn the engine over several timeswith the starter. (This will coat thecylinder walls with oil.)

. Remove the spark plug caps fromthe spark plugs, install the sparkplugs and then the spark plugcaps.

EWA00003

WARNINGen turning the engine over, bee to ground the spark plug elec-es to prevent damage or injury sparking.

6. Lubricate all control cables andthe pivoting points of all levers andpedals as well as of the sidestand/centerstand.

7. Check and, if necessary, correctthe tire air pressure, then raise themotorcycle so that both of itswheels are off the ground. Alterna-tively, turn the wheels a little everymonth in order to prevent the tiresfrom becoming degraded in onespot.

8. Cover up the muffler outlets withplastic bags to prevent moisturefrom entering.

9.

NO@

Masto@

SPECIFICATIONS

8

Specifications ..................................................................................... 8-1HOW TO USE THE CONVERSION TABLE ....................................... 8-5

E_4tx_SpecTOC.fm Page 1 Saturday, October 16, 1999 9:38 AM

8

EAU01038

E_4tx_Spec.fm Page 1 Saturday, October 16, 1999 9:38 AM

8-SP

SpM

oil API Service SE, SF, SG type or higher

3.5 L

ment 3.6 L

4.2 L

1.7 L

-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C

SAE 10W/30

SAE 15W/40

SAE 20W/40

SAE 20W/50

SAE 10W/40

or oils that do not contain anti-frictioner car motor oils (often labeled) contain anti-friction additives which/or starter clutch slippage, resulting inlife and poor engine performance.

D

Bf

E

8-1

ECIFICATIONS

ecificationsodel TDM850

imensions

Overall length 2,165 mm(for GB, NL, B, F, E, P, I, GR, D, DK)

2,200 mm (for N, S, SF)

Overall width 790 mm

Overall height 1,285 mm

Seat height 805 mm

Wheelbase 1,475 mm

Ground clearance 165 mm

Minimum turning radius 2,900 mm

asic weight (with oil and full uel tank) 232 kg

ngine

Engine type Liquid cooled 4-stroke, DOHC

Cylinder arrangement Forward inclined parallel 2-cylinder

Displacement 849 cm3

Bore × Stroke 89.5 × 67.5 mm

Compression ratio 10.5:1

Starting system Electric starter

Lubrication system Dry sump

Engine oil

Type

Recommended engine classification

Quantity

Periodic oil change

With oil filter replace

Total amount

Cooling system capacity (total amount)

CAUTION:

Be sure to use motmodifiers. Passeng“Energy Conserving”will cause clutch andreduced component

SPECIFICATIONS

8

1st 2.643

2nd 1.947

3rd 1.500

4th 1.174

5th 0.964

Diamond

24.5°

103 mm

Tubeless

110/80 ZR18 (58W)

er/Bridgestone / BT54F

Michelin / MACADAM 90X

Pirelli / MTR03

Tubeless

150/70 ZR17 (69W)

er/Bridgestone / BT54R

Michelin / MACADAM 90X

Pirelli / MTR04


8-2

Air filter Dry type element

Fuel

Type Regular unleaded gasoline

Fuel tank capacity 20 L

Reserve amount 3.1 L

Carburetor

Type × quantity BDSR38 × 2

Manufacturer MIKUNI

Spark plug

Manufacturer/Type NGK / DPR8EA-9 or DENSO / X24EPR-U9

Gap 0.8 ~ 0.9 mm

Clutch type Wet, multiple-disc

Transmission

Primary reduction system Spur gear

Primary reduction ratio 1.718

Secondary reduction system Chain drive

Secondary reduction ratio 2.688

Number of sprocket teeth (rear/front) 43/16

Transmission type Constant mesh 5-speed

Operation Left foot operation

Gear ratio

Chassis

Frame type

Caster angle

Trail

Tires

Front

Type

Size

Manufacturmodel

Rear

Type

Size

Manufacturmodel

SP

8

Single disc brake

Right foot operation

DOT 4

Telescopic fork

Swingarm

Coil spring / oil damper

Coil spring / gas-oil damper

149 mm

144 mm

T.C.I. (digital)

A.C. magneto

tput 14 V, 23.5 A @ 5,000 r/min

GT12B-4

acity 12 V, 10 AH

Quartz bulb (halogen)


ECIFICATIONS

8-3

Maximum load* 203 kg

Air pressure (cold tire)

Up to 90 kg load*

Front 225 kPa (2.25 kg/cm2, 2.25 bar)

Rear 275 kPa (2.75 kg/cm2, 2.75 bar)

90 kg load ~ maximum load*


Rear 275 kPa (2.75 kg/cm2, 2.75 bar)

High speed riding


Rear 275 kPa (2.75 kg/cm2, 2.75 bar)

* Load is total weight of cargo, rider, passenger and accessories.

