OWNER’S MANUAL TDM850 4TX-28199-E4
E_4tx_Intro0.fm Page 1 Saturday, October 16, 1999 9:35 AM INTRODUCTION EAU00001 Welcome to the Yamaha world of motorcycling! As the owner of a TDM850, you are benefiting from Yamaha’s vast experience in and newest technology for the design and the manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all your TDM850’s advantages.
E_4tx_Info0.fm Page 1 Saturday, October 16, 1999 9:35 AM IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
E_4tx_Info0.fm Page 2 Saturday, October 16, 1999 9:35 AM IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
E_4tx_Info0.fm Page 3 Saturday, October 16, 1999 9:35 AM IMPORTANT MANUAL INFORMATION EAU00008 TDM850 OWNER’S MANUAL © 1999 by Yamaha Motor Co., Ltd. 1st Edition, September 1999 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
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E_4tx_LabelTOC.fm Page 1 Saturday, October 16, 1999 9:35 AM GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY.................................................
E_4tx_Label.fm Page 1 Saturday, October 16, 1999 9:35 AM GIVE SAFETY THE RIGHT OF WAY EAU00021 1- Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. 1 Regular care and maintenance are essential for preserving your motorcycle’s value and operating condition.
E_4tx_DescriptionTOC.fm Page 1 Saturday, October 16, 1999 9:35 AM DESCRIPTION Left view ............................................................................................. 2-1 Right view........................................................................................... 2-2 Controls/Instruments ..........................................................................
E_4tx_Description.fm Page 1 Saturday, October 16, 1999 9:36 AM DESCRIPTION EAU00026 2- Left view 2 1. Coolant reservoir tank 2. Helmet holder 3. Seat lock 4. Rear shock absorber spring preload adjusting nut (for fine adjustment) 5.
E_4tx_Description.fm Page 2 Saturday, October 16, 1999 9:36 AM DESCRIPTION Right view 2 6. Luggage strap holders 7. Rear shock absorber spring preload adjusting lever (for coarse adjustment) 8. Fuses 9. Engine oil level check window 10. Front fork spring preload adjusting bolt 11.
E_4tx_Description.fm Page 3 Saturday, October 16, 1999 9:36 AM DESCRIPTION Controls/Instruments 2 12. Clutch lever 13. Handlebar switches 14. Starter (choke) “ ” 15. Speedometer 16. Main switch/steering lock 17. Tachometer 18. Fuel gauge 19. Throttle grip 20.
E_4tx_FunctionsTOC.fm Page 1 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock ......................................3-1 Indicator lights ......................................................3-2 Speedometer ........................................................3-3 Tachometer ...........................................................3-4 Diagnosis device...................................................3-5 Antitheft alarm (optional) ...........................
E_4tx_Functions.fm Page 1 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00027 3- 3 EAU00029* Main switch/steering lock The main switch controls the ignition and lighting systems. Its operation is described below. EAU00036 ON Electrical circuits are switched on. The engine can be started. The key cannot be removed in this position. EAU00040 LOCK The steering is locked in this position and all electrical circuits are switched off. The key can be removed in this position.
E_4tx_Functions.fm Page 2 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00063 High beam indicator light “ ” This indicator comes on when the headlight high beam is used. EAU01707 EAU00048 (Parking) The steering is locked in this position, and the taillight and auxiliary light come on but all other circuits are off. The key can be removed in this position. To use the parking position, first lock the steering, then turn the key to “ ”.
E_4tx_Functions.fm Page 3 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS EAU01666 3 Fuel indicator light “ ” When the fuel level drops below approximately 3,1 L, this light will come on. When this light comes on, fill the tank at the first opportunity. To check that the indicator light is working properly: ● Turn the engine stop switch to “ ” and the main switch to “ON”. ● Put the transmission in neutral or apply the clutch lever. ● Push the start switch.
