service YAMAHA TDM 850 2000 Owners Manual

INSTRUMENT AND CONTROL FUNCTIONS
3-16
3 3. Tighten the locknut to the speci-
fied torque.
EC000018
CAUTION:@ Always tighten the locknut against
the spring adjusting nut and tighten
the locknut to the specified torque. @
Damping force adjustment
Turn the adjusting knob in direction
a
to increase damping force and in direc-
tion
b to decrease damping force.CI-29E
EC000015CAUTION:@ Never attempt to turn an adjuster
beyond the maximum or minimum
setting. @
EAU00315
WARNING
@ This shock absorber contains high-
ly pressurized nitrogen gas. Read
and understand the following infor-
mation before handling the shock
absorber. The manufacturer cannot
be held responsible for property
damage or personal injury that may
result from improper handling.l
Do not tamper with or attempt to
open the cylinder assembly.
l
Do not subject the shock ab-
sorber to an open flame or other
high heat source. This may
cause the unit to explode due to
excessive gas pressure.
l
Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.
l
Take your shock absorber to a
Yamaha dealer for any service.
@
Tightening torque:
Locknut:
70 Nm (7.0 m·kg)
1. Adjusting knobMinimum (soft) 20 clicks out*
Standard 10 clicks out*
Maximum (hard) 0 click out*
* From the fully turned-in position
E_4tx_Functions.fm Page 16 Saturday, October 16, 1999 9:36 AM

6-1
6
EAU00462
6-PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
Periodic inspection, adjustment and lu-
brication will keep your motorcycle in
the safest and most efficient condition
possible. Safety is an obligation of the
motorcycle owner. The maintenance
and lubrication schedule chart should
be considered strictly as a guide to
general maintenance and lubrication
intervals. YOU MUST TAKE INTO
CONSIDERATION THAT WEATHER,
TERRAIN, GEOGRAPHICAL LOCA-
TIONS, AND A VARIETY OF INDIVID-
UAL USES ALL TEND TO DEMAND
THAT EACH OWNER ALTER THIS
TIME SCHEDULE TO SHORTER IN-
TERVALS TO MATCH THE ENVI-
RONMENT. The most important points
of motorcycle inspection, adjustment,
and lubrication are explained in the fol-
lowing pages.
EW000060
WARNING
@ If you are not familiar with motor-
cycle service, this work should be
done by a Yamaha dealer. @
EAU01299
Tool kitThe tool kit is located inside the storage
compartment under the seat. (See
page 3-12 for seat opening proce-
dures.) The tools provided in the own-
er’s tool kit are to assist you in the
performance of periodic maintenance.
However, some other tools such as a
torque wrench are also necessary to
perform the maintenance correctly.
The service information included in this
manual is intended to provide you, the
owner, with the necessary information
for completing some of your own pre-
ventive maintenance and minor re-
pairs.
NOTE:@ If you do not have necessary tools re-
quired during a service operation, take
your motorcycle to a Yamaha dealer for
service. @
EW000063
WARNING
@ Modifications to this motorcycle not
approved by Yamaha may cause
loss of performance, and render it
unsafe for use. Consult a Yamaha
dealer before attempting any chang-
es. @
1. Tool kit
E_4tx_Periodic.fm Page 1 Saturday, October 16, 1999 9:37 AM

