air filter YAMAHA TDM 850 2000 Owners Manual

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Tool kit................................................................... 6-1
Periodic maintenance and lubrication ................... 6-2
Cowling and panel removal and installation.......... 6-5
Cowlings A and B ................................................. 6-5
Panels A and B ..................................................... 6-6
Spark plugs........................................................... 6-6
Engine oil .............................................................. 6-8
Cooling system ................................................... 6-10
Changing the coolant .......................................... 6-11
Air filter ............................................................... 6-13
Carburetor adjustment ........................................ 6-15
Idle speed adjustment ........................................ 6-15
Throttle cable free play inspection ...................... 6-16
Valve clearance adjustment ................................ 6-16
Tires .................................................................... 6-17
Clutch lever free play adjustment........................ 6-19
Rear brake pedal height adjustment ................... 6-20
Brake light switch adjustment ............................. 6-21
Checking the front and rear brake pads.............. 6-21
Inspecting the brake fluid level............................ 6-22
Brake fluid replacement ...................................... 6-23Drive chain slack check ...................................... 6-23
Drive chain slack adjustment ............................. 6-23
Drive chain lubrication........................................ 6-24
Cable inspection and lubrication ........................ 6-24
Throttle cable and grip lubrication ...................... 6-25
Brake and shift pedal lubrication ........................ 6-25
Brake and clutch lever lubrication ...................... 6-25
Sidestand lubrication.......................................... 6-26
Rear suspension lubrication............................... 6-26
Front fork inspection ........................................... 6-27
Steering inspection ............................................ 6-27
Wheel bearings .................................................. 6-28
Battery................................................................ 6-28
Fuse replacement .............................................. 6-29
Headlight bulb replacement ............................... 6-30
Tail/brake light bulb replacement ........................ 6-31
Turn signal light bulb replacement...................... 6-32
Troubleshooting .................................................. 6-32
Troubleshooting chart ......................................... 6-33
Engine overheating ............................................ 6-34
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU00473
PERIODIC MAINTENANCE AND LUBRICATION
CP-01ENO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)
1
*Fuel line• Check fuel hoses for cracks or damage.
• Replace if necessary.ÖÖ
2*Fuel filter• Check condition.
• Replace if necessary.Ö
3 Spark plugs• Check condition.
• Clean, regap or replace if necessary.ÖÖÖ
4*Valves• Check valve clearance.
• Adjust if necessary.Every 42,000 km or 42 months
(whichever comes first)
5 Air filter
• Clean or replace if necessary.ÖÖ
6Clutch• Check operation.
• Adjust or replace cable.ÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
• Correct accordingly.
• Replace brake pads if necessary.ÖÖÖ
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
• Correct accordingly.
• Replace brake pads if necessary.ÖÖÖ
9*Wheels• Check balance, runout and for damage.
• Rebalance or replace if necessary.ÖÖ
10*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.ÖÖ
11*Wheel bearings• Check bearing for looseness or damage.
• Replace if necessary. ÖÖ
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
12
*Swingarm• Check swingarm pivoting point for play.
• Correct if necessary.
• Lubricate with molybdenum disulfide grease every 24,000 km
or 24 months (whichever comes first).ÖÖ
13 Drive chain• Check chain slack.
• Adjust if necessary. Make sure that the rear wheel is properly aligned.
• Clean and lubricate. Every 500 km and after washing the
motorcycle or riding in the rain
14*Steering bearings• Check bearing play and steering for roughness.
• Correct accordingly.
• Lubricate with lithium soap base grease every 24,000 km
or 24 months (whichever comes first).ÖÖ
15*Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.ÖÖ
16 Sidestand• Check operation.
• Lubricate and repair if necessary.ÖÖ
17*Sidestand switch• Check operation.
• Replace if necessary.ÖÖÖ
18*Front fork• Check operation and for oil leakage.
• Correct accordingly.ÖÖ
19*Rear shock absorber
assembly• Check operation and shock absorber for oil leakage.
• Replace shock absorber assembly if necessary. ÖÖ
20*Rear shock absorber
assembly pivoting points• Check operation.
• Lubricate with molybdenum disulfide grease every 24,000 km
or 24 months (whichever comes first).ÖÖ
21*Carburetors• Check engine idling speed, synchronization and starter operation.
• Adjust if necessary.ÖÖÖ
22 Engine oil• Check oil level and vehicle for oil leakage.
• Correct if necessary.
• Change. (Warm engine before draining.)ÖÖÖ
23 Engine oil filter element
• Replace.ÖÖ NO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
EAU02970*
NOTE:@ l
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l
Hydraulic brake system
• When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level
regularly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
• Replace the brake hoses every four years or if cracked or damaged.
@24
*Cooling system• Check coolant level and vehicle for coolant leakage.
• Correct if necessary.
• Change coolant every 24,000 km or 24 months (whichever comes first).ÖÖ NO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)
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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
6-13
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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PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6
EC000082
CAUTION:@ l
Make sure the air filter is prop-
erly seated in the air filter case.
l
The engine should never be run
without the air filter installed.
Excessive piston and/or cylin-
der wear may result.
@
EAU00630
Carburetor adjustmentThe carburetors are important parts of
the engine and require very sophisti-
cated adjustment. Most adjustments
should be left to a Yamaha dealer who
has the professional knowledge and
experience to do so. However, the idle
speed may be adjusted by the owner
as part of routine maintenance.
EC000095
CAUTION:@ The carburetors were set at the
Yamaha factory after many tests. If
they are changed, poor engine per-
formance and damage may result. @
EAU00632
Idle speed adjustment1. Start the engine and warm it up for
a few minutes at approximately
1,000 to 2,000 r/min. Occasionally
rev the engine to 4,000 to
5,000 r/min. The engine is warm
when it quickly responds to the
throttle.
2. Set the idle to the specified engine
speed by adjusting the throttle
stop screw. Turn the screw in di-
rection
a to increase engine
speed and in direction
b to de-
crease engine speed.1. Throttle stop screw
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SPECIFICATIONS
8-2
8
Air filterDry type element
Fuel
Type Regular unleaded gasoline
Fuel tank capacity 20 L
Reserve amount 3.1 L
Carburetor
Type ´ quantity BDSR38 ´ 2
Manufacturer MIKUNI
Spark plug
Manufacturer/Type NGK / DPR8EA-9 or
DENSO / X24EPR-U9
Gap 0.8 ~ 0.9 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 1.718
Secondary reduction system Chain drive
Secondary reduction ratio 2.688
Number of sprocket teeth
(rear/front) 43/16
Transmission type Constant mesh 5-speed
Operation Left foot operationGear ratio
1st 2.643
2nd 1.947
3rd 1.500
4th 1.174
5th 0.964
Chassis
Frame type Diamond
Caster angle 24.5°
Trail 103 mm
Tires
Front
Type Tubeless
Size 110/80 ZR18 (58W)
Manufacturer/
model Bridgestone / BT54F
Michelin / MACADAM 90X
Pirelli / MTR03
Rear
Type Tubeless
Size 150/70 ZR17 (69W)
Manufacturer/
model Bridgestone / BT54R
Michelin / MACADAM 90X
Pirelli / MTR04
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