E_4tx_Functions.fm Page 4 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS Selecting a mode Push the “SELECT” button to change between the odometer mode “ODO” and the trip odometer modes “TRIP 1”, “TRIP 2” and “CLOCK” in the following order: “ODO” → “TRIP 1” → “TRIP 2” → “CLOCK” → “ODO” Resetting a trip meter To reset a trip odometer to 0.0, select it by pushing the “SELECT” button and push the “RESET” button for at least one second.
E_4tx_Functions.fm Page 5 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00103 3 EAU00109 Diagnosis device Antitheft alarm (optional) This model is equipped with a diagnosis device for the Throttle Position Sensor (T.P.S.) circuit. If some trouble should occur in the circuit, the tachometer will repeatedly display as follows: An antitheft alarm can be equipped to this motorcycle. Consult your Yamaha dealer to obtain and install the alarm. CB-61E 0 r/min for 3 seconds.
E_4tx_Functions.fm Page 6 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS 1. 2. 3. 4. 5. Pass switch “PASS” Dimmer switch Turn signal switch Horn switch “ ” Hazard switch “ ” EAU00127 EAU00144 Turn signal switch To signal a right-hand turn, push the switch to “ ”. To signal a left-hand turn, push the switch to “ ”. Once the switch is released it will return to the center position. To cancel the signal, push the switch in after it has returned to the center position.
E_4tx_Functions.fm Page 7 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00143 Start switch “ ” The starter motor cranks the engine when pushing the start switch. EC000005 CAUTION: See starting instructions prior to starting the engine. @ 3 @ 1. Engine stop switch 2. Lights switch 3. Start switch “ ” 1. Starter (choke) “ ” EAU02976 Starter (choke) “ EAU00138 ” Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture.
E_4tx_Functions.fm Page 8 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Clutch lever 1. Shift pedal EAU00152 EAU00157 Clutch lever Shift pedal The clutch lever is located on the left handlebar, and the ignition circuit cutoff system is incorporated in the clutch lever holder. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation.
E_4tx_Functions.fm Page 9 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Brake lever position adjuster a. Lever distance EAU00160 Front brake lever The front brake lever is located on the right handlebar and is equipped with a position adjuster. To activate the front brake, pull the lever toward the handlebar. 1. Adjusting nut 2. Proper position 1. Rear brake pedal To adjust the front brake lever position, turn the adjusting nut while pulling the lever forward.
E_4tx_Functions.fm Page 10 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS NOTE: This tank cap cannot be closed unless the key is in the lock. The key cannot be removed if the cap is not locked properly. @ @ EW000023 WARNING Be sure the cap is properly installed and locked in place before riding the motorcycle. @ 1. Lock cover 2. Open @ EAU02935 Fuel tank cap To open Open the lock cover. Insert the key and turn it 1/4 turn clockwise.
E_4tx_Functions.fm Page 11 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00186 NOTE: If knocking or pinging occurs, use a different brand of gasoline or higher octane grade. @ @ 3 1. Filler tube 2. Fuel level EAU01183 Fuel Make sure there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown in the illustration. EW000130 WARNING Do not overfill the fuel tank. Avoid spilling fuel on the hot engine.
E_4tx_Functions.fm Page 12 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Fuel tank breather hose 1. Open EAU00196 Fuel tank breather hose (for Germany only) This model is equipped with a fuel tank breather hose. Before using this motorcycle, 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 Seat To remove Insert the key in the lock and turn it clockwise.
E_4tx_Functions.fm Page 13 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Helmet holder EAU00263 Helmet holder 1. U-LOCK (optional) 2. Strap (× 2) EAU01688 The helmet holder is under the seat. Remove the seat and hook the helmet on the helmet holder. Then, reinstall the seat and lock it. EW000030 WARNING Never ride with a helmet in the helmet holder. The helmet may hit objects, causing loss of control and possibly an accident. @ 1. U-LOCK (optional) 2.