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)
E_4tx_Periodic.fm Page 4 Saturday, October 16, 1999 9:37 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6
NOTE:@ If the specified idle speed cannot be
obtained by performing the above ad-
justment, consult a Yamaha dealer. @
EAU00635
Throttle cable free play
inspectionThere should be a free play of 3 ~
5 mm at the throttle grip. If the free play
is incorrect, ask a Yamaha dealer to
make this adjustment.
EAU00637
Valve clearance adjustmentThe correct valve clearance changes
with use, resulting in improper fuel/air
supply or engine noise. To prevent this,
the valve clearance must be adjusted
regularly. This adjustment however,
should be left to a professional
Yamaha service technician. Standard idle speed:
1,050 ~ 1,250 r/min
a. Free play
E_4tx_Periodic.fm Page 16 Saturday, October 16, 1999 9:37 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU00658
TiresTo ensure maximum performance,
long service and safe operation, note
the following:
Tire air pressure
Always check and adjust the tire pres-
sure before operating the motorcycle.
EW000082
WARNING
@ Tire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire infla-
tion pressure must be adjusted ac-
cording to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if approved
for this model), and vehicle speed. @
CE-33EEW000083
WARNING
@ Proper loading of your motorcycle
is important for several characteris-
tics of your motorcycle, such as
handling, braking, performance and
safety. Do not carry loosely packed
items that can shift. Securely pack
your heaviest items close to the
center of the motorcycle, and dis-
tribute the weight evenly from side
to side. Properly adjust the suspen-
sion for your load, and check the
condition and pressure of your tires.
NEVER OVERLOAD YOUR MOTOR-
CYCLE. Make sure the total weight
of the cargo, rider, passenger, and
accessories (fairing, saddlebags,
etc. if approved for this model) does
not exceed the maximum load of the
motorcycle. Operation of an over-
loaded motorcycle could cause tire
damage, an accident, or even injury. @
Maximum load* 203 kg
Cold tire pressure Front Rear
Up to 90 kg load*225 kPa
(2.25 kg/cm
2,
2.25 bar)275 kPa
(2.75 kg/cm
2,
2.75 bar)
90 kg load ~
Maximum load*225 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)
* Load is the total weight of cargo, rider, passenger
and accessories.
E_4tx_Periodic.fm Page 17 Saturday, October 16, 1999 9:37 AM

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
E_4tx_Periodic.fm Page 18 Saturday, October 16, 1999 9:37 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
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
E_4tx_Periodic.fm Page 23 Saturday, October 16, 1999 9:37 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
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
E_4tx_Periodic.fm Page 24 Saturday, October 16, 1999 9:37 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6
EAU01095
Turn signal light bulb
replacement1. Remove the screw and the lens.
2. Remove the defective bulb by
pushing it inward and turning it
counterclockwise.
3. Install a new bulb by pushing it in-
ward and turning it clockwise.
4. Install the lens and tighten the
screw.
EAU01008
TroubleshootingAlthough Yamaha motorcycles receive
a rigid inspection before shipment from
the factory, trouble may occur during
operation.
Any problem in the fuel, compression,
or ignition systems can cause poor
starting and loss of power. The trouble-
shooting chart describes a quick, easy
procedure for making checks.
If your motorcycle requires any repair,
bring it to a Yamaha dealer. The skilled
technicians at a Yamaha dealership
have the tools, experience, and know-
how to properly service your motor-
cycle. Use only genuine Yamaha parts
on your motorcycle. Imitation parts may
look like Yamaha parts, but they are of-
ten inferior. Consequently, they have a
shorter service life and can lead to ex-
pensive repair bills.
1. Screw
2. Lens
1. Bulb
E_4tx_Periodic.fm Page 32 Saturday, October 16, 1999 9:37 AM

8-1
8
EAU01038
8-SPECIFICATIONSSpecifications
Model TDM850
Dimensions
Overall length 2,165 mm
(for GB, NL, B, F, E, P, I, GR, D,
DK)
2,200 mm (for N, S, SF)
Overall width 790 mm
Overall height 1,285 mm
Seat height 805 mm
Wheelbase 1,475 mm
Ground clearance 165 mm
Minimum turning radius 2,900 mm
Basic weight (with oil and full
fuel tank)
232 kg
Engine
Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Forward inclined parallel
2-cylinder
Displacement 849 cm
3
Bore ´ Stroke 89.5 ´ 67.5 mm
Compression ratio 10.5:1
Starting system Electric starter
Lubrication system Dry sumpEngine oil
Ty p e
Recommended engine oil
classification API Service SE, SF, SG type or
higher
Quantity
Periodic oil change 3.5 L
With oil filter replacement 3.6 L
Total amount 4.2 L
Cooling system capacity
(total amount)
1.7 L
-20˚ -10˚ 0˚
10˚20˚ 30˚
40˚50˚C
SAE 10W/30
SAE 15W/40SAE 20W/40SAE 20W/50
SAE 10W/40
CAUTION:Be sure to use motor oils that do not contain anti-friction
modifiers. Passenger car motor oils (often labeled
“Energy Conserving”) contain anti-friction additives which
will cause clutch and/or starter clutch slippage, resulting in
reduced component life and poor engine performance.
E_4tx_Spec.fm Page 1 Saturday, October 16, 1999 9:38 AM