2001 YAMAHA TDM 850 tires

PRE-OPERATION CHECKS
4-2
4
NOTE:_ Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved. _
EWA00033
WARNING
_ If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle. _Control cables• Make sure that operation is smooth.
• Lubricate if necessary.6-29
Drive chain• Check chain slack.
• Adjust if necessary.
• Check chain condition.
• Lubricate if necessary.6-27
Wheels and tires• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.6-19–6-22
Brake and shift pedals• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.6-30
Brake and clutch levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.6-31
Sidestand• Make sure that operation is smooth.
• Lubricate pivot if necessary.6-31
Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.—
Instruments, lights, signals
and switches• Check operation.
• Correct if necessary.—
Sidestand switch• Check operation of ignition circuit cut-off system.
• If system is defective, have Yamaha dealer check vehicle.3-17 ITEM CHECKS PAGE
E_4tx.book Page 2 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
6-19
6
EAU00635
Adjusting the throttle cable
free play The throttle cable free play should
measure 3–5 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
EAU00637
Adjusting the valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU00658
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EW000082
WARNING
_ l
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
l
The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
_
a. Throttle cable free playE_4tx.book Page 19 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
6-21
6
EW000079
WARNING
_ l
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.
l
The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
_
Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
EW000080
WARNING
_ l
The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motor-
cycle cannot be guaranteed.
l
After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.
l
Always make sure that the valve
caps are securely installed to
prevent air pressure leakage.
l
Use only the tire valves and
valve cores listed below to
avoid tire deflation during a
high-speed ride.
_
1. Tire air valve
2. Valve core
3. Valve cap with seal
E_4tx.book Page 21 Wednesday, October 4, 2000 4:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
CE-10E
CE-14EEAU00684
WARNING
@ This motorcycle is fitted with super-
high-speed tires. Note the following
points in order to make the most ef-
ficient use of these tires.l
Use only the specified replace-
ment tires. Other tires may run
the danger of bursting at super
high speeds.
l
Brand-new tires can have a rela-
tively poor grip on certain road
surfaces until they have been
“broken in”. Therefore, it is ad-
visable before doing any high-
speed riding to ride conserva-
tively for approximately 100 km
after installing a new tire.
l
The tires must be warmed up
before a high-speed run.
l
Always adjust the tire air pres-
sure according to the operating
conditions.
@
FRONT
Manufacturer Size Model
Bridgestone 110/80 ZR18 (58W) BT54F
Pirelli 110/80 ZR18 (58W) MTR03
Michelin 110/80 ZR18 (58W) MACADAM 90X
REAR
Manufacturer Size Model
Bridgestone 150/70 ZR17 (69W) BT54R
Pirelli 150/70 ZR17 (69W) MTR04
Michelin 150/70 ZR17 (69W) MACADAM 90X
FRONT & REAR
Tire air valve TR412
Valve core #9000A (original)
E_4tx.book Page 22 Wednesday, October 4, 2000 4:28 PM

MOTORCYCLE CARE AND STORAGE
7-3
71. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
CAUTION:@ Do not use warm water since it in-
creases the corrosive action of the
salt. @2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick-
el-plated, surfaces to prevent cor-
rosion.After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
EWA00001
WARNING
@ l
Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent.
l
Before operating the motor-
cycle test its braking perfor-
mance and cornering behavior.
@
E_4tx.book Page 3 Wednesday, October 4, 2000 4:28 PM