E_4tx_Functions.fm Page 14 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS Adjusting spring preload Turn the adjusting bolt in direction a to increase spring preload and in direction b to decrease spring preload. CI-18E Soft Adjusting position 1 Standard 2 3 Hard 4 5 3 1. Spring preload adjusting bolt 2. Adjusting position 3. Standard setting 1.
E_4tx_Functions.fm Page 15 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Adjusting lever EAU01768* Rear shock absorber adjustment This shock absorber is equipped with two spring preload adjusters and one damping force adjuster. Spring preload Coarse adjustment (top) Use the special tool in the owner’s tool kit to turn the lever to “S” when riding solo and to “H” when riding with a passenger. 1. Locknut 2. Adjusting nut a.
E_4tx_Functions.fm Page 16 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS 3. Tighten the locknut to the specified torque. EAU00315 @ Tightening torque: Locknut: 70 Nm (7.0 m·kg) EC000018 CAUTION: Always tighten the locknut against the spring adjusting nut and tighten the locknut to the specified torque. @ @ WARNING This shock absorber contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber.
E_4tx_Functions.fm Page 17 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00330 Sidestand This model is equipped with an ignition circuit cut-off system. The motorcycle must not be ridden when the sidestand is down. The sidestand is located on the left side of the frame. (Refer to page 5-1 for an explanation of this system.) 3 EW000044 1.
E_4tx_Functions.fm Page 18 Saturday, October 16, 1999 9:36 AM INSTRUMENT AND CONTROL FUNCTIONS CD-11E SIDESTAND IS DOWN. ENGINE WILL STALL. SIDESTAND SWITCH IS OK. 3 EW000045 WARNING If improper operation is noted, consult a Yamaha dealer immediately.
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E_4tx_PreopTOC.fm Page 1 Saturday, October 16, 1999 9:36 AM PRE-OPERATION CHECKS Pre-operation check list......................................................................
E_4tx_Preop.fm Page 1 Saturday, October 16, 1999 9:36 AM PRE-OPERATION CHECKS EAU01114 4- Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or loss of tire pressure could have serious consequences.
E_4tx_Preop.fm Page 2 Saturday, October 16, 1999 9:36 AM PRE-OPERATION CHECKS ITEM CHECKS PAGE Brake and clutch lever pivots • Check for smooth operation. • Lubricate if necessary. 6-25 Sidestand pivot • Check for smooth operation. • Lubricate if necessary. 6-26 Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. • Tighten if necessary. Lights, signals and switches • Check for proper operation. Fuel • Check fuel level. • Fill with fuel if necessary.
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E_4tx_OperationTOC.fm Page 1 Saturday, October 16, 1999 9:37 AM OPERATION AND IMPORTANT RIDING POINTS Starting the engine............................................................................. 5-1 Starting a warm engine ...................................................................... 5-4 Shifting ............................................................................................... 5-4 Tips for reducing fuel consumption ....................................................
E_4tx_Operation.fm Page 1 Saturday, October 16, 1999 9:37 AM OPERATION AND IMPORTANT RIDING POINTS 5- EAU00373 @ 5 WARNING ● Before riding this motorcycle, become thoroughly familiar with all operating controls and their functions. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. ● Never start your engine or let it run for any length of time in a closed area.
E_4tx_Operation.fm Page 2 Saturday, October 16, 1999 9:37 AM OPERATION AND IMPORTANT RIDING POINTS CF-28E TURN THE MAIN SWITCH TO “ON” AND THE ENGINE STOP SWITCH TO “ ”. IF TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN, IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP, PUSH THE START SWITCH. ENGINE WILL START. PULL IN THE CLUTCH LEVER AND PUSH THE START SWITCH. ENGINE WILL START. 5 RETRACT THE SIDESTAND AND PUT TRANSMISSION IN GEAR. MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN.
E_4tx_Operation.fm Page 3 Saturday, October 16, 1999 9:37 AM OPERATION AND IMPORTANT RIDING POINTS 1. Turn the main switch to “ON” and the engine stop switch to “ ”. EC000035 CAUTION: If the fuel indicator light comes on, check the fuel level. If necessary, fill the tank with fuel. @ NOTE: If the engine fails to start, release the start switch, wait a few seconds, then try again. Each attempt should be as short as possible to preserve the battery.
