2001 YAMAHA TDM 850 Owners Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU03541
NOTE:_l
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l
Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
_22
*Carburetors• Check starter (choke) operation.
• Adjust engine idling speed and synchronization.ÖÖÖÖÖ Ö
23 Engine oil• Change.ÖÖÖÖÖ Ö
24 Engine oil filter element• Replace.ÖÖÖ
25*Cooling system• Check coolant level and vehicle for coolant leakage.ÖÖÖÖ Ö
• Change. Every 3 years
26*Front and rear brake
switches• Check operation.ÖÖÖÖÖ Ö
27 Moving parts and cables• Lubricate.ÖÖÖÖ Ö
28*Lights, signals and
switches• Check operation.
• Adjust headlight beam.ÖÖÖÖÖ Ö NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
E_4tx.book Page 4 Wednesday, October 4, 2000 4:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU01139
Removing and installing
cowlings and panels The cowlings and panels shown above
need to be removed to perform some
of the maintenance jobs described in
this chapter. Refer to this section each
time a cowling or panel needs to be re-
moved and installed.
EAU03494
Cowlings A and B
To remove one of the cowlingsRemove the cowling screws, and then
pull the cowling off as shown.
To install the cowlingPlace the cowling in the original posi-
tion, and then install the screws.
1. Cowling A
2. Panel A
1. Cowling B
2. Panel B
1. Screw (´ 3)
E_4tx.book Page 5 Wednesday, October 4, 2000 4:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU03317
Panels A and B
To remove one of the panels1. Remove the corresponding cowl-
ing A or B. (See page 6-5 for cowl-
ing removal and installation
procedures.)
2. Remove the seat. (See page 3-11
for seat removal and installation
procedures.)
3. Remove the screw, and then take
the panel off.To install the panel
1. Place the panel in the original po-
sition, and then install the screw.
2. Install the seat and the cowling.
1. Screw
E_4tx.book Page 6 Wednesday, October 4, 2000 4:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
EAU01668
Checking the spark plugs The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
To remove a spark plug
1. Remove cowling A. (See page 6-5
for cowling removal and installa-
tion procedures.)
2. Remove the spark plug cap.3. Remove the spark plug as shown
with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medium-to-
light tan (the ideal color when the
motorcycle is ridden normally).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:@ If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle. @3. Check each spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and replace
it if necessary.
1. Spark plug cap
1. Spark plug wrench
Specified spark plug:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
E_4tx.book Page 7 Wednesday, October 4, 2000 4:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6 To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:@ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. @4. Install the spark plug cap.
5. Install the cowling.
a. Spark plug gap
Spark plug gap:
0.8–0.9 mm
Tightening torque:
Spark plug:
18 Nm (1.8 m·kg)
E_4tx.book Page 8 Wednesday, October 4, 2000 4:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
EAU01692
Engine oil and oil filter
element The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:@ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. @2. Start the engine, warm it up for
15 minutes, and then turn it off.3. Check the oil level through the
check window located on the right
side of the engine oil tank.
NOTE:@ l
The engine oil tank is located be-
hind the cylinders.
l
The engine oil should be between
the minimum and maximum level
marks.
@4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1. Engine oil tank cap
E_4tx.book Page 9 Wednesday, October 4, 2000 4:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 3. Remove the engine oil tank cap
and drain bolts to drain the oil from
the crankcase.
NOTE:@ Skip steps 4–6 if the oil filter element is
not being replaced. @
4. Remove the oil filter element cover
by removing the bolts.5. Remove and replace the oil filter
element and O-rings.
6. Install the oil filter element cover
by installing the bolts, then tighten-
ing them to the specified torque.
NOTE:@ Make sure that the O-rings are properly
seated.@7. Install the engine oil drain bolts,
and then tighten them to the spec-
ified torques.
1. Engine oil drain bolt A
1. Engine oil drain bolt B
2. Oil filter element cover
3. Bolt (´ 5)
1. Oil filter element
2. O-ring (´ 2)Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kg)
E_4tx.book Page 10 Wednesday, October 4, 2000 4:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
68. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil tank
cap.
EC000072
CAUTION:@ l
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of a higher
grade than “CD”. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.
l
Make sure that no foreign mate-
rial enters the crankcase.
@9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU03495
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
If the engine overheats, see page 6-45
for further instructions.
To check the coolant level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:@ l
The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
l
Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A slight
tilt to the side can result in a false
reading.
@
Tightening torques:
Engine oil drain bolt A:
35 Nm (3.5 m·kg)
Engine oil drain bolt B:
30 Nm (3.0 m·kg)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
3.5 L
With oil filter element
replacement:
3.6 L
Total amount (dry engine):
4.2 L
E_4tx.book Page 11 Wednesday, October 4, 2000 4:28 PM