check engine YAMAHA TDM 850 2000 User Guide

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
6-26
6
EAU02986
Sidestand lubricationLubricate the sidestand pivoting point
and metal-to-metal contact surfaces.
Check that the sidestand moves up
and down smoothly.
EW000113
WARNING
@ If the sidestand does not move
smoothly, consult a Yamaha dealer. @
EAU00790
Rear suspension lubricationLubricate the pivoting parts.
Recommended lubricant:
Engine oilRecommended lubricant:
Molybdenum disulfide grease
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU02939
Front fork inspectionVisual check
EW000115
WARNING
@ Securely support the motorcycle so
there is no danger of it falling over. @Check for scratches or damage on the
inner tube and excessive oil leakage
from the front fork.
Operation check
1. Place the motorcycle on a level
place.
2. Hold the motorcycle in an upright
position and apply the front brake.
3. Push down hard on the handle-
bars several times and check if the
fork rebounds smoothly.
EC000098
CAUTION:@ If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer. @
EAU00794
Steering inspectionPeriodically inspect the condition of the
steering. Worn out or loose steering
bearings may be dangerous. Place a
stand under the engine to raise the
front wheel off the ground. Hold the
lower end of the front forks and try to
move them forward and backward. If
any free play can be felt, ask a Yamaha
dealer to inspect and adjust the steer-
ing. Inspection is easier if the front
wheel is removed.
EW000115
WARNING
@ Securely support the motorcycle so
there is no danger of it falling over. @
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAU02990*
Troubleshooting chart
EW000125
WARNING
@ Never check the fuel system while smoking or in the vicinity of an open flame. @
Check if there is fuel
in the fuel tank.1. Fuel
Enough fuel.
No fuel.
Go to compression check.
Supply fuel.
Engine doesn’t start, go to compression check.
Use the electric starter.2. Compression
There is compression.
No compression.
Go to ignition check.
Ask a Yamaha dealer to
inspect.
Remove spark plugs
and check electrodes.3. Ignition
Wet.
Dry.
Wipe clean with dry cloth and correct
spark gap or replace spark plugs.
Ask a Yamaha dealer to inspect.
Engine doesn’t start, ask a Yamaha
dealer to inspect.Engine doesn’t start, go to battery
check.Open throttle half-way and start
the engine.
Use the electric starter.4. Battery
Engine turns over
quickly.
Engine turns over
slowly.
Battery good.Check connections or
recharge.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6
Engine overheating
EW000070
WARNING
@ Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown
out under pressure, which could cause serious injury. Open the radiator cap as follows. Wait until the engine has
cooled. Remove the radiator cap stopper by removing the screw. Place a thick rag like a towel over the radiator cap
and slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it. @NOTE:@ If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recom-
mended coolant as soon as possible. @
Wait until the
engine has cooled.
Check the coolant level in the
reservoir tank and/or radiator.
Level is OK.Level is low, check the
cooling system for leakage.
No
leakage.Leakage.
Ask a Yamaha dealer to inspect
and repair the cooling system.Add coolant. (See NOTE.)
Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and repair the cooling system.
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MOTORCYCLE CARE AND STORAGE
7-5
7a. Remove the spark plug caps and
spark plugs.
b. Pour a teaspoonful of engine oil
into each spark plug bore.
c. Install the spark plug caps onto the
spark plugs and place the spark
plugs on the cylinder head so that
the electrodes are grounded. (This
will limit sparking during the next
step.)
d. Turn the engine over several times
with the starter. (This will coat the
cylinder walls with oil.)
e. Remove the spark plug caps from
the spark plugs, install the spark
plugs and then the spark plug
caps.
EWA00003
WARNING
@ When turning the engine over, be
sure to ground the spark plug elec-
trodes to prevent damage or injury
from sparking. @
6. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
7. Check and, if necessary, correct
the tire air pressure, then raise the
motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover up the muffler outlets with
plastic bags to prevent moisture
from entering.9. Remove the battery and fully
charge it. Store it in a cool, dry
place and recharge it once a
month. Do not store the battery in
an excessively cold or warm place
(less than 0 °C or more than
30 °C). For more information, see
“Battery storage” in the chapter
“PERIODIC MAINTENANCE AND
MINOR REPAIRS”.