E_4tx_Operation.fm Page 4 Saturday, October 16, 1999 9:37 AM OPERATION AND IMPORTANT RIDING POINTS EAU01258 EC000048 Starting a warm engine @ The starter (choke) is not required when the engine is warm. EC000046 CAUTION: See the “Engine break-in” section prior to operating the motorcycle for the first time. @ @ 1. Shift pedal N. Neutral EAU00423 Shifting The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc.
E_4tx_Operation.fm Page 5 Saturday, October 16, 1999 9:37 AM OPERATION AND IMPORTANT RIDING POINTS EAU00424 Tips for reducing fuel consumption 5 Your motorcycle’s fuel consumption depends to a large extent on your riding style. The following tips can help reduce fuel consumption: ● Warm up the engine before riding. ● Turn off the starter (choke) as soon as possible. ● Shift up swiftly and avoid high engine speeds during acceleration.
E_4tx_Operation.fm Page 6 Saturday, October 16, 1999 9:37 AM OPERATION AND IMPORTANT RIDING POINTS 1,000 km and beyond Full throttle can be used. EAU00457 Parking EC000053 @ @ CAUTION: ● Never let engine speeds enter the red zone. ● If any engine trouble should occur during the break-in period, consult a Yamaha dealer immediately. When parking the motorcycle, stop the engine and remove the ignition key. Turn the fuel cock to “OFF” whenever stopping the engine.
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E_4tx_PeriodicTOC.fm Page 1 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR Tool kit...................................................................6-1 Periodic maintenance and lubrication...................6-2 Cowling and panel removal and installation..........6-5 Cowlings A and B .................................................6-5 Panels A and B .....................................................6-6 Spark plugs...........................................................
E_4tx_Periodic.fm Page 1 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00462 6- EAU00464 6 Periodic inspection, adjustment and lubrication will keep your motorcycle in the safest and most efficient condition possible. Safety is an obligation of the motorcycle owner. The maintenance and lubrication schedule chart should be considered strictly as a guide to general maintenance and lubrication intervals.
E_4tx_Periodic.fm Page 2 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00473 PERIODIC MAINTENANCE AND LUBRICATION CP-01E EVERY NO. 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.
E_4tx_Periodic.fm Page 3 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EVERY NO. 12 * 13 6 ITEM CHECKS AND MAINTENANCE JOBS 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.
E_4tx_Periodic.fm Page 4 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EVERY NO. 24 * ITEM Cooling system CHECKS AND MAINTENANCE JOBS INITIAL (1,000 km) • Check coolant level and vehicle for coolant leakage. • Correct if necessary. • Change coolant every 24,000 km or 24 months (whichever comes first).
E_4tx_Periodic.fm Page 5 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cowling A 2. Panel A 1. Cowling B 2. Panel B 1. Screw (× 3) EAU00484* Cowlings A and B EAU01139 Cowling and panel removal and installation 6 To remove Remove the screws and pull outward as shown. The cowlings and panels illustrated need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a cowling or panel has to be removed or reinstalled.
E_4tx_Periodic.fm Page 6 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw 1. Spark plug cap 1. Spark plug wrench EAU01691* EAU01668* Panels A and B Spark plugs To remove 1. Remove the seat. (See page 3-12 for removal and installation procedures.) 2. Remove the screw. Removal 1. Remove cowlings A and B. (See page 6-5 for removal and installation procedures.) 2. Remove the spark plug caps. 3.
E_4tx_Periodic.fm Page 7 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR Do not attempt to diagnose such problems yourself. Instead, take the motorcycle to a Yamaha dealer. You should periodically remove and inspect the spark plugs because heat and deposits will cause any spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug.
E_4tx_Periodic.fm Page 8 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Oil level window 2. Minimum level mark 3. Maximum level mark EAU01692 Engine oil Oil level inspection 1. Place the motorcycle on a level place. Warm up the engine at idle for 15 minutes. NOTE: Be sure the motorcycle is positioned straight up when checking the oil level. A slight tilt toward the side can result in false readings. @ 1. Engine oil drain bolt a 1. Engine oil filler cap 2.
E_4tx_Periodic.fm Page 9 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil drain bolt b 2. Oil filter cover bolt (× 5) 3. Oil filter cover 1. Oil filter 2. O-ring (× 2) EC000066 Tightening torque: Oil filter cover bolt: 10 Nm (1.0 m·kg) 5. Install the drain bolts and tighten them to the specified torque. 6 Tightening torque: Drain bolt a: 35 Nm (3.5 m·kg) Drain bolt b: 30 Nm (3.0 m·kg) 6. Install the new oil filter, O-rings and the filter cover.
E_4tx_Periodic.fm Page 10 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR 8. Start the engine and warm up for a few minutes. While warming up, check for oil leakage. If oil leakage is found, stop the engine immediately and check for the cause. 9. Stop the engine and check the oil level. 1. Coolant reservoir 2. Maximum level mark 3. Minimum level mark 1. Coolant reservoir cap Coolant reservoir capacity: 0.3 L EAU03024* Cooling system 1.
E_4tx_Periodic.fm Page 11 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: ● If water is added, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible. ● The radiator fan operation is completely automatic. It is switched on or off according to the coolant temperature in the radiator. @ @ 5. If your motorcycle overheats, see page 6-34 for details. 1. Radiator cap stopper bolt 2. Radiator cap 1. Water pump drain bolt 2.
E_4tx_Periodic.fm Page 12 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR 11. Drain the coolant completely and thoroughly flush the cooling system with clean tap water. 12. If the washers are damaged, replace them. Tighten the water pump drain bolt and cylinder drain bolt to the specified torques. 1. 2. 3. 4. Coolant reservoir Bolt Coolant reservoir hose clamp Hose 6. Remove the seat. (See page 3-12 for seat removal and installation procedures.) 7.
E_4tx_Periodic.fm Page 13 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Bolt (× 2) 1. Fuel sender coupler EAU01769* Air filter 6 The air filter should be cleaned at the specified intervals. It should be cleaned more frequently if you are riding in unusually wet or dusty areas. 1. Remove the seat. (See page 3-12 for seat removal and installation procedures.) 2. Remove cowlings A and B and panels A and B. (See pages 6-5 ~ 6-6 for removal and installation procedures.) 3.
E_4tx_Periodic.fm Page 14 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Air filter case cover 2. Screw (× 3) 1. Air filter 7. Remove the air filter. 8. Tap the air filter lightly to remove most of the dust and dirt. Blow out the remaining dirt with compressed air as shown. If the air filter is damaged, replace it. 9. Install by reversing the removal procedure. 6. Remove the air filter case cover by removing the screws.
E_4tx_Periodic.fm Page 15 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EC000082 @ @ CAUTION: ● Make sure the air filter is properly seated in the air filter case. ● The engine should never be run without the air filter installed. Excessive piston and/or cylinder wear may result. EAU00630 Carburetor adjustment The carburetors are important parts of the engine and require very sophisticated adjustment.
E_4tx_Periodic.fm Page 16 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00637 Valve clearance adjustment Standard idle speed: 1,050 ~ 1,250 r/min The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician.
E_4tx_Periodic.fm Page 17 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00658 Tires CE-33E Maximum load* Cold tire pressure To ensure maximum performance, long service and safe operation, note the following: Tire air pressure Always check and adjust the tire pressure before operating the motorcycle. EW000082 WARNING Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature.
E_4tx_Periodic.fm Page 18 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EW000095 EW000080 WARNING Operating the motorcycle with excessively worn tires decrease riding stability and can lead to loss of control. Have excessively worn tires replaced by a Yamaha dealer immediately. Brakes, tires, and related wheel parts replacement should be left to a Yamaha Service Technician. WARNING ● After extensive tests, the tires mentioned below have been approved by Yamaha Motor Co., Ltd.