Wheels

Front

Type Cast

Size 18 × MT3.00

Rear

Type Cast

Size 17 × MT4.00

Brakes

Front

Type Dual disc brake

Operation Right hand operation

Fluid DOT 4

Rear

Type

Operation

Fluid

Suspension

Front

Type

Rear

Type

Shock absorber

Front

Rear

Wheel travel

Front

Rear

Electrical system

Ignition system

Charging system

Type

Standard ou

Battery

Type

Voltage, cap

Headlight type

SPECIFICATIONS

8


8-4

Bulb voltage, wattage × quantity

Headlight 12 V, 55 W × 2

Auxiliary light 12 V, 5 W × 1

Tail/brake light 12 V, 5/21 W × 2

Turn signal light 12 V, 21 W × 4

Meter light 12 V, 2 W × 3

Neutral indicator light 14 V, 1.4 W × 1

High beam indicator light 14 V, 1.4 W × 1

Turn indicator light 14 V, 1.4 W × 2

Coolant temperature indicator light 14 V, 1.4 W × 1

Fuel indicator light 12 V, 2 W × 1

Fuses

Main fuse 30 A

Headlight fuse 15 A

Signaling system fuse 15 A

Ignition fuse 10 A

Hazard light fuse 10 A

Odometer fuse 5 A

Radiator fan fuse 7.5 A

SP

8

HOCS-0

AllMEUsunEx

M

ERSION TABLERIC TO IMPERIAL

nit Multiplier Imperial unit

7.23386.7940.07230.8679

ft·lbin·lbft·lbin·lb

2.2050.03527

lboz

0.6214 mph

0.62143.2811.0940.39370.03937

miftydinin

0.035270.061020.87990.2199

oz (IMP liq.)cu·inqt (IMP liq.)gal (IMP liq.)

(°C)

55.99714.22349/5 + 32

lb/inpsi (lb/in2)Fahrenheit (°F)


ECIFICATIONS

8-5

EAU01064

W TO USE THE CONVERSION TABLE2E

specification data in this manual are listed in SI andTRIC UNITS. e this table to convert METRIC unit data to IMPERIALit data..

ETRIC MULTIPLIER IMPERIAL

**mm × 0.03937 = **in

2 mm × 0.03937 = 0.08 in

CONVMET

Metric u

Torque

m·kgm·kgcm·kgcm·kg

Weight kgg

Speed km/hr

Distance

kmmmcmmm

Volume /Capacity

cc (cm3)cc (cm3)lt (liter)lt (liter)

Misc.kg/mmkg/cm2

Centigrade

CONSUMER INFORMATION

9

Identification number records............................................................. 9-1Key identification number ................................................................... 9-1Vehicle identification number.............................................................. 9-1Model label......................................................................................... 9-2

E_4tx_ConsumerTOC.fm Page 1 Saturday, October 16, 1999 9:38 AM

9

EAU01039

E_4tx_Consumer.fm Page 1 Saturday, October 16, 1999 9:38 AM

9-CO

IdeRec

EAU01043

hicle identification number vehicle identification number is

mped into the steering head pipe.ord this number in the space pro-d.

TE: vehicle identification number isd to identify your motorcycle andy be used to register your motor-le with the licensing authority inr state.

ehicle identification number

vehel lavidespafor len.

1.CA-02

2.

CA-02

3.CA-01

9-1

NSUMER INFORMATIONEAU02944

ntification number recordsord the key identification number,icle identification number and mod-bel information in the spaces pro-d for assistance when orderingre parts from a Yamaha dealer orreference in case the vehicle is sto-

KEY IDENTIFICATION NUMBER:E

VEHICLE IDENTIFICATION NUMBER:

E

MODEL LABEL INFORMATION:E

EAU01041

Key identification numberThe key identification number isstamped on the key tag. Record thisnumber in the space provided and useit for reference when obtaining a newkey.

VeThestaRecvide

NO@

Theusemacycyou@

1. Key identification number 1. V

MER INFORMATION

9

MThunremvitode

1.

E_4tx_Consumer.fm Page 2 Saturday, October 16, 1999 9:38 AM

CONSU

9-2

EAU01050

odel labele model label is affixed to the frameder the seat. (See page 3-12 for seatmoval procedures.) Record the infor-ation on this label in the space pro-ded. This information will be needed order spare parts from your Yamahaaler.

