YAMAHA TDM 850 2000 Workshop Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU01139
Cowling and panel removal
and installationThe cowlings and panels illustrated
need to be removed to perform some
of the maintenance described in this
chapter. Refer to this section each time
a cowling or panel has to be removed
or reinstalled.
EAU00484*
Cowlings A and BTo remove
Remove the screws and pull outward
as shown.
To install
Place the cowlings in the original posi-
tion and install the screws.
1. Cowling A
2. Panel A
1. Cowling B
2. Panel B
1. Screw (´ 3)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU01691*
Panels A and BTo remove
1. Remove the seat. (See page 3-12
for removal and installation proce-
dures.)
2. Remove the screw.
To install
1. Place the panels in the original po-
sition and install the screw.
2. Install the seat.
EAU01668*
Spark plugsRemoval
1. Remove cowlings A and B. (See
page 6-5 for removal and installa-
tion procedures.)
2. Remove the spark plug caps.
3. Use the spark plug wrench in the
tool kit to remove the spark plugs
as shown.Inspection
The spark plug is an important engine
component and is easy to inspect. The
condition of the spark plug can indicate
the condition of the engine.
Normally, all spark plugs from the
same engine should have the same
color on the white insulator around the
center electrode. The ideal color at this
point is a medium-to-light tan color for a
motorcycle that is being ridden normal-
ly. If one spark plug shows a distinctly
different color, there could be some-
thing wrong with the engine.
1. Screw
1. Spark plug cap
1. Spark plug wrench
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6Do not attempt to diagnose such prob-
lems yourself. Instead, take the motor-
cycle to a Yamaha dealer. You should
periodically remove and inspect the
spark plugs because heat and deposits
will cause any spark plug to slowly
break down and erode. If electrode ero-
sion becomes excessive, or if carbon
and other deposits are excessive, you
should replace the spark plug with the
specified plug.Installation
1. Measure the electrode gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the gasket surface. Wipe off
any grime from the threads.
3. Install the spark plugs and tighten
them to the specified torque.
NOTE:@ If a torque wrench is not available when
you are installing a spark plug, a good
estimate of the correct torque is 1/4 to
1/2 turn past finger tight. Have the
spark plug tightened to the specified
torque as soon as possible. @4. Install the spark plug caps.
5. Install the cowling. Specified spark plug:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
a. Spark plug gap
Spark plug gap:
0.8 ~ 0.9 mm
Tightening torque:
Spark plug:
18 Nm (1.8 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
EAU01692
Engine oilOil level inspection
1. Place the motorcycle on a level
place. Warm up the engine at idle
for 15 minutes.NOTE:@ Be sure the motorcycle is positioned
straight up when checking the oil level.
A slight tilt toward the side can result in
false readings. @
2. The oil tank is located behind the
engine cylinders. With the engine
stopped, check the oil level
through the level window located
on the right side of the oil tank.
3. The oil level should be between
the maximum and minimum
marks. If the level is low, fill engine
with sufficient oil to raise it to the
specified level.Engine oil and oil filter element re-
placement
1. Warm up the engine for a few min-
utes.
2. Stop the engine. Place an oil pan
under the engine and remove the
oil filler cap.
3. Remove the drain bolts and drain
the oil.
4. Remove the oil filter cover bolts
and oil filter.
1. Oil level window
2. Minimum level mark
3. Maximum level mark
1. Engine oil filler cap
1. Engine oil drain bolt a
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
65. Install the drain bolts and tighten
them to the specified torque.
6. Install the new oil filter, O-rings
and the filter cover. Tighten the oil
filter cover bolts to the specified
torque.
NOTE:@ Make sure the O-rings are seated prop-
erly. @7. Fill engine with oil. Install the oil fill-
er cap and tighten.
EC000066
CAUTION:@ l
Do not put in any chemical addi-
tives. Engine oil also lubricates
the clutch and additives could
cause clutch slippage.
l
Be sure no foreign material en-
ters the crankcase.
@
1. Engine oil drain bolt b
2. Oil filter cover bolt (´ 5)
3. Oil filter coverTightening torque:
Drain bolt
a:
35 Nm (3.5 m·kg)
Drain bolt
b:
30 Nm (3.0 m·kg)
1. Oil filter
2. O-ring (´ 2)
Tightening torque:
Oil filter cover bolt:
10 Nm (1.0 m·kg)
Recommended oil:
See page 8-1.
Oil quantity:
Total amount:
4.2 L
Periodic oil change:
3.5 L
With oil filter replacement:
3.6 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 8. Start the engine and warm up for a
few minutes. While warming up,
check for oil leakage. If oil leakage
is found, stop the engine immedi-
ately and check for the cause.