E_4tx_Periodic.fm Page 19 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00684 WARNING This motorcycle is fitted with super high-speed running tires. The following points must be observed in order for you to make fully effective use of these tires. ● Never fail to use the specified tires in tire replacement. Other tires may have a danger of bursting at super high-speeds. ● New tires have a relatively low grip on the road surface until they have been slightly worn.
E_4tx_Periodic.fm Page 20 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EW000109 NOTE: If proper adjustment cannot be obtained or the clutch does not work correctly, ask a Yamaha dealer to inspect the internal clutch mechanism. @ WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated.
E_4tx_Periodic.fm Page 21 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR Front 1. Brake light switch 2. Adjusting nut 1. Wear indicator (× 2) 1. Wear indicator (× 2) EAU00715 EAU00713 Brake light switch adjustment 6 Rear The rear brake light switch is activated by the brake pedal and is properly adjusted when the brake light comes on just before braking takes effect.
E_4tx_Periodic.fm Page 22 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR Front 1. Minimum level mark 1. Minimum level mark EAU00731 Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level and replenish when necessary.
E_4tx_Periodic.fm Page 23 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00742 Brake fluid replacement The brake fluid should be replaced only by trained Yamaha service personnel. Have the Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking: ● oil seals (every two years) ● brake hoses (every four years) a.
E_4tx_Periodic.fm Page 24 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03006 Drive chain lubrication 1. Caliper bracket bolt EC000096 CAUTION: Too little chain slack will overload the engine and other vital parts. Keep the slack within the specified limits. @ @ 3. After adjusting, tighten the axle nut and caliper bracket bolt to the specified torque. Tightening torque: Axle nut: 110 Nm (11.0 m·kg) Caliper bracket bolt: 35 Nm (3.
E_4tx_Periodic.fm Page 25 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00773 EAU02984 EAU02985 Throttle cable and grip lubrication Brake and shift pedal lubrication Brake and clutch lever lubrication The throttle twist grip assembly should be greased at the time that the cable is lubricated, since the grip must be removed to get at the end of the throttle cable. After removing the screws, hold the end of the cable up in the air and put in several drops of lubricant.
E_4tx_Periodic.fm Page 26 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02986 EAU00790 Sidestand lubrication Rear suspension lubrication Lubricate the sidestand pivoting point and metal-to-metal contact surfaces. Check that the sidestand moves up and down smoothly. Lubricate the pivoting parts. Recommended lubricant: Molybdenum disulfide grease Recommended lubricant: Engine oil EW000113 WARNING If the sidestand does not move smoothly, consult a Yamaha dealer.
E_4tx_Periodic.fm Page 27 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02939 Front fork inspection Visual check EW000115 WARNING Securely support the motorcycle so there is no danger of it falling over. @ @ Check for scratches or damage on the inner tube and excessive oil leakage from the front fork. 6 Operation check 1. Place the motorcycle on a level place. 2. Hold the motorcycle in an upright position and apply the front brake. 3.
E_4tx_Periodic.fm Page 28 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01144 EAU00800 Wheel bearings Battery If there is play in the front or rear wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer inspect the wheel bearings. This motorcycle is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or fill the battery with distilled water. ● If the battery seems to have discharged, consult a Yamaha dealer.
E_4tx_Periodic.fm Page 29 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR Battery storage When the motorcycle is not used for a month or longer, remove the battery, fully charge it and store it in a cool, dry place. EC000102 @ 6 @ CAUTION: ● Completely recharge the battery before storing. Storing a discharged battery can cause permanent battery damage. ● Use a battery charger designed for a sealed-type (MF) battery.
E_4tx_Periodic.fm Page 30 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR Specified fuses: Main fuse: Headlight fuse: Signaling system fuse: Ignition fuse: Hazard light fuse: Odometer fuse: Radiator fan fuse: 30 A 15 A 15 A 10 A 10 A 5A 7.5 A 1. Bulb holder cover EAU00827 1. Connector (× 2) 2. Bulb holder Headlight bulb replacement This motorcycle is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace the bulb as follows: 1.
E_4tx_Periodic.fm Page 31 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR 4. Install the bulb holder cover and reconnect the headlight connectors. If the headlight beam adjustment is necessary, ask a Yamaha dealer to make that adjustment. 1. Screw (× 2) 2. Lens 1. Bulb (× 2) EAU01623* Tail/brake light bulb replacement 1. Remove the screws and the lens. 2. Remove the defective bulb by pushing it inward and turning it counterclockwise. 3.
E_4tx_Periodic.fm Page 32 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01008 Troubleshooting 1. Screw 2. Lens Although Yamaha motorcycles receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks.
E_4tx_Periodic.fm Page 33 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02990* Troubleshooting chart EW000125 WARNING Never check the fuel system while smoking or in the vicinity of an open flame. @ @ 1. Fuel Enough fuel. Go to compression check. No fuel. Supply fuel. Check if there is fuel in the fuel tank. Engine doesn’t start, go to compression check. 2. Compression There is compression. Go to ignition check. No compression. Ask a Yamaha dealer to inspect.
E_4tx_Periodic.fm Page 34 Saturday, October 16, 1999 9:37 AM PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EW000070 WARNING Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Open the radiator cap as follows. Wait until the engine has cooled. Remove the radiator cap stopper by removing the screw.
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E_4tx_CleaningTOC.fm Page 1 Saturday, October 16, 1999 9:38 AM MOTORCYCLE CARE AND STORAGE Care ................................................................................................... 7-1 Storage...............................................................................................
E_4tx_Cleaning.fm Page 1 Saturday, October 16, 1999 9:38 AM MOTORCYCLE CARE AND STORAGE EAU01517 7- Care The exposure of its technology makes a motorcycle charming but also vulnerable. Although high-quality components are used, they are not all rust-resistant. While a rusty exhaust pipe may remain unnoticed on a car, it does look unattractive on a motorcycle. Frequent and proper care, however, will keep your motorcycle looking good, extend its life and maintain its performance.
E_4tx_Cleaning.fm Page 2 Saturday, October 16, 1999 9:38 AM MOTORCYCLE CARE AND STORAGE ECA00010 @ CAUTION: ● Avoid using strong acidic wheel cleaners, especially on spoked wheels. If you do use such products for hard-to-remove dirt, do not leave it on any longer than instructed, then thoroughly rinse it off with water, immediately dry the area and apply a corrosion protection spray. ● Improper cleaning can damage windshields, cowlings, panels and other plastic parts.
E_4tx_Cleaning.fm Page 3 Saturday, October 16, 1999 9:38 AM MOTORCYCLE CARE AND STORAGE 1. Clean your motorcycle with cold water and soap after the engine has cooled down. ECA00012 CAUTION: Do not use warm water since it increases the corrosive action of the salt. @ @ 2. Be sure to apply a corrosion protection spray on all (even chromeand nickel-plated) metal surfaces to prevent corrosion. 7 After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2.
E_4tx_Cleaning.fm Page 4 Saturday, October 16, 1999 9:38 AM MOTORCYCLE CARE AND STORAGE ECA00013 @ CAUTION: ● Apply spray oil and wax sparingly and wipe off any excess. ● Never apply oil or wax on rubber and plastic parts, but treat them with a suitable care product. ● Avoid using abrasive polishing compounds as they wear away the paint. Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.
E_4tx_Cleaning.fm Page 5 Saturday, October 16, 1999 9:38 AM MOTORCYCLE CARE AND STORAGE a. Remove the spark plug caps and spark plugs. b. Pour a teaspoonful of engine oil into each spark plug bore. c. Install the spark plug caps onto the spark plugs and place the spark plugs on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder walls with oil.) e.
