Yamaha TRX850 Manuals

Manuals and User Guides for Yamaha TRX850. We have 1 Yamaha TRX850 manual available for free PDF download: User Manual

Yamaha TRX850 User Manual (212 pages)

Brand: Yamaha | Category: Motorcycle | Size: 13.3 MB

Safety First!
1
Remember
1
Frame and Engine Numbers
2
Identification Numbers
2
Buying Spare Parts
2
Daily (Pre-Ride) Checks
4
Engine/Transmission Oil Level Check
4
TDM850 (1991 to 1995) and XTZ750 Models
4
TDM850 (1996-On) and TRX Models
5
Brake Fluid Level Checks
6
Front Brake Fluid Level
6
Before You Start
6
Rear Brake Fluid Level
7
Coolant Level Check
8
Tyre Tread Depth
9
Tyre Care
9
The Correct Pressures
9
Tyre Checks
9
Routine Maintenance and Servicing
10
Contents
10
Routine Maintenance
11
Specifications
11
Torque Settings
12
Recommended Lubricants and Fluids
12
Component Locations
13
Component Locations
15
Maintenance Schedule
16
Introduction
17
Every 300 Miles (500 Km)
17
Lubrication
18
Hint
18
Every 4000 Miles (6000 Km) or 6 Months
19
Spark Plugs - Check and Adjustment
19
Idle Speed - Check and Adjustment
20
Carburettors - Synchronisation
20
Air Filter - Cleaning
21
Fuel System - Check
22
Engine - Oil Change
22
Filter Cleaning
22
Brake Pads - Wear Check
23
Brake System - Check
23
Clutch - Check and Adjustment
25
Battery - Check
25
Wheels and Tyres - General Check
26
Wheel Bearings - Check
26
Sidestand and Cut-Off Switches - Check
26
Nuts and Bolts - Tightness Check
26
Cooling System - Check
27
Throttle and Choke Cables - Check
27
Throttle Cables
27
Pivot Points
28
Stand, Lever Pivots and Cables - Lubrication
28
Choke Cable
28
Swingarm and Suspension Bearings (XTZ Models) - Re-Greasing
28
Suspension - Check
29
Steering Head Bearings - Freeplay Check and Adjustment
29
Front Suspension
29
Rear Suspension
29
Every 8000 Miles (12,000 Km) or 12 Months
31
Engine - Oil and Filter Change
31
Every 16,000 Miles (24,000 Km) or Two Years
32
Fuel Filter - Renewal (1999 TDM Models)
32
Swingarm and Suspension Bearings (TDM and TRX Models) - Re-Greasing
32
Steering Head Bearings - Lubrication
32
Cooling System - Draining, Flushing and Refilling
33
Refilling
34
Valve Clearances - Check and Adjustment
34
Every 28,000 Miles (42,000 Km)
34
Shim Selection Chart - Inlet Valves
36
Shim Selection Chart - Exhaust Valves
36
Every Four Years
37
Non-Scheduled Maintenance
37
Brake Hoses - Renewal
37
Headlight Aim - Check and Adjustment
37
Cylinder Compression - Check
38
Engine - Oil Pressure Check
38
Front Forks - Oil Change
39
TDM, Trxand 1995 XTZ Models
39
1989 To 1994 XTZ Models
39
Engine, Clutch and Transmission
40
Degrees of Difficulty
40
Cylinder Head
41
Cylinder Block
41
Oil Pump
43
General Information
45
Operations Possible with the Engine in the Frame
45
Operations Requiring Engine Removal
45
Major Engine Repair - General Note
45
Engine Disassembly and Reassembly - General Information
49
Valve Cover - Removal and Installation
50
Camshafts and Followers - Removal, Inspection and Installation
51
Cam Chain Tensioner - Removal, Inspection and Installation
56
Cylinder Head - Removal and Installation
57
Valves/Valve Seats/Valve Guides - Overhaul
59
Cylinder Head and Valves - Disassembly, Inspection and Reassembly
59
Cylinder Block-Removal, Inspection and Installation
62
Pistons - Removal, Inspection and Installation
64
Piston Rings - Inspection and Installation
66
Clutch - Removal, Inspection and Installation
67
Clutch Assembly
69
Clutch Cable - Removal and Installation
73
Starter Clutch and Idle/Reduction Gear - Removal, Inspection and Installation
74