Model label

D

ftit

ttakakakak

brbreaeattnoowsw

g

iviviv

igh beam indicator light..........................3-2orn switch ..............................................3-6

dentification number records ...................9-1dle speed adjustment ............................6-15ndicator lights..........................................3-2

Coolant temperature indicator light .....3-2Fuel indicator light...............................3-3High beam indicator light ....................3-2Neutral indicator light ..........................3-2Turn indicator lights ............................3-2

nspecting the brake fluid level ...............6-22

ey identification number .........................9-1

eft view...................................................2-1ights switch ............................................3-7uggage strap holders ...........................3-17

ain switch/steering lock .........................3-1odel label ..............................................9-2

eutral indicator light ...............................3-2

anels A and B ........................................6-6arking.....................................................5-6ass switch..............................................3-6eriodic maintenance and lubrication.......6-2re-operation check list............................4-1

E_4txIX.fm Page 1 Saturday, October 16, 1999 9:38 AM

10-IN

AAirAn

BBaBrBrBrBr

CCaCaCaChCh

reCluCluCoCoCoCo

inCo

DDiaDimDrDrDr

cking the front and r brake pads ...................................6-21

ch lever..............................................3-8ch lever free play adjustment ...........6-19trols/Instruments................................2-3lant temperature indicator light...........3-2ling system ......................................6-10ling and panel removal and tallation .............................................6-5lings A and B ....................................6-5

nosis device......................................3-5mer switch .........................................3-6e chain lubrication............................6-24e chain slack adjustment..................6-23e chain slack check..........................6-23

Fuel tank cap......................................... 3-10Fuse replacement.................................. 6-29

GGive safety the right of way ..................... 1-1

HHandlebar switches ................................. 3-6

Dimmer switch ................................... 3-6Engine stop switch ............................. 3-7Hazard switch .................................... 3-6Horn switch ........................................ 3-6Lights switch ...................................... 3-7Pass switch........................................ 3-6Start switch ........................................ 3-7Turn signal switch .............................. 3-6

Hazard switch.......................................... 3-6Headlight bulb replacement ................... 6-30Helmet holder ........................................ 3-13

LLLL

MMM

NN

PPPPPP

EX

ilter ..................................................6-13heft alarm (optional) ..........................3-5

ery ...................................................6-28e and clutch lever lubrication...........6-25e and shift pedal lubrication ............6-25e fluid replacement .........................6-23e light switch adjustment.................6-21

le inspection and lubrication ............6-24uretor adjustment ...........................6-15.........................................................7-1

nging the coolant .............................6-11

EEngine break-in ....................................... 5-5Engine oil ................................................ 6-8Engine overheating................................. 6-34Engine stop switch................................... 3-7

FFront brake lever ..................................... 3-9Front fork adjustment............................. 3-14Front fork inspection .............................. 6-27Fuel ....................................................... 3-11Fuel gauge .............................................. 3-5Fuel indicator light ................................... 3-3Fuel tank breather hose

(for Germany only) .............................. 3-12

HH

IIII

I

KK

INDEX

RReReReReRig

SSeShShSidSid

cSidSpSpSpStaStaStaStaSteStoSto

TTaTaThThTipTirTo

E_4txIX.fm Page 2 Saturday, October 16, 1999 9:38 AM

ol kit..................................................... 6-1

ark plugs ............................................. 6-6ecifications .......................................... 8-1eedometer........................................... 3-3rter (choke) “ ”................................ 3-7rting a warm engine............................ 5-4rting the engine .................................. 5-1rt switch.............................................. 3-7ering inspection ................................ 6-27rage.................................................... 7-4rage compartment ............................ 3-13

chometer ............................................. 3-4il/brake light bulb replacement ........... 6-31rottle cable and grip lubrication .......... 6-25rottle cable free play inspection ......... 6-16s for reducing fuel consumption .......... 5-5es ...................................................... 6-17

ar brake pedal ..................................... 3-9ar brake pedal height adjustment ...... 6-20ar shock absorber adjustment ........... 3-15ar suspension lubrication................... 6-26ht view................................................ 2-2

at....................................................... 3-12ifting .................................................... 5-4ift pedal ............................................... 3-8estand .............................................. 3-17estand/clutch switch operation

heck .................................................. 3-17estand lubrication ............................. 6-26

Troubleshooting .................................... 6-32Troubleshooting chart ........................... 6-33Turn indicator lights................................. 3-2Turn signal light bulb replacement......... 6-32Turn signal switch ................................... 3-6

VValve clearance adjustment .................. 6-16Vehicle identification number................... 9-1

WWheel bearings ..................................... 6-28

PRINTED IN JAPAN99 · 9 - 0.8 × 1 CR

(E)

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

YAMAHA TDM 850-4TX GUIDE.pdf

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