YAMAHA TDM 850 2001 Workshop Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU03317
Panels A and B
To remove one of the panels1. Remove the corresponding cowl-
ing A or B. (See page 6-5 for cowl-
ing removal and installation
procedures.)
2. Remove the seat. (See page 3-11
for seat removal and installation
procedures.)
3. Remove the screw, and then take
the panel off.To install the panel
1. Place the panel in the original po-
sition, and then install the screw.
2. Install the seat and the cowling.
1. Screw
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
EAU01668
Checking the spark plugs The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
To remove a spark plug
1. Remove cowling A. (See page 6-5
for cowling removal and installa-
tion procedures.)
2. Remove the spark plug cap.3. Remove the spark plug as shown
with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medium-to-
light tan (the ideal color when the
motorcycle is ridden normally).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:@ If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle. @3. Check each spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and replace
it if necessary.
1. Spark plug cap
1. Spark plug wrench
Specified spark plug:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6 To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:@ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. @4. Install the spark plug cap.
5. Install the cowling.
a. Spark plug gap
Spark plug gap:
0.8–0.9 mm
Tightening torque:
Spark plug:
18 Nm (1.8 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
EAU01692
Engine oil and oil filter
element The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:@ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. @2. Start the engine, warm it up for
15 minutes, and then turn it off.3. Check the oil level through the
check window located on the right
side of the engine oil tank.
NOTE:@ l
The engine oil tank is located be-
hind the cylinders.
l
The engine oil should be between
the minimum and maximum level
marks.
@4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1. Engine oil tank cap
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 3. Remove the engine oil tank cap
and drain bolts to drain the oil from
the crankcase.
NOTE:@ Skip steps 4–6 if the oil filter element is
not being replaced. @
4. Remove the oil filter element cover
by removing the bolts.5. Remove and replace the oil filter
element and O-rings.
6. Install the oil filter element cover
by installing the bolts, then tighten-
ing them to the specified torque.
NOTE:@ Make sure that the O-rings are properly
seated.@7. Install the engine oil drain bolts,
and then tighten them to the spec-
ified torques.
1. Engine oil drain bolt A
1. Engine oil drain bolt B
2. Oil filter element cover
3. Bolt (´ 5)
1. Oil filter element
2. O-ring (´ 2)Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
68. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil tank
cap.
EC000072
CAUTION:@ l
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of a higher
grade than “CD”. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.
l
Make sure that no foreign mate-
rial enters the crankcase.
@9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU03495
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
If the engine overheats, see page 6-45
for further instructions.
To check the coolant level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:@ l
The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
l
Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A slight
tilt to the side can result in a false
reading.
@
Tightening torques:
Engine oil drain bolt A:
35 Nm (3.5 m·kg)
Engine oil drain bolt B:
30 Nm (3.0 m·kg)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
3.5 L
With oil filter element
replacement:
3.6 L
Total amount (dry engine):
4.2 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6 2. Check the coolant level in the
coolant reservoir.
NOTE:@ The coolant should be between the
minimum and maximum level marks. @
3. If the coolant is at or below the
minimum level mark, remove the
seat (See page 3-11 for seat re-
moval and installation proce-
dures.), and then open the coolant
reservoir cap.
4. Add coolant or distilled water to
raise the coolant to the specified
level, close the coolant reservoir
cap, and then install the seat.
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.
EW000067
WARNING
Never attempt to remove the radia-
tor cap when the engine is hot.
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
1. Coolant reservoir capCoolant reservoir capacity:
0.3 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
NOTE:@ l
The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.
l
If the engine overheats, see page
6-45 for further instructions.
@
EAU03300
To change the coolant
1. Place the motorcycle on a level
surface and let the engine cool if
necessary.
2. Remove the seat. (See page 3-11
for seat removal and installation
procedures.)
3. Remove cowling B and panel B.
(See pages 6-5 and 6-6 for cowl-
ing and panel removal and instal-
lation procedures.)
4. Place a container under the en-
gine to collect the used coolant.5. Remove the radiator cap retaining
bolt and the radiator cap.
EW000067
WARNING
@ Never attempt to remove the radia-
tor cap when the engine is hot. @1. Radiator cap retaining bolt
2. Radiator cap
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6 6. Remove the coolant drain bolts to
drain the cooling system.
7. Remove the coolant reservoir
bolts.
8. Slightly move the coolant reservoir
back, and then disconnect the
hose at the bottom of the coolant
reservoir.
9. Drain the coolant from the coolant
reservoir by opening the cap, then
turning the reservoir upside down.
10. Connect the hose to the coolant
reservoir.
11. Install the coolant reservoir by
placing it in the original position,
then installing the bolts.12. After the coolant is completely
drained, thoroughly flush the cool-
ing system with clean tap water.
13. Install the coolant drain bolts, and
then tighten them to the specified
torque.
NOTE:@ Check the washers for damage and re-
place them if necessary. @14. Pour the recommended coolant
into the radiator until it is full.
1. Coolant drain bolt (´ 2)
1. Coolant reservoir
2. Bolt (´ 2)
3. Clamp
4. Hose
Tightening torque:
Coolant drain bolt:
7 Nm (0.7 m·kg)
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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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