NOTE:@ Make any necessary repairs before
storing the motorcycle. @
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10-INDEXAAir filter .................................................. 6-13
Antitheft alarm (optional) ..........................3-5BBattery ................................................... 6-28
Brake and clutch lever lubrication........... 6-25
Brake and shift pedal lubrication ............ 6-25
Brake fluid replacement ......................... 6-23
Brake light switch adjustment ................. 6-21CCable inspection and lubrication ............ 6-24
Carburetor adjustment ........................... 6-15
Care.........................................................7-1
Changing the coolant ............................. 6-11
Checking the front and
rear brake pads ................................... 6-21
Clutch lever ..............................................3-8
Clutch lever free play adjustment ........... 6-19
Controls/Instruments ................................2-3
Coolant temperature indicator light...........3-2
Cooling system ...................................... 6-10
Cowling and panel removal and
installation .............................................6-5
Cowlings A and B ....................................6-5DDiagnosis device......................................3-5
Dimmer switch .........................................3-6
Drive chain lubrication ............................ 6-24
Drive chain slack adjustment.................. 6-23
Drive chain slack check.......................... 6-23
EEngine break-in ....................................... 5-5
Engine oil ................................................ 6-8
Engine overheating ................................. 6-34
Engine stop switch................................... 3-7FFront brake lever ..................................... 3-9
Front fork adjustment............................. 3-14
Front fork inspection .............................. 6-27
Fuel ....................................................... 3-11
Fuel gauge .............................................. 3-5
Fuel indicator light ................................... 3-3
Fuel tank breather hose
(for Germany only) .............................. 3-12
Fuel tank cap ......................................... 3-10
Fuse replacement.................................. 6-29GGive safety the right of way ..................... 1-1HHandlebar switches ................................. 3-6
Dimmer switch ................................... 3-6
Engine stop switch ............................. 3-7
Hazard switch .................................... 3-6
Horn switch ........................................ 3-6
Lights switch ...................................... 3-7
Pass switch ........................................ 3-6
Start switch ........................................ 3-7
Turn signal switch .............................. 3-6
Hazard switch .......................................... 3-6
Headlight bulb replacement ................... 6-30
Helmet holder ........................................ 3-13
High beam indicator light ..........................3-2
Horn switch ..............................................3-6IIdentification number records ...................9-1
Idle speed adjustment ............................6-15
Indicator lights ..........................................3-2
Coolant temperature indicator light .....3-2
Fuel indicator light...............................3-3
High beam indicator light ....................3-2
Neutral indicator light ..........................3-2
Turn indicator lights ............................3-2
Inspecting the brake fluid level ...............6-22KKey identification number .........................9-1LLeft view...................................................2-1
Lights switch ............................................3-7
Luggage strap holders ...........................3-17MMain switch/steering lock .........................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-2PPanels A and B ........................................6-6
Parking.....................................................5-6
Pass switch ..............................................3-6
Periodic maintenance and lubrication .......6-2
Pre-operation check list ............................4-1
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INDEX
RRear brake pedal ..................................... 3-9
Rear brake pedal height adjustment ...... 6-20
Rear shock absorber adjustment ........... 3-15
Rear suspension lubrication................... 6-26
Right view................................................ 2-2SSeat....................................................... 3-12
Shifting .................................................... 5-4
Shift pedal ............................................... 3-8
Sidestand .............................................. 3-17
Sidestand/clutch switch operation
check .................................................. 3-17
Sidestand lubrication ............................. 6-26
Spark plugs ............................................. 6-6
Specifications .......................................... 8-1
Speedometer ........................................... 3-3
Starter (choke) “ ”................................ 3-7
Starting a warm engine ............................ 5-4
Starting the engine .................................. 5-1
Start switch .............................................. 3-7
Steering inspection ................................ 6-27
Storage.................................................... 7-4
Storage compartment ............................ 3-13TTachometer ............................................. 3-4
Tail/brake light bulb replacement ........... 6-31
Throttle cable and grip lubrication .......... 6-25
Throttle cable free play inspection ......... 6-16
Tips for reducing fuel consumption .......... 5-5
Tires ...................................................... 6-17
Tool kit..................................................... 6-1
Troubleshooting .................................... 6-32
Troubleshooting chart ........................... 6-33
Turn indicator lights ................................. 3-2
Turn signal light bulb replacement ......... 6-32
Turn signal switch ................................... 3-6VValve clearance adjustment .................. 6-16
Vehicle identification number................... 9-1WWheel bearings ..................................... 6-28
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