Gearchange Mechanism External Components - Removal, Inspection and Installation
74
Oil Pumps - Removal and Installation
76
Oil Tank - Removal and Installation (1996-On TDM Models and All TRX Models)
79
Balancer Shafts - Removal, Inspection and Installation
81
Cam Chain and Guides - Removal, Inspection and Installation
84
Crankcase Halves - Separation and Reassembly
84
Crankcase Bolts - 1991 to 1995 TDM Models and XTZ Models
85
Crankcase Bolts - 1996-On TDM Models and TRX Models
85
Crankcase Halves - Inspection and Servicing
87
Main and Connecting Rod Bearings - General Information
87
Connecting Rods - Removal, Inspection and Installation
88
Oil Clearance Check
88
Bearing Shell Selection
89
Main Bearing Shell Selection
91
Transmission Shafts and Bearings - Removal and Installation
92
Transmission Shafts - Disassembly, Inspection and Reassembly
93
Input Shaft Reassembly
94
Output Shaft Disassembly
95
Output Shaft Inspection
95
Output Shaft Reassembly
95
Selector Drum and Forks Removal, Inspection and Installation
96
Initial Start-Up after Overhaul
98
Recommended Running-In Procedure
98
Cooling System
99
Radiator Pressure Cap - Check
100
Coolant Reservoir - Removal and Installation
100
Cooling Fan and Cooling Fan Switch - Check and Renewal
101
Coolant Temperature Gauge/Warning Light and Sender - Check and Renewal
102
Coolant Temperature Warning Light (1999 TDM Models)
102
Coolant Temperature Gauge (XTZ, TRX and 1991-98 TDM Models)
102
Sender Check (All Models)
102
All Models
103
Thermostat Housing and Thermostat - Removal, Check and Installation
103
Radiator - Removal and Installation
104
Water Pump - Check, Removal, and Installation
105
Coolant Hoses - Removal and Installation
106
Fuel and Exhaust Systems
107
Fuel Tank and Fuel Tap(S) - Removal and Installation
109
General Information and Precautions
109
Fuel Tank - TDM Models
109
Fuel Tank - TRX Models
110
Fuel Tank - XTZ Models
110
Fuel Tap(S)
110
Fuel Tank - Cleaning and Repair
112
Air Filter Housing - Removal and Installation
112
Idle Fuel/Air Mixture Adjustment - General Information
112
Carburettors - Removal and Installation
113
Carburettor Overhaul - General Information
113
Carburettors Cleaning and Inspection
114
1991 To 1998 TDM Models, All TRX and XTZ Models
114
Ignition System
116
Ignition HT Coils - Check, Removal and Installation
118
Ignitor Unit - Check, Removal and Installation
119
Ignition Timing - General Information and Check
120
Throttle Position Sensor (1996- % on TDM and TRX)- Check, Adjustment and Replacement
120
Frame, Suspension and Final Drive
122
Frame - Inspection and Repair
124
Footrests, Brake Pedal and Gearchange Lever - Removal and Installation
124
Brake Pedal
125
Gearchange Lever
125
Sidestand - Removal and Installation
126
Handlebars and Levers - Removal and Installation
126
Handlebars
126
Forks - Removal and Installation
128
Front Brake Lever
128
Clutch Lever
128
Forks - Disassembly, Inspection and Reassembly
130
1991 To 199S TDM Models
130
1996-On TDM Models and TRX Models
134
XTZ Models
135
Front Fork Components - XTZ Models
136
Steering Stem - Removal and Installation
137
Steering Head Bearings - Inspection and Replacement
139
Rear Shock Absorber - Removal, Inspection and Installation
140
Rear Suspension Linkage (TRX and XTZ Models) - Removal, Inspection and Installation
141
Suspension Linkage and Swingarm Assembly - TRX Models
142
Suspension - Adjustments
143
Front Forks
143
Suspension Linkage and Swingarm Assembly - XTZ Models
143
Bearing Replacement - XTZ Models
146
Bearing Replacement - TDM and TRX Models
