2001 YAMAHA TDM 850 maintenance

TABLE OF CONTENTS
1 GIVE SAFETY THE RIGHT OF WAY
1
2 DESCRIPTION
2
3 INSTRUMENT AND CONTROL FUNCTIONS
3
4 PRE-OPERATION CHECKS
4
5 OPERATION AND IMPORTANT RIDING POINTS
5
6 PERIODIC MAINTENANCE AND MINOR REPAIR
6
7 MOTORCYCLE CARE AND STORAGE
7
8 SPECIFICATIONS
8
9 CONSUMER INFORMATION
9
INDEX
EAU00009
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM

1
1-1
EAU00021
1-GIVE SAFETY THE RIGHT OF WAY
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.
Regular care and maintenance are essential for preserving value and operating condition of your
motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders—more than car drivers—must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and
passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant
synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet.
Optimum protective wear, however, should not encourage carelessness. Although full-coverage
helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will
always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to
take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely,
predictably and defensively—avoiding all dangers, including those caused by others.
Enjoy your ride!
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Removing and installing cowlings and panels ..... 6-5
Checking the spark plugs .................................... 6-7
Engine oil and oil filter element ............................ 6-9
Coolant .............................................................. 6-11
Cleaning the air filter element ............................ 6-15
Adjusting the carburetors ................................... 6-18
Adjusting the engine idling speed ...................... 6-18
Adjusting the throttle cable free play .................. 6-19
Adjusting the valve clearance ............................ 6-19
Tires ................................................................... 6-19
Adjusting the clutch lever free play .................... 6-23
Adjusting the brake pedal position ..................... 6-23
Adjusting the rear brake light switch .................. 6-24
Checking the front and rear brake pads ............. 6-25
Checking the brake fluid level ............................ 6-25
Changing the brake fluid .................................... 6-26
Drive chain slack ................................................ 6-27
Lubricating the drive chain ................................. 6-29
Checking and lubricating the cables .................. 6-29Checking and lubricating the throttle grip and
cable ............................................................... 6-30
Checking and lubricating the brake and
shift pedals ...................................................... 6-30
Checking and lubricating the brake and
clutch levers .................................................... 6-31
Checking and lubricating the sidestand ............ 6-31
Lubricating the rear suspension ........................ 6-32
Checking the front fork ...................................... 6-32
Checking the steering ....................................... 6-33
Checking the wheel bearings ............................ 6-33
Battery ............................................................... 6-34
Replacing the fuses .......................................... 6-35
Replacing a headlight bulb ................................ 6-36
Replacing the tail/brake light bulb ..................... 6-37
Replacing a turn signal light bulb ...................... 6-38
Supporting the motorcycle ................................ 6-39
Front wheel ....................................................... 6-39
Rear wheel ........................................................ 6-41
Troubleshooting ................................................. 6-43
Troubleshooting charts ...................................... 6-44
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM

6-1
6
EAU00462
6-PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
EW000060
WARNING
@ If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you. @
EAU01299
Owner’s tool kit The owner’s tool kit is located inside
the storage compartment under the
seat. (See page 3-11 for seat removal
procedures.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:@ If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you. @
EW000063
WARNING
@ Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es. @
1. Owner’s tool kit
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_ l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_
CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line• Check fuel hoses for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
• Replace.ÖÖ
4*Valves• Check valve clearance.
•Adjust.Every 40,000 km
5 Air filter element•Clean.ÖÖ
• Replace.ÖÖ
6Clutch• Check operation.
•Adjust.ÖÖÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
E_4tx.book Page 2 Wednesday, October 4, 2000 4:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9
*Brake hose• Check for cracks or damage.ÖÖÖÖ Ö
• Replace. (See NOTE on page 6-4.) Every 4 years
10*Wheels• Check runout and for damage.ÖÖÖÖ
11*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.ÖÖÖÖ
12*Wheel bearings• Check bearing for looseness or damage.ÖÖÖÖ
13*Swingarm• Check operation and for excessive play.ÖÖÖÖ
• Lubricate with molybdenum disulfide grease. Every 50,000 km
14 Drive chain• Check chain slack.
• Make sure that the rear wheel is properly aligned.
• Clean and lubricate.Every 1,000 km and after washing
the motorcycle or riding in the rain.
15*Steering bearings• Check bearing play and steering for roughness.ÖÖÖÖÖ
• Lubricate with lithium-soap-based grease. Every 20,000 km
16*Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖ Ö
17 Sidestand• Check operation.
• Lubricate.ÖÖÖÖ Ö
18*Sidestand switch• Check operation.ÖÖÖÖÖ Ö
19*Front fork• Check operation and for oil leakage.ÖÖÖÖ
20*Rear shock absorber
assembly• Check operation and shock absorber for oil leakage.ÖÖÖÖ
21*Rear suspension relay
arm and connecting arm
pivoting points• Check operation.ÖÖÖÖ
• Lubricate with molybdenum disulfide grease.ÖÖ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
E_4tx.book Page 3 Wednesday, October 4, 2000 4:28 PM

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