maintenance YAMAHA TDM 850 2000 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6 Tire inspection
Always check the tires before operating
the motorcycle. If center tread depth
reaches the limit as shown, if the tire
has a nail or glass fragments in it, or if
the side wall is cracked, contact a
Yamaha dealer immediately and have
the tire replaced.
EW000095
WARNING
@ Operating the motorcycle with ex-
cessively worn tires decrease riding
stability and can lead to loss of con-
trol. Have excessively worn tires re-
placed by a Yamaha dealer
immediately. Brakes, tires, and relat-
ed wheel parts replacement should
be left to a Yamaha Service Techni-
cian. @CE-26ENOTE:@ These limits may be different by regula-
tion from country to country. If so, con-
form to the limits specified by the
regulations of your own country. @Tire information
This motorcycle is equipped with tube-
less tires, tire valves and cast wheels.
EW000080
WARNING
@ l
After extensive tests, the tires
mentioned below have been ap-
proved by Yamaha Motor Co.,
Ltd. for this model. No guaran-
tee for handling characteristics
can be given if tire combina-
tions other than what is ap-
proved are used on this
motorcycle. The front and rear
tires should be of the same
manufacture and design.
l
The use of tire valves and valve
cores other than listed below
could cause tire deflation dur-
ing extreme high speed riding.
Always use genuine parts or
their equivalent for replace-
ment.
l
Be sure to install the valve caps
securely, as these are important
to prevent air pressure leakage
during extreme high speed
riding.
@
1. Side wall
a. Tread depth
Minimum tire tread depth
(front and rear)1.6 mm
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PERIODIC MAINTENANCE AND MINOR REPAIR
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6
CE-10E
CE-12EEAU00684
WARNING
@ This motorcycle is fitted with super
high-speed running tires. The fol-
lowing points must be observed in
order for you to make fully effective
use of these tires.l
Never fail to use the specified
tires in tire replacement. Other
tires may have a danger of
bursting at super high-speeds.
l
New tires have a relatively low
grip on the road surface until
they have been slightly worn.
Therefore, approximately 100 km
should be traveled at normal
speed before any high-speed
riding is done.
l
Before any high-speed runs, the
tires should be warmed-up suf-
ficiently.
l
Always inflate to the correct tire
pressure according to the oper-
ating conditions.
@
EAU00692
Clutch lever free play
adjustmentThe clutch lever free play should be ad-
justed to 10 ~ 15 mm. If the free play is
incorrect, adjust as follows.
1. Loosen the locknut.
2. Turn the adjusting bolt at the
clutch lever in direction
a to in-
crease free play or in direction
b
to decrease free play.
3. Tighten the locknut.
1. Tire valve
2. Valve core
3. Valve cap with sealFRONT
Manufacturer Size Type
Bridgestone 110/80 ZR18 (58W) BT-54F
Pirelli 110/80 ZR18 (58W) MTR03
Michelin 110/80 ZR18 (58W) MACADAM 90X
REAR
Manufacturer Size Type
Bridgestone 150/70 ZR17 (69W) BT-54R
Pirelli 150/70 ZR17 (69W) MTR04
Michelin 150/70 ZR17 (69W) MACADAM 90X
Type
Tire valve TR412
Valve core #9000A (original)
1. Locknut
2. Adjusting bolt
c. Free play
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
NOTE:@ If proper adjustment cannot be ob-
tained or the clutch does not work cor-
rectly, ask a Yamaha dealer to inspect
the internal clutch mechanism. @
EAU00712
Rear brake pedal height
adjustmentThe top of the brake pedal should be
positioned 29 mm below the top of the
footrest. If not, ask a Yamaha dealer to
adjust it.
EW000109
WARNING
@ A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the brake system. This air
must be removed by bleeding the
brake system before the motorcycle
is operated. Air in the system will
cause greatly diminished braking
capability and can result in loss of
control and an accident. Have a
Yamaha dealer inspect and bleed
the system if necessary. @
a. Pedal height
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EAU00713
Brake light switch adjustmentThe rear brake light switch is activated
by the brake pedal and is properly ad-
justed when the brake light comes on
just before braking takes effect. To ad-
just the rear brake light switch, hold the
switch body so it does not rotate while
turning the adjusting nut.
Turn the adjusting nut in direction
a to
make the brake light come on earlier.
Turn the adjusting nut in direction
b to
make the brake light come on later.
EAU00715
Checking the front and rear
brake padsA wear indicator is provided on each
brake. This indicator allows checking
of brake pad wear without disassem-
bling the brake. Apply the brake and
inspect the wear indicator. If the indica-
tor is ALMOST in contact with the disc
plate, ask a Yamaha dealer to replace
the pads.
1. Brake light switch
2. Adjusting nut
1. Wear indicator (´ 2)Front
1. Wear indicator (´ 2)Rear
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PERIODIC MAINTENANCE AND MINOR REPAIR
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6
EAU00731
Inspecting the brake fluid
levelInsufficient brake fluid may let air enter
the brake system, possibly causing the
brakes to become ineffective.
Before riding, check that the brake fluid
is above the minimum level and replen-
ish when necessary.
Observe these precautions:
l
When checking the fluid level,
make sure the top of the master
cylinder is level by turning the han-
dlebars.
l
Use only the designated quality
brake fluid. Otherwise, the rubber
seals may deteriorate, causing
leakage and poor brake perfor-
mance.
l
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.
l
Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.
l
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
l
Have a Yamaha dealer check the
cause if the brake fluid level goes
down.
1. Minimum level markFront
1. Minimum level markRecommended brake fluid: DOT 4Rear
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PERIODIC MAINTENANCE AND MINOR REPAIR
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6
EAU00742
Brake fluid replacementThe brake fluid should be replaced only
by trained Yamaha service personnel.
Have the Yamaha dealer replace the
following components during periodic
maintenance or when they are dam-
aged or leaking:l
oil seals (every two years)
l
brake hoses (every four years)
EAU00744
Drive chain slack checkNOTE:@ Spin the wheel several times and find
the tightest position of the chain. Check
and/or adjust the chain slack while it’s
in this tightest position. @To check the chain slack the motor-
cycle must be held straight up with both
wheels on the ground and without rider.
Check the slack at the position shown
in the illustration. Normal slack is ap-
proximately 40 ~ 50 mm. If the slack
exceeds 50 mm, adjust.
EAU00765
Drive chain slack adjustment1. Loosen the axle nut and caliper
bracket bolt.
2. Loosen the locknuts on each side
of the swingarm. To tighten the
chain, turn the adjusting nut in di-
rection
a. To loosen the chain,
turn the adjusting nut in
direction
b and push the wheel
forward. Turn each adjusting nut
exactly the same amount to main-
tain correct axle alignment. There
are marks on each side of the
swingarm. Use these marks to
align the rear wheel.
a. Chain slack
1. Axle nut
2. Locknut
3. Adjusting nut
4. Alignment marks
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PERIODIC MAINTENANCE AND MINOR REPAIR
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6
EC000096
CAUTION:@ Too little chain slack will overload
the engine and other vital parts.
Keep the slack within the specified
limits. @3. After adjusting, tighten the axle nut
and caliper bracket bolt to the
specified torque.
EAU03006
Drive chain lubricationThe chain consists of many parts which
work with each other. If the chain is not
maintained properly, it will wear out
quickly. Therefore, the chain must be
serviced regularly. This service is es-
pecially necessary when riding in dusty
areas. This motorcycle is equipped
with a sealed type chain. Steam clean-
ing, high-pressure washers, and sol-
vents can damage the drive chain, so
do not use these for cleaning it. Use
only kerosene to clean the drive chain.
Wipe it dry, and thoroughly lubricate it
with SAE 30 ~ 50W motor oil. Do not
use any other lubricants on the drive
chain. They may contain solvents that
could damage the sealed chain.
EC000097
CAUTION:@ Be sure to oil the chain after wash-
ing the motorcycle or riding in the
rain. @
EAU02962
Cable inspection and
lubrication
EW000112
WARNING
@ Damage to the outer housing of ca-
bles may lead to internal rusting and
interfere with the cable movement.
Replace damaged cables as soon as
possible to prevent unsafe condi-
tions. @Lubricate the cables and cable ends. If
a cable does not operate smoothly, ask
a Yamaha dealer to replace it.
1. Caliper bracket bolt
Tightening torque:
Axle nut:
110 Nm (11.0 m·kg)
Caliper bracket bolt:
35 Nm (3.5 m·kg)
Recommended lubricant:
Engine oil
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PERIODIC MAINTENANCE AND MINOR REPAIR
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6
EAU00773
Throttle cable and grip
lubricationThe throttle twist grip assembly should
be greased at the time that the cable is
lubricated, since the grip must be re-
moved to get at the end of the throttle
cable. After removing the screws, hold
the end of the cable up in the air and
put in several drops of lubricant. With
the throttle grip disassembled, coat the
metal surface of the grip assembly with
a suitable all-purpose grease.
EAU02984
Brake and shift pedal
lubricationLubricate the pivoting parts.
EAU02985
Brake and clutch lever
lubricationLubricate the pivoting parts.
Recommended lubricant:
Engine oil
Recommended lubricant:
Engine oil
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PERIODIC MAINTENANCE AND MINOR REPAIR
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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
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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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