2000 YAMAHA TDM 850 check engine

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
12
*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).ÖÖ
13 Drive chain• Check chain slack.
• Adjust if necessary. Make sure that the rear wheel is properly aligned.
• Clean and lubricate. Every 500 km and after washing the
motorcycle or riding in the rain
14*Steering bearings• Check bearing play and steering for roughness.
• Correct accordingly.
• Lubricate with lithium soap base grease every 24,000 km
or 24 months (whichever comes first).ÖÖ
15*Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.ÖÖ
16 Sidestand• Check operation.
• Lubricate and repair if necessary.ÖÖ
17*Sidestand switch• Check operation.
• Replace if necessary.ÖÖÖ
18*Front fork• Check operation and for oil leakage.
• Correct accordingly.ÖÖ
19*Rear shock absorber
assembly• Check operation and shock absorber for oil leakage.
• Replace shock absorber assembly if necessary. ÖÖ
20*Rear shock absorber
assembly pivoting points• Check operation.
• Lubricate with molybdenum disulfide grease every 24,000 km
or 24 months (whichever comes first).ÖÖ
21*Carburetors• Check engine idling speed, synchronization and starter operation.
• Adjust if necessary.ÖÖÖ
22 Engine oil• Check oil level and vehicle for oil leakage.
• Correct if necessary.
• Change. (Warm engine before draining.)ÖÖÖ
23 Engine oil filter element
• Replace.ÖÖ NO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)
E_4tx_Periodic.fm Page 3 Saturday, October 16, 1999 9:37 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
EAU01692
Engine oilOil 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. @
2. The oil tank is located behind the
engine cylinders. With the engine
stopped, check the oil level
through the level window located
on the right side of the oil tank.
3. The oil level should be between
the maximum and minimum
marks. If the level is low, fill engine
with sufficient oil to raise it to the
specified level.Engine oil and oil filter element re-
placement
1. Warm up the engine for a few min-
utes.
2. Stop the engine. Place an oil pan
under the engine and remove the
oil filler cap.
3. Remove the drain bolts and drain
the oil.
4. Remove the oil filter cover bolts
and oil filter.
1. Oil level window
2. Minimum level mark
3. Maximum level mark
1. Engine oil filler cap
1. Engine oil drain bolt a
E_4tx_Periodic.fm Page 8 Saturday, October 16, 1999 9:37 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 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 immedi-
ately and check for the cause.
9. Stop the engine and check the oil
level.
EAU03024*
Cooling system1. Check the coolant level in the
coolant reservoir when the engine
is cold as the coolant level will vary
with engine temperature. The
coolant level should be between
the maximum and minimum
marks.
2. If the level is low, remove the seat.
(See page 3-12 for seat removal
and installation procedures.)
3. Remove the coolant reservoir cap,
then add coolant or distilled water
to raise it to the specified level.4. Install the coolant reservoir cap
and seat.
ECA00041
CAUTION:@ Hard water or salt water is harmful
to the engine. You may use soft wa-
ter if you can’t get distilled water. @
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
1. Coolant reservoir capCoolant reservoir capacity:
0.3 L
E_4tx_Periodic.fm Page 10 Saturday, October 16, 1999 9:37 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
NOTE:@ l
If water is added, have a Yamaha
dealer check the antifreeze con-
tent of the coolant as soon as pos-
sible.
l
The radiator fan operation is com-
pletely automatic. It is switched on
or off according to the coolant tem-
perature in the radiator.
@5. If your motorcycle overheats, see
page 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 stopper
bolt and radiator cap.
EW000067
WARNING
@ Do not remove the radiator cap
when the engine is hot. @
5. Remove the water pump drain bolt
and cylinder drain bolt.
1. Radiator cap stopper bolt
2. Radiator cap
1. Water pump drain bolt
2. Cylinder drain bolt
E_4tx_Periodic.fm Page 11 Saturday, October 16, 1999 9:37 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6 6. Remove the seat. (See page 3-12
for seat removal and installation
procedures.)
