2001 YAMAHA TDM 850 suspension

INSTRUMENT AND CONTROL FUNCTIONS
3-13
3
EAU01728
Adjusting the front fork The front fork is equipped with spring
preload adjusting bolts and damping
force adjusting screws.
EW000035
WARNING
@ Always adjust both fork legs equal-
ly, otherwise poor handling and loss
of stability may result. @
Spring preload
To increase the spring preload and
thereby harden the suspension, turn
the adjusting bolt on each fork leg in di-
rection
a. To decrease the spring pre-
load and thereby soften the
suspension, turn the adjusting bolt on
each fork leg in direction
b.NOTE:@ Align the appropriate groove on the ad-
justing mechanism with the top of the
front fork cap bolt. @
CI-10E
1. Spring preload adjusting bolt
2. Current setting
3. Standard setting
4. Front fork cap bolt
Setting
Minimum (soft) 1
Standard 3
Maximum (hard) 5
E_4tx.book Page 13 Wednesday, October 4, 2000 4:28 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-15
3
EAU03834
Adjusting the shock absorber
assembly This shock absorber assembly is
equipped with a spring preload adjust-
ing lever and adjusting nut and a damp-
ing force adjusting dial.
EC000015
CAUTION:_ Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings. _
Spring preload
Coarse adjustmentFor riding solo, move the adjusting le-
ver (at the top of the shock absorber
assembly) to “SOFT”. For riding with a
passenger, move the adjusting lever to
“HARD”. NOTE:_ Use the special tool included in the
owner’s tool kit to make the adjust-
ment. _
Fine adjustment1. Loosen the locknut.
2. To increase the spring preload
and thereby harden the suspen-
sion, turn the adjusting nut (at the
bottom of the shock absorber as-
sembly) in direction
a. To de-
crease the spring preload and
thereby soften the suspension,
turn the adjusting nut in
direction
b.
1. Spring preload adjusting lever
1. Locknut
2. Spring preload adjusting nut
E_4tx.book Page 15 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

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
6-20
6
CE-01E
CE-07EEWA00012
WARNING
_ Because loading has an enormous
impact on the handling, braking, per-
formance and safety characteristics
of your motorcycle, you should keep
the following precautions in mind. l
NEVER OVERLOAD THE
MOTORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider, pas-
senger, cargo, and accessories
does not exceed the specified
maximum load for the vehicle.
l
Do not carry along loosely
packed items, which can shift
during a ride.
l
Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.
l
Adjust the suspension and tire
air pressure with regard to the
load.
l
Check the tire condition and air
pressure before each ride.
_
Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the side-
wall is cracked, have a Yamaha dealer
replace the tire immediately.CE-08ENOTE:_ The tire tread depth limits may differ
from country to country. Always comply
with the local regulations. _
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg225 kPa
(2.25 kg/cm
2,
2.25 bar)275 kPa
(2.75 kg/cm
2,
2.75 bar)
90 kg–maximum225 kPa
(2.25 kg/cm
2,
2.25 bar)275 kPa
(2.75 kg/cm
2,
2.75 bar)
High-speed riding225 kPa
(2.25 kg/cm
2,
2.25 bar)275 kPa
(2.75 kg/cm
2,
2.75 bar)
Maximum load* 203 kg
* Total weight of rider, passenger, cargo and
accessories
1. Tire sidewall
a. Tire tread depthMinimum tire tread depth
(front and rear)1.6 mm
E_4tx.book Page 20 Wednesday, October 4, 2000 4:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6
EAU00790
Lubricating the rear
suspension The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:@ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. @
Recommended lubricant:
Molybdenum disulfide grease
E_4tx.book Page 32 Wednesday, October 4, 2000 4:28 PM

SPECIFICATIONS
8-3
8
Maximum load* 203 kg
Tire air pressure
(measured on cold tires)
Up to 90 kg*
Front 225 kPa (2.25 kg/cm
2, 2.25 bar)
Rear 275 kPa (2.75 kg/cm2, 2.75 bar)
90 kg–maximum*
Front 225 kPa (2.25 kg/cm2, 2.25 bar)
Rear 275 kPa (2.75 kg/cm2, 2.75 bar)
High-speed riding
Front 225 kPa (2.25 kg/cm2, 2.25 bar)
Rear 275 kPa (2.75 kg/cm2, 2.75 bar)
* Total weight of rider, passenger, cargo and accessories
Wheels
Front
Type Cast wheel
Size 18 ´ MT 3.00
Rear
Type Cast wheel
Size 17 ´ MT 4.00Brakes
Front
Type Dual disc brake
Operation Right hand
Fluid DOT 4
Rear
Type Single disc brake
Operation Right foot
Fluid DOT 4
Suspension
Front Telescopic fork
Rear Swingarm (monocross)
Spring/shock absorber
Front Coil spring / oil damper
Rear Coil spring / gas-oil damper
Wheel travel
Front 149 mm
Rear 144 mm
E_4tx.book Page 3 Wednesday, October 4, 2000 4:28 PM

INDEX
Shifting .................................................... 5-3
Shift pedal ............................................... 3-7
Shift points (for Switzerland only)............. 5-3
Shock absorber assembly, adjusting ..... 3-15
Sidestand .............................................. 3-17
Sidestand, checking and lubricating....... 6-31
Spark plugs, checking ............................. 6-7
Specifications .......................................... 8-1
Speedometer unit .................................... 3-3
Starter (choke) lever .............................. 3-10
Starting a cold engine .............................. 5-1
Starting a warm engine ............................ 5-2
Start switch .............................................. 3-6
Steering, checking ................................. 6-33
Storage.................................................... 7-4
Storage compartment ............................ 3-12
Supporting the motorcycle ..................... 6-39
Suspension (rear), lubricating ................ 6-32TTachometer ............................................. 3-4
Tail/brake light bulb, replacing ............... 6-37
Throttle cable free play, adjusting .......... 6-19
Throttle grip and cable, checking and
lubricating............................................ 6-30
Tires ...................................................... 6-19
Tool kit..................................................... 6-1
Troubleshooting..................................... 6-43
Troubleshooting charts .......................... 6-44
Turn signal indicator lights ....................... 3-2
Turn signal light bulb, replacing ............. 6-38
Turn signal switch .................................... 3-6
VValve clearance, adjusting .................... 6-19
Vehicle identification number................... 9-1WWheel bearings, checking ..................... 6-33
Wheel (front) ......................................... 6-39
Installing .......................................... 6-40
Removing ........................................ 6-39
Wheel (rear) .......................................... 6-41
Installing .......................................... 6-42
Removing ........................................ 6-41
E_4tx.book Page 2 Wednesday, October 4, 2000 4:28 PM