E_4tx_SpecTOC.fm Page 1 Saturday, October 16, 1999 9:38 AM SPECIFICATIONS Specifications ..................................................................................... 8-1 HOW TO USE THE CONVERSION TABLE .......................................
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E_4tx_Spec.fm Page 2 Saturday, October 16, 1999 9:38 AM SPECIFICATIONS Air filter Dry type element Gear ratio Fuel 1st 2.643 Regular unleaded gasoline 2nd 1.947 Fuel tank capacity 20 L 3rd 1.500 Reserve amount 3.1 L 4th 1.174 5th 0.964 Type Carburetor Type × quantity BDSR38 × 2 Manufacturer MIKUNI Chassis Spark plug Manufacturer/Type Gap Clutch type NGK / DPR8EA-9 or DENSO / X24EPR-U9 Frame type Diamond Caster angle 24.5° Trail 103 mm Tires 0.8 ~ 0.
E_4tx_Spec.fm Page 3 Saturday, October 16, 1999 9:38 AM SPECIFICATIONS Maximum load* 203 kg Rear Air pressure (cold tire) Up to 90 kg load* 2 Front 225 kPa (2.25 kg/cm , 2.25 bar) Rear 275 kPa (2.75 kg/cm2, 2.75 bar) Single disc brake Operation Right foot operation Fluid DOT 4 Type Telescopic fork Type Swingarm Suspension 90 kg load ~ maximum load* Front Front 225 kPa (2.25 kg/cm2, 2.25 bar) Rear 275 kPa (2.75 kg/cm2, 2.75 bar) Rear High speed riding Front 225 kPa (2.25 kg/cm2, 2.
E_4tx_Spec.fm Page 4 Saturday, October 16, 1999 9:38 AM SPECIFICATIONS 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.
E_4tx_Spec.fm Page 5 Saturday, October 16, 1999 9:38 AM SPECIFICATIONS EAU01064 HOW TO USE THE CONVERSION TABLE CS-02E CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC MULTIPLIER METRIC TO IMPERIAL Metric unit IMPERIAL **mm × 0.03937 = **in 2 mm × 0.03937 = 0.08 in 8 8-5 Multiplier Imperial unit Torque m·kg m·kg cm·kg cm·kg 7.233 86.794 0.0723 0.
E_4tx_ConsumerTOC.fm Page 1 Saturday, October 16, 1999 9:38 AM CONSUMER INFORMATION Identification number records............................................................. 9-1 Key identification number ................................................................... 9-1 Vehicle identification number.............................................................. 9-1 Model label.........................................................................................
E_4tx_Consumer.fm Page 1 Saturday, October 16, 1999 9:38 AM CONSUMER INFORMATION EAU01039 9- EAU02944 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: 1. Key identification number CA-02E 2. VEHICLE IDENTIFICATION NUMBER: CA-02E 1.
E_4tx_Consumer.fm Page 2 Saturday, October 16, 1999 9:38 AM CONSUMER INFORMATION 1. Model label EAU01050 Model label The model label is affixed to the frame under the seat. (See page 3-12 for seat removal procedures.) Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer.
E_4txIX.fm Page 1 Saturday, October 16, 1999 9:38 AM INDEX 10- A E Air filter ..................................................6-13 Antitheft alarm (optional) ..........................3-5 Engine break-in ....................................... 5-5 Engine oil ................................................ 6-8 Engine overheating................................. 6-34 Engine stop switch................................... 3-7 B Battery ...................................................
E_4txIX.fm Page 2 Saturday, October 16, 1999 9:38 AM INDEX R Rear brake pedal ..................................... 3-9 Rear brake pedal height adjustment ...... 6-20 Rear shock absorber adjustment ........... 3-15 Rear suspension lubrication................... 6-26 Right view................................................ 2-2 S Seat....................................................... 3-12 Shifting .................................................... 5-4 Shift pedal ...................................
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 99 · 9 - 0.
