fuel YAMAHA TDM 850 2001 User Guide

OPERATION AND IMPORTANT RIDING POINTS
5-2
5
NOTE:_ If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt. _
ECA00022
CAUTION:_ l
The coolant temperature warn-
ing light and fuel level warning
light should come on when the
start switch is pushed, and they
should go off when the start
switch is released.
l
If the coolant temperature warn-
ing light remains on after start-
ing, immediately stop the
engine, and then have a
Yamaha dealer check the elec-
trical circuit.
l
If the fuel level warning light re-
mains on after starting, stop the
engine, and then check the fuel
level. If necessary, refuel assoon as possible, and then
check the warning light again. If
the warning light does not come
on when pushing the start
switch, or if it does not go off af-
ter starting with sufficient fuel,
have a Yamaha dealer check the
electrical circuit.
_5. After starting the engine, move the
starter (choke) lever back halfway.
ECA00045
CAUTION:_ For maximum engine life, never ac-
celerate hard when the engine is
cold! _6. When the engine is warm, turn the
starter (choke) off.NOTE:_ The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off. _
EAU01258
Starting a warm engine Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
E_4tx.book Page 2 Wednesday, October 4, 2000 4:28 PM

OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EAU00424
Tips for reducing fuel
consumption Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:l
Thoroughly warm up the engine.
l
Turn the starter (choke) off as
soon as possible.
l
Shift up swiftly, and avoid high en-
gine speeds during acceleration.
l
Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the engine.
l
Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at traf-
fic lights or at railroad crossings).
EAU00436
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1,000 km. For this rea-
son, you should read the following ma-
terial carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,000 km. The various parts in the en-
gine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full-throttle oper-
ation or any condition that might result
in engine overheating must be avoided.
EAU00440*
0–150 kml
Avoid prolonged operation above
5,000 r/min.
l
After every hour of operation, stop
the engine, and then let it cool for
five to ten minutes.
l
Vary the engine speed from time
to time. Do not operate the engine
at one set throttle position.
150–500 km
l
Avoid prolonged operation above
6,000 r/min.
l
Rev the engine freely through the
gears, but do not use full throttle at
any time.
500–1,000 km
l
Avoid prolonged full-throttle oper-
ation.
l
Avoid prolonged operation above
7,000 r/min.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_ l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_
CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line• Check fuel hoses for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
• Replace.ÖÖ
4*Valves• Check valve clearance.
•Adjust.Every 40,000 km
5 Air filter element•Clean.ÖÖ
• Replace.ÖÖ
6Clutch• Check operation.
•Adjust.ÖÖÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6
EC000080
CAUTION:@ l
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
l
If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.
l
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
@15. Install the radiator cap, start the
engine, let it idle for several min-
utes, and then turn it off.
16. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radia-
tor, and then install the radiator
cap and the cap retaining bolt.
17. Check the coolant level in the res-
ervoir. If necessary, remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the cap.
18. Install the panel, the cowling, and
the seat.
19. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
EAU03496
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the seat. (See page 3-11
for seat removal and installation
procedures.)
2. Remove cowlings A and B as well
as panels A and B. (See pages 6-5
and 6-6 for cowling and panel re-
moval and installation proce-
dures.)
3. Remove the fuel tank bolts. Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Coolant quantity:
Total amount:
1.7 L
Coolant reservoir capacity:
0.3 L1. Bolt (´ 3)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6 4. Disconnect the fuel sender cou-
pler.
5. Slightly lift the rear of the fuel tank,
turn the fuel cock lever to “OFF”,
disconnect the fuel hose and
breather hose, and then take the
fuel tank off.6. Remove the air filter case cover by
removing the screws.
1. Fuel sender coupler
1. Fuel cock
2. Fuel hose
3. Fuel tank breather hose
1. Air filter case cover
2. Screw (´ 3)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
67. Pull the air filter element out. 8. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.
9. Insert the air filter element into the
air filter case.
EC000082
CAUTION:@ l
Make sure that the air filter ele-
ment is properly seated in the
air filter case.
l
The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
@10. Install the air filter case cover by
installing the screws.
11. Connect the fuel hose, breather
hose and fuel sender coupler, turn
the fuel cock lever to “ON”, and
then install the fuel tank by install-
ing the bolts.
EWA00013
WARNING
@ Make sure that the fuel hose and
breather hose are properly connect-
ed and routed, and not pinched. Re-
place any damaged hoses. @12. Install the panels and cowlings.
13. Install the seat.
1. Air filter elementE_4tx.book Page 17 Wednesday, October 4, 2000 4:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU00635
Adjusting the throttle cable
free play The throttle cable free play should
measure 3–5 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
EAU00637
Adjusting the valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU00658
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EW000082
WARNING
_ l
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
l
The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
_
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-43
6
EAU03087
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills. E_4tx.book Page 43 Wednesday, October 4, 2000 4:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-44
6
EAU02990
Troubleshooting charts Starting problems or poor engine performance
EW000125
WARNING
@ Keep away open flames and do not smoke while checking or working on the fuel system. @
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.DryWet
The engine does not start.
Check the battery.Open the throttle halfway and operate
the electric starter.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
E_4tx.book Page 44 Wednesday, October 4, 2000 4:28 PM

MOTORCYCLE CARE AND STORAGE
7-2
7
l
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
l
Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments, switch-
es and lights), breather hoses
and vents.
l
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure that it does
not leave any marks. If the wind-
shield is scratched, use a quali-
ty plastic polishing compound
after washing.
@
After normal useRemove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:@ Salt sprayed on roads in the winter may
remain well into spring. @
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