check engine YAMAHA TDM 850 2001 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU03006
Lubricating the drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
EC000097
CAUTION:@ The drive chain must be lubricated
after washing the motorcycle or
riding in the rain. @1. Clean the drive chain with kero-
sene and a small soft brush.
ECA00053
CAUTION:@ To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents. @
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA00052
CAUTION:@ Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings. @
EAU02962
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EW000112
WARNING
@ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. @
Recommended lubricant:
Engine oil
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
EAU03209
Checking and lubricating the
throttle grip and cable The operation of the throttle grip and
the condition of the throttle cable
should be checked before each ride,
and the cable should be lubricated or
replaced if necessary.NOTE:@ Since the throttle grip must be removed
to access the throttle cable end, the
throttle grip and the cable should al-
ways be lubricated at the same time. @1. Remove the throttle grip by remov-
ing the screws.
2. Disconnect the throttle cable, hold
it up, and then apply several drops
of oil to the cable end, allowing it to
trickle into the sheath.
3. Connect the throttle cable, and
then grease the inside of the throt-
tle grip housing.
4. Grease the metal-to-metal contact
surface of the throttle grip, and
then install the grip by installing
the screws.
EAU03370
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary. Recommended lubricant:
Throttle cable:
Engine oil
Throttle grip housing and grip:
Lithium-soap-based grease
(all-purpose grease) Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
E_4tx.book Page 30 Wednesday, October 4, 2000 4:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAU00794
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steer-
ing.
EAU01144
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
E_4tx.book Page 33 Wednesday, October 4, 2000 4:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6
EAU01579
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU03498*
Front wheel To remove the front wheel
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so that there is no danger
of it falling over.
@1. Loosen the front wheel axle pinch
bolt, then the wheel axle and the
brake caliper bolts.
2. Lift the front wheel off the ground
according to the procedure.1. Wheel axle
2. Front wheel axle pinch bolt
E_4tx.book Page 39 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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-45
6Engine overheating
EW000070
WARNING
@ l
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. Be sure to wait until the engine has cooled.
l
After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hiss-
ing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
@NOTE:@ If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible. @
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See NOTE.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.
E_4tx.book Page 45 Wednesday, October 4, 2000 4:28 PM

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 then place the
spark plugs on the cylinder head
so that the electrodes are ground-
ed. (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, and then install
the spark plugs and the spark plug
caps.
EWA00003
WARNING
@ To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over. @
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, and then lift
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 the muffler outlets with plas-
tic bags to prevent moisture from
entering them.9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place (less
than 0 °C or more than 30 °C). For
more information on storing the
battery, see page 6-34.
NOTE:@ Make any necessary repairs before
storing the motorcycle. @
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10-INDEXAAir filter element, cleaning ...................... 6-15
Anti-theft alarm ........................................3-5BBattery ................................................... 6-34
Brake and clutch levers, checking and
lubricating ............................................ 6-31
Brake and shift pedals, checking and
lubricating ............................................ 6-30
Brake fluid, changing ............................. 6-26
Brake fluid level, checking...................... 6-25
Brake lever...............................................3-7
Brake light switch (rear), adjusting ......... 6-24
Brake pads, checking............................. 6-25
Brake pedal..............................................3-8
Brake pedal position, adjusting .............. 6-23CCables, checking and lubricating............ 6-29
Carburetors, adjusting............................ 6-18
Care.........................................................7-1
Clutch lever ..............................................3-7
Clutch lever free play, adjusting ............. 6-23
Conversion table ......................................8-5
Coolant .................................................. 6-11
Changing .......................................... 6-13
Checking .......................................... 6-11
Coolant temperature warning light............3-2
Cowlings and panels, removing and
installing ................................................6-5
DDimmer switch ......................................... 3-5
Drive chain, lubricating .......................... 6-29
Drive chain slack ................................... 6-27
Adjusting .......................................... 6-27
Checking .......................................... 6-27EEngine break-in ....................................... 5-4
Engine oil and oil filter element ................ 6-9
Engine stop switch................................... 3-6FFront fork, adjusting ............................... 3-13
Front fork, checking ............................... 6-32
Fuel ......................................................... 3-9
Fuel consumption, tips for reducing ......... 5-4
Fuel gauge .............................................. 3-5
Fuel level warning light ............................ 3-3
Fuel tank breather hose
(Germany only) ................................... 3-10
Fuel tank cap ........................................... 3-9
Fuses, replacing .................................... 6-35HHandlebar switches ................................. 3-5
Hazard switch .......................................... 3-6
Headlight bulb, replacing ....................... 6-36
Helmet holder ........................................ 3-11
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-6
IIdentification numbers ..............................9-1
Idling speed, adjusting ...........................6-18
Ignition circuit cut-off system ..................3-18
Indicator and warning lights......................3-2KKey identification number .........................9-1LLight switch ..............................................3-6
Luggage strap holders ...........................3-17MMain switch/steering lock .........................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-2PParking.....................................................5-5
Part locations ...........................................2-1
Pass switch ..............................................3-5
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list ............................4-1SSafety information ....................................1-1
Seat .......................................................3-11
Self-diagnosis device ...............................3-4
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INDEX
Shifting .................................................... 5-3
Shift pedal ............................................... 3-7
Shift points (for Switzerland only)............. 5-3
Shock absorber assembly, adjusting ..... 3-15
Sidestand .............................................. 3-17
Sidestand, checking and lubricating....... 6-31
Spark plugs, checking ............................. 6-7
Specifications .......................................... 8-1
Speedometer unit .................................... 3-3
Starter (choke) lever .............................. 3-10
Starting a cold engine .............................. 5-1
Starting a warm engine ............................ 5-2
Start switch .............................................. 3-6
Steering, checking ................................. 6-33
Storage.................................................... 7-4
Storage compartment ............................ 3-12
Supporting the motorcycle ..................... 6-39
Suspension (rear), lubricating ................ 6-32TTachometer ............................................. 3-4
Tail/brake light bulb, replacing ............... 6-37
Throttle cable free play, adjusting .......... 6-19
Throttle grip and cable, checking and
lubricating............................................ 6-30
Tires ...................................................... 6-19
Tool kit..................................................... 6-1
Troubleshooting..................................... 6-43
Troubleshooting charts .......................... 6-44
Turn signal indicator lights ....................... 3-2
Turn signal light bulb, replacing ............. 6-38
Turn signal switch .................................... 3-6
VValve clearance, adjusting .................... 6-19
Vehicle identification number................... 9-1WWheel bearings, checking ..................... 6-33
Wheel (front) ......................................... 6-39
Installing .......................................... 6-40
Removing ........................................ 6-39
Wheel (rear) .......................................... 6-41
Installing .......................................... 6-42
Removing ........................................ 6-41
E_4tx.book Page 2 Wednesday, October 4, 2000 4:28 PM