146
Swingarm - Inspection and Bearing Replacement
146
Drive Chain - Removal, Cleaning and Installation
147
Endless Type Chain
147
Riveted Link Type Chain
148
Sprockets - Check and Replacement
148
Rear Sprocket Coupling/Rubber Dampers - Check and Replacement
150
Table of Contents
151
Brakes, Wheels and Tyre
151
Brake Pads - Replacement
153
Brake Calipers - Removal, Overhaul and Installation
156
Overhaul
157
Brake Discs - Inspection, Removal and Installation
158
Front Brake Master Cylinder - Removal, Overhaul and Installation
158
Rear Brake Master Cylinder - Removal, Overhaul and Installation
160
Rear Wheel - Removal and Installation
166
- Wheel Bearings - Removal, Inspection and Installation
  167
- Front Wheel Bearings
  167
- Rear Wheel Bearings
  168
- Sprocket Coupling Bearing
  169
Tyres - General Information and Fitting
169
- Common Tyre Sidewall Markings
  170
- Bodywork
  171
- Seat - Removal and Installation
  172
- 1996-On TDM Models
  172
- 1991 To 1995 TDM Models
  172
- TRX Models
  172
- TDM Models
  173
- Fainng - Removal and Installation
  176
- Engine Bashplate (1991-95 TDM and All XTZ) - Removal and Installation
  178
- Electrical System
  179
- Starter Motor
  180
- Battery-Removal, Installation, Inspection and Maintenance
  181
- Electrical System - Fault Finding
  181
- Torque Settings
  181
- Battery - Charging
  182
- Inspection and Maintenance
  182
- Fuses - Check and Renewal
  183
- Lighting System - Check
  183
- Headlight
  183
- Tail Light
  183
- Headlight Bulb and Auxiliary Light Bulb - Renewal
  184
- Auxiliary Light
  184
- Brake Light
  184
- Headlight Assembly - Removal and Installation
  185
- Brake/Tail Light Bulb - Renewal
  185
- Hazard Relay (1999 TDM Models)
  186
- Flasher Relay
  186
- Tail Light Assembly - Removal and Installation
  186
- Turn Signal Circuit - Check
  186
- Turn Signal Bulbs - Renewal
  187
- Turn Signal Assemblies - Removal and Installation
  187
- Brake Light Switches - Check and Replacement
  188
- Circuit Check
  188
- Switch Replacement
  188
- Front Brake Lever Switch
  188
- Instrument Cluster and Speedometer Cable - Removal and Installation
  189
- Instrument Cluster
  189
- Speedometer Cable (TRX, XTZ Andterminal and 1991 to 1998 TDM Models)
  190
- Instruments - Check, Replacement and Bulbs
  190
- Tachometer
  191
- Coolant Temperature Gauge (TRX, XTZ and 1991 to 1998 TDM Models)
  191
- Bulb Renewal
  192
- Ignition (Main) Switch - Check, Removal and Installation
  192
- Fuel Gauge (1999 TDM Models)
  192
- Fuel Gauge and Sender Unit - Check and Replacement (1999 TDM Models)
  192
- Handlebar Switches - Check
  193
- Handlebar Switches - Removal and Installation
  193
- Neutral Switch - Check, Removal and Installation
  194
- Chock
  194
- Sidestand Switch - Check and Replacement
  195
- Clutch Switch - Check and Replacement
  195
- Diode (XTZ Models) - Check and Replacement
  195
- Horn - Check and Replacement
  197
- Starter Relay - Check and Replacement
  197
- Starter Motor - Removal and Installation
  198
- Starter Motor - Disassembly, Inspection and Reassembly
  199
- Charging System Testing - General Information and Precautions
  202
- Charging System - Leakage and Output Test
  202
- Output Test
  203
- Regulator/Rectifier - Check and Replacement
  206
- Wiring Diagrams
  207

Yamaha Categories

Motorcycle Musical Instrument Electronic Keyboard Receiver Amplifier

More Yamaha Manuals

Yamaha TRX850 Manuals

Yamaha TRX850 User Manual (212 pages)

Table of Contents

Related Products

Yamaha Categories