2000 YAMAHA TDM 850 engine

OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EAU01258
Starting a warm engineThe 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. @
EAU00423
ShiftingThe transmission lets you control the
amount of power you have available at
a given speed for starting, accelerating,
climbing hills, etc. The use of the shift
pedal is shown in the illustration.
To shift into neutral, depress the shift
pedal repeatedly until it reaches the
end of its travel, then raise the pedal
slightly.
EC000048
CAUTION:@ l
Do not coast for long periods
with the engine off, and do not
tow the motorcycle a long dis-
tance. Even with gears in neu-
tral, the transmission is only
properly lubricated when the
engine is running. Inadequate
lubrication may damage the
transmission.
l
Always use the clutch when
changing gears. The engine,
transmission, and driveline are
not designed to withstand the
shock of forced shifting and can
be damaged by shifting without
using the clutch.
@
1. Shift pedal
N. Neutral
E_4tx_Operation.fm Page 4 Saturday, October 16, 1999 9:37 AM

OPERATION AND IMPORTANT RIDING POINTS
5-5
5
EAU00424
Tips for reducing fuel
consumptionYour motorcycle’s fuel consumption
depends to a large extent on your
riding style. The following tips can help
reduce fuel consumption:l
Warm up the engine before riding.
l
Turn off the starter (choke) as
soon as possible.
l
Shift up swiftly and avoid high en-
gine speeds during acceleration.
l
Do not double-clutch or rev the en-
gine while shifting down and avoid
high engine speeds with no load
on the engine.
l
Turn off the engine instead of let-
ting it idle for an extended length
of time, i.e. in traffic jams, at traffic
lights or railroad crossings.
EAU00436
Engine break-inThere is never a more important period
in the life of your motorcycle than the
period between zero and 1,000 km. For
this reason we ask that you carefully
read the following material. Because
the engine is brand new, you must not
put an excessive load on it for the first
1,000 km. The various parts in the en-
gine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full throttle oper-
ation, or any condition which might re-
sult in excessive heating of the engine,
must be avoided.
EAU00440
0 ~ 150 km
Avoid operation above 5,000 r/min.
Stop the engine and let it cool for 5 to
10 minutes after every hour of opera-
tion. Vary the speed of the motorcycle
from time to time. Do not operate it at
one set throttle position.
150 ~ 500 km
Avoid prolonged operation above
6,000 r/min. Rev the motorcycle freely
through the gears, but do not use full
throttle at any time.
500 ~ 1,000 km
Avoid prolonged full throttle operation.
Avoid cruising speeds in excess of
7,000 r/min.
EC000052
CAUTION:@ After 1,000 km of operation, be sure
to replace the engine oil and oil fil-
ter. @
E_4tx_Operation.fm Page 5 Saturday, October 16, 1999 9:37 AM

OPERATION AND IMPORTANT RIDING POINTS
5-6
5 1,000 km and beyond
Full throttle can be used.
EC000053
CAUTION:@ l
Never let engine speeds enter
the red zone.
l
If any engine trouble should oc-
cur during the break-in period,
consult a Yamaha dealer imme-
diately.
@
EAU00457
ParkingWhen parking the motorcycle, stop the
engine and remove the ignition key.
Turn the fuel cock to “OFF” whenever
stopping the engine.
EW000058
WARNING
@ The exhaust system is hot. Park the
motorcycle in a place where pedes-
trians or children are not likely to
touch the motorcycle. Do not park
the motorcycle on a slope or soft
ground; the motorcycle may over-
turn. @
E_4tx_Operation.fm Page 6 Saturday, October 16, 1999 9:37 AM

6
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........................................................... 6-6
Engine oil .............................................................. 6-8
Cooling system ................................................... 6-10
Changing the coolant .......................................... 6-11
Air filter ............................................................... 6-13
Carburetor adjustment ........................................ 6-15
Idle speed adjustment ........................................ 6-15
Throttle cable free play inspection ...................... 6-16
Valve clearance adjustment ................................ 6-16
Tires .................................................................... 6-17
Clutch lever free play adjustment........................ 6-19
Rear brake pedal height adjustment ................... 6-20
Brake light switch adjustment ............................. 6-21
Checking the front and rear brake pads.............. 6-21
Inspecting the brake fluid level............................ 6-22
Brake fluid replacement ...................................... 6-23Drive chain slack check ...................................... 6-23
Drive chain slack adjustment ............................. 6-23
Drive chain lubrication........................................ 6-24
Cable inspection and lubrication ........................ 6-24
Throttle cable and grip lubrication ...................... 6-25
Brake and shift pedal lubrication ........................ 6-25
Brake and clutch lever lubrication ...................... 6-25
Sidestand lubrication.......................................... 6-26
Rear suspension lubrication............................... 6-26
Front fork inspection ........................................... 6-27
Steering inspection ............................................ 6-27
Wheel bearings .................................................. 6-28
Battery................................................................ 6-28
Fuse replacement .............................................. 6-29
Headlight bulb replacement ............................... 6-30
Tail/brake light bulb replacement ........................ 6-31
Turn signal light bulb replacement...................... 6-32
Troubleshooting .................................................. 6-32
Troubleshooting chart ......................................... 6-33
Engine overheating ............................................ 6-34
E_4tx_PeriodicTOC.fm Page 1 Saturday, October 16, 1999 9:37 AM

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
6-6
6
EAU01691*
Panels A and BTo remove
1. Remove the seat. (See page 3-12
for removal and installation proce-
dures.)
2. Remove the screw.
To install
1. Place the panels in the original po-
sition and install the screw.
2. Install the seat.
EAU01668*
Spark plugsRemoval
1. Remove cowlings A and B. (See
page 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 plugs
as shown.Inspection
The spark plug is an important engine
component and is easy to inspect. The
condition of the spark plug can indicate
the condition of the engine.
Normally, all spark plugs from the
same engine should have the same
color on the white insulator around the
center electrode. The ideal color at this
point is a medium-to-light tan color for a
motorcycle that is being ridden normal-
ly. If one spark plug shows a distinctly
different color, there could be some-
thing wrong with the engine.
1. Screw
1. Spark plug cap
1. Spark plug wrench
E_4tx_Periodic.fm Page 6 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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
65. Install the drain bolts and tighten
them to the specified torque.
6. Install the new oil filter, O-rings
and the filter cover. Tighten the oil
filter cover bolts to the specified
torque.
NOTE:@ Make sure the O-rings are seated prop-
erly. @7. Fill engine with oil. Install the oil fill-
er cap and tighten.
EC000066
CAUTION:@ l
Do not put in any chemical addi-
tives. Engine oil also lubricates
the clutch and additives could
cause clutch slippage.
l
Be sure no foreign material en-
ters the crankcase.
@
1. Engine oil drain bolt b
2. Oil filter cover bolt (´ 5)
3. Oil filter coverTightening torque:
Drain bolt
a:
35 Nm (3.5 m·kg)
Drain bolt
b:
30 Nm (3.0 m·kg)
1. Oil filter
2. O-ring (´ 2)
Tightening torque:
Oil filter cover bolt:
10 Nm (1.0 m·kg)
Recommended oil:
See page 8-1.
Oil quantity:
Total amount:
4.2 L
Periodic oil change:
3.5 L
With oil filter replacement:
3.6 L
E_4tx_Periodic.fm Page 9 Saturday, October 16, 1999 9:37 AM