2001 YAMAHA TDM 850 steering

DESCRIPTION
2-3
2
Controls and instruments1. Clutch lever (page 3-7)
2. Left handlebar switches (page 3-5)
3. Starter (choke) lever (page 3-10)
4. Speedometer unit (page 3-3)
5. Main switch/steering lock (page 3-1)6. Tachometer (page 3-4)
7. Fuel gauge (page 3-5)
8. Right handlebar switches (page 3-6)
9. Throttle grip (page 6-19)
10. Brake lever (page 3-7)
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3
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock ..................................... 3-1
Indicator and warning lights ................................ 3-2
Speedometer unit ................................................ 3-3
Tachometer .......................................................... 3-4
Self-diagnosis device .......................................... 3-4
Anti-theft alarm (optional) .................................... 3-5
Fuel gauge ........................................................... 3-5
Handlebar switches ............................................. 3-5
Clutch lever .......................................................... 3-7
Shift pedal ............................................................ 3-7
Brake lever .......................................................... 3-7
Brake pedal .......................................................... 3-8
Fuel tank cap ....................................................... 3-9Fuel ..................................................................... 3-9
Fuel tank breather hose (for Germany only) ..... 3-10
Starter (choke) lever .......................................... 3-10
Seat ................................................................... 3-11
Helmet holder .................................................... 3-11
Storage compartment ....................................... 3-12
Adjusting the front fork ...................................... 3-13
Adjusting the shock absorber assembly ............ 3-15
Luggage strap holders ...................................... 3-17
Sidestand .......................................................... 3-17
Ignition circuit cut-off system ............................. 3-18
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3-1
3
EAU00027
3-INSTRUMENT AND CONTROL FUNCTIONS
EAU00029
Main switch/steering lock The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
EAU00036
ON
All electrical systems are supplied with
power, and the engine can be started.
The key cannot be removed.
EAU00038
OFF
All electrical systems are off. The key
can be removed.
EAU00040
LOCK
The steering is locked, and all electrical
systems are off. The key can be re-
moved.
To lock the steering1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF” po-
sition, and then turn it to “LOCK”
while still pushing it.
3. Remove the key.
To unlock the steeringPush the key in, and then turn it to
“OFF” while still pushing it.
EW000016
WARNING
@ Never turn the key to “OFF” or
“LOCK” while the motorcycle is
moving, otherwise the electrical
systems will be switched off, which
may result in loss of control or an
accident. Make sure that the motor-
cycle is stopped before turning the
key to “OFF” or “LOCK”. @1. Push.
2. Turn.
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-2
3
EAU01590
(Parking)
The steering is locked, and the taillight
and auxiliary light are on, but all other
electrical systems are off. The key can
be removed.
The steering must be locked before the
key can be turned to “ ”.
ECA00043
CAUTION:_ Do not use the parking position for
an extended length of time, other-
wise the battery may discharge. _
EAU03034
Indicator and warning lights
EAU03299
Turn signal indicator lights
“”/“”
The corresponding indicator light flash-
es when the turn signal switch is
pushed to the left or right.
EAU00061
Neutral indicator light “ ”
This indicator light comes on when the
transmission is in the neutral position.
EAU00063
High beam indicator light “ ”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU01707
Coolant temperature warning light
“”
This warning light comes on when the
engine overheats. When this occurs,
stop the engine immediately and allow
the engine to cool.
The electrical circuit of the warning light
can be checked according to the fol-
lowing procedure.
1. Set the engine stop switch to “ ”
and turn the key to “ON”.
2. Shift the transmission into the neu-
tral position or pull the clutch lever.
3. Push the start switch. If the warn-
ing light does not come on while
pushing the start switch, have a
Yamaha dealer check the electri-
cal circuit.
EC000002
CAUTION:@ Do not operate the engine if it is
overheated. @
1. Left turn signal indicator light “ ”
2. Neutral indicator light “ ”
3. High beam indicator light “ ”
4. Coolant temperature warning light “ ”
5. Right turn signal indicator light “ ”
6. Fuel level warning light “ ”
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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

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
6-33
6
EAU00794
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steer-
ing.
EAU01144
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
E_4tx.book Page 33 Wednesday, October 4, 2000 4:28 PM

9-1
9
EAU01039
9-CONSUMER INFORMATION
EAU02944
Identification numbers Record the key identification number,
vehicle identification number and mod-
el label information in the spaces pro-
vided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehi-
cle is stolen.
1. KEY IDENTIFICATION NUMBER:CA-02E2. VEHICLE IDENTIFICATION
NUMBER:CA-02E3. MODEL LABEL INFORMATION:CA-01EEAU01041
Key identification number The key identification number is
stamped into the key tag. Record this
number in the space provided and use
it for reference when ordering a new
key.
EAU01043
Vehicle identification number The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro-
vided.NOTE:@ The vehicle identification number is
used to identify your motorcycle and
may be used to register your motor-
cycle with the licensing authority in
your area. @
1. Key identification number
1. Vehicle identification number
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM