Yamaha TDM, TRX850, XTZ750 Super Tenere Repair Manual 1989-1999

The 1989-1999 Yamaha TDM850, TRX850, XTZ750 Super Tenere repair manual by Haynes, covers the following dual-sport models:

• Yamaha TDM850, 1991-1999
• Yamaha TRX850, 1996-1999
• Yamaha XTZ750 Super Tenere, 1989-1995

Book Excerpt: 1989-1999 Yamaha TDM850, TRX850, XTZ750 Repair Manual ENGINE, CLUTCH AND TRANSMISSION

BALANCER SHAFTS | REMOVAL, INSPECTION, INSTALLATION NOTE: On 1991 to 1995 TDM models and XTZ models, the balancer shafts can be removed with the engine in the frame. If the engine has been removed, ignore the steps which do not apply. On 1996-on TDM models and all TRX models, the engine must be removed from the frame. REMOVAL

1. On 1991 to 1995 TDM models and XTZ models, remove the seat, side covers and engine bash plate (see Chapter 8), the fuel tank and exhaust system (see Chapter 4), the starter clutch and idle/reduction gear (see Section 22).
2. On 1996-on TDM models and TRX models, remove the oil tank (see Section 21), the starter clutch and idle/reduction gear (see Section 18), and the oil pump sump (see Section 22).
3. On 1992 to 1995 TDM models, unscrew the bolts securing the mud flap/engine top cover and remove the cover, feeding the earth cable through as you do (see illustration).
4. On 1991 to 1995 TDM models and XTZ models, unscrew the oil pipe banjo bolts and the bracket bolt securing the oil pipe to the cylinder head and the crankcase top cover and remove the pipe (see illustration). Discard the sealing washers as new ones must be used. Working evenly in a criss-cross pattern, unscrew the bolts securing the cover to the top of the crankcase and remove the cover (see illustration). Note the position of the earth cable and cable guide and of the bolt with the copper sealing washer. Discard the gasket as a new one must be used. Note the positions of the dowels and remove them if they are loose.
5. Unscrew the bolts securing the oil strainer holder and remove the holder (see illustration). Remove the O-ring from the oil passage collar in the crankcase (see illustration); a new O-ring is required for reassembly.

FRAME, SUSPENSION AND FINAL DRIVE

SUSPENSION | ADJUSTMENTS FRONT FORKS

1. On XTZ ,models, the front forks are not adjustable.
2. On TDM and TRX models, spring pre-load is adjusted using a suitable spanner on the adjuster flats on the top of the forks (see illustration). The amount of the pre-load indicated by the lines on the adjuster. There are five lines on the TDM models and eight on the TRX models. The standard position is with the fifth (1991 to 1995 TDM models), third (1996-on TDM models) or sixth (TRX models) line just visible above the top bolt hex. Turn the adjuster clockwise to increase pre-load and anti-clockwise to decrease it. Always make sure both adjusters are set equally.
3. On TDM models, rebound damping is adjusted using a screwdriver in the slot in the adjuster protruding from the pre-load adjuster (see illustration 12.2). The amount of damping is indicated by the number of clicks when turned anti-clockwise from the fully screwed in position. There are six positions on 1991 to 1995 TDM models and five on 1996-on TDM models. The standard position is four clicks out. Turn the turn the adjuster clockwise to increase damping and anti-clockwise to decrease it.

Subject: 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Yamaha TDM850, TRX850, XTZ750 Super Tenere service, maintenance, repair. ISBN-10: 1859605400 | ISBN-13: 9781859605400 | Haynes 3540