9. Stop the engine and check the oil
level.
EAU03024*
Cooling system1. Check the coolant level in the
coolant reservoir when the engine
is cold as the coolant level will vary
with engine temperature. The
coolant level should be between
the maximum and minimum
marks.
2. If the level is low, remove the seat.
(See page 3-12 for seat removal
and installation procedures.)
3. Remove the coolant reservoir cap,
then add coolant or distilled water
to raise it to the specified level.4. Install the coolant reservoir cap
and seat.
ECA00041
CAUTION:@ Hard water or salt water is harmful
to the engine. You may use soft wa-
ter if you can’t get distilled water. @
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
1. Coolant reservoir capCoolant reservoir capacity:
0.3 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
NOTE:@ l
If water is added, have a Yamaha
dealer check the antifreeze con-
tent of the coolant as soon as pos-
sible.
l
The radiator fan operation is com-
pletely automatic. It is switched on
or off according to the coolant tem-
perature in the radiator.
@5. If your motorcycle overheats, see
page 6-34 for details.
EAU01176*
Changing the coolant1. Put the motorcycle on a level
place.
2. Remove cowling B. (See page 6-5
for cowling removal and installa-
tion procedures.)
3. Place a container under the en-
gine.
4. Remove the radiator cap stopper
bolt and radiator cap.
EW000067
WARNING
@ Do not remove the radiator cap
when the engine is hot. @
5. Remove the water pump drain bolt
and cylinder drain bolt.
1. Radiator cap stopper bolt
2. Radiator cap
1. Water pump drain bolt
2. Cylinder drain bolt
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6 6. Remove the seat. (See page 3-12
for seat removal and installation
procedures.)
7. Remove the coolant reservoir by
removing the bolts.
8. Remove the coolant reservoir
hose clamp and disconnect the
hose.
9. Drain the coolant from the coolant
reservoir by turning it upside
down.
10. Install the hose and connect the
coolant reservoir hose clamp. 11. Drain the coolant completely and
thoroughly flush the cooling sys-
tem with clean tap water.
12. If the washers are damaged, re-
place them. Tighten the water
pump drain bolt and cylinder drain
bolt to the specified torques.
13. Pour the recommended coolant
into the radiator until it is full.
ECA00041
CAUTION:@ Hard water or salt water is harmful
to the engine. You may use soft wa-
ter if you can’t get distilled water. @14. Run the engine several minutes.
Stop the engine and recheck the
coolant level in the radiator. If it is
low, add more coolant until it
reaches the top of the radiator.
15. Fill the coolant reservoir with cool-
ant up to maximum level.
16. Install the radiator cap, radiator
cap stopper bolt and coolant res-
ervoir cap.
17. Check for coolant leakage. If any
leakage is found, ask a Yamaha
dealer to inspect the cooling sys-
tem.
1. Coolant reservoir
2. Bolt
3. Coolant reservoir hose clamp
4. Hose
Tightening torque:
Water pump and cylinder drain
bolts:
10 Nm (1.0 m·kg)
Recommended antifreeze:
High quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines.
Antifreeze and water mixing ratio:
1 : 1
Total amount:
1.7 L
Coolant reservoir capacity:
0.3 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
EAU01769*
Air filterThe air filter should be cleaned at the
specified intervals. It should be cleaned
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the seat. (See page 3-12
for seat removal and installation
procedures.)
2. Remove cowlings A and B and
panels A and B. (See pages 6-5
~
6-6 for removal and installation
procedures.)
3. Remove the fuel tank holding
bolts.4. Disconnect the fuel sender cou-
pler.
5. Lift up the rear of the fuel tank
slightly, turn the fuel cock to “OFF”
and disconnect the fuel hose and
breather hose. Then remove the
fuel tank.
1. Bolt (´ 2)
1. Fuel sender coupler
1. Fuel cock
2. Fuel hose
3. Breather hose
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6 6. Remove the air filter case cover by
removing the screws.7. Remove the air filter. 8. Tap the air filter lightly to remove
most of the dust and dirt. Blow out
the remaining dirt with com-
pressed air as shown. If the air fil-
ter is damaged, replace it.
9. Install by reversing the removal
procedure.
EWA00013
WARNING
@ Make sure that the fuel hose and
breather hose are properly connect-
ed, in place and not pinched. If a
hose is damaged, be sure to replace
it. @
1. Air filter case cover
2. Screw (´ 3)
1. Air filter
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