7. Remove the coolant reservoir by
removing the bolts.
8. Remove the coolant reservoir
hose clamp and disconnect the
hose.
9. Drain the coolant from the coolant
reservoir by turning it upside
down.
10. Install the hose and connect the
coolant reservoir hose clamp. 11. Drain the coolant completely and
thoroughly flush the cooling sys-
tem with clean tap water.
12. If the washers are damaged, re-
place them. Tighten the water
pump drain bolt and cylinder drain
bolt to the specified torques.
13. Pour the recommended coolant
into the radiator until it is full.
ECA00041
CAUTION:@ Hard water or salt water is harmful
to the engine. You may use soft wa-
ter if you can’t get distilled water. @14. Run the engine several minutes.
Stop the engine and recheck the
coolant level in the radiator. If it is
low, add more coolant until it
reaches the top of the radiator.
15. Fill the coolant reservoir with cool-
ant up to maximum level.
16. Install the radiator cap, radiator
cap stopper bolt and coolant res-
ervoir cap.
17. Check for coolant leakage. If any
leakage is found, ask a Yamaha
dealer to inspect the cooling sys-
tem.
1. Coolant reservoir
2. Bolt
3. Coolant reservoir hose clamp
4. Hose
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
E_4tx_Periodic.fm Page 12 Saturday, October 16, 1999 9:37 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU02986
Sidestand lubricationLubricate the sidestand pivoting point
and metal-to-metal contact surfaces.
Check that the sidestand moves up
and down smoothly.
EW000113
WARNING
@ If the sidestand does not move
smoothly, consult a Yamaha dealer. @
EAU00790
Rear suspension lubricationLubricate the pivoting parts.
Recommended lubricant:
Engine oilRecommended lubricant:
Molybdenum disulfide grease
E_4tx_Periodic.fm Page 26 Saturday, October 16, 1999 9:37 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU02939
Front fork inspectionVisual 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.
Operation check
1. Place the motorcycle on a level
place.
2. Hold the motorcycle in an upright
position and apply the front brake.
3. Push down hard on the handle-
bars several times and check if the
fork rebounds smoothly.
EC000098
CAUTION:@ If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer. @
EAU00794
Steering inspectionPeriodically inspect the condition of the
steering. Worn out or loose steering
bearings may be dangerous. Place a
stand under the engine to raise the
front wheel off the ground. Hold the
lower end of the front forks and try to
move them forward and backward. If
any free play can be felt, ask a Yamaha
dealer to inspect and adjust the steer-
ing. Inspection is easier if the front
wheel is removed.
EW000115
WARNING
@ Securely support the motorcycle so
there is no danger of it falling over. @
E_4tx_Periodic.fm Page 27 Saturday, October 16, 1999 9:37 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAU02990*
Troubleshooting chart
EW000125
WARNING
@ Never check the fuel system while smoking or in the vicinity of an open flame. @
Check if there is fuel
in the fuel tank.1. Fuel
Enough fuel.
No fuel.
Go to compression check.
Supply fuel.
Engine doesn’t start, go to compression check.
Use the electric starter.2. Compression
There is compression.
No compression.
Go to ignition check.
Ask a Yamaha dealer to
inspect.
Remove spark plugs
and check electrodes.3. Ignition
Wet.
Dry.
Wipe clean with dry cloth and correct
spark gap or replace spark plugs.
Ask a Yamaha dealer to inspect.
Engine doesn’t start, ask a Yamaha
dealer to inspect.Engine doesn’t start, go to battery
check.Open throttle half-way and start
the engine.
Use the electric starter.4. Battery
Engine turns over
quickly.
Engine turns over
slowly.
Battery good.Check connections or
recharge.
E_4tx_Periodic.fm Page 33 Saturday, October 16, 1999 9:37 AM