OWNERS MANUAL

YAMAHA MOTOR CO., LTD.

TDM850

PRINTED IN JAPAN - 0.CR (E)
PRINTED ON RECYCLED PAPER

4TX-28199-E5

H_5KS_Toc0.fm Page 2 Monday, August 21, 2000 11:11 AM
E_4tx.book Page 1 Wednesday, October 4, 2000 4:28 PM

EAU03338

INTRODUCTION
Welcome to the Yamaha world of motorcycling! As the owner of a TDM850, you are benefiting from Yamahas vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TDM850. The owners manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury. In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any further questions, do not hesitate to contact your Yamaha dealer. The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer.

EAU00005

CAUTION:
NOTE: q This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. q Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
E_4tx.book Page 2 Wednesday, October 4, 2000 4:28 PM

EW000002

WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
E_4tx.book Page 3 Wednesday, October 4, 2000 4:28 PM

EAU03337

TDM850 OWNERS MANUAL 2000 by Yamaha Motor Co., Ltd. 1st Edition, August 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

EAU00009

TABLE OF CONTENTS
1 GIVE SAFETY THE RIGHT OF WAY 2 DESCRIPTION 3 INSTRUMENT AND CONTROL FUNCTIONS 4 PRE-OPERATION CHECKS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 7 MOTORCYCLE CARE AND STORAGE 8 SPECIFICATIONS 9 CONSUMER INFORMATION INDEX
GIVE SAFETY THE RIGHT OF WAY
GIVE SAFETY THE RIGHT OF WAY.. 1-1 1

EAU00021

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. 1 Regular care and maintenance are essential for preserving value and operating condition of your motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of course, out of the question. Motorcycle ridersmore than car driversmust always be at their mental and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take dangerous risks. Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum protective wear, however, should not encourage carelessness. Although full-coverage helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensivelyavoiding all dangers, including those caused by others. Enjoy your ride!

1. 2. 3. 4.

Speedometer Odometer/tripmeter/clock SELECT button RESET button

EAU03492

Speedometer unit
The speedometer unit is equipped with the following: q a speedometer (which shows the riding speed) q an odometer (which shows the total distance traveled) q two tripmeters (which show the distance traveled since they were last set to zero) q a clock
Odometer and tripmeter modes Pushing the SELECT button switches the display between the odometer mode ODO and the tripmeter modes TRIP 1, TRIP 2 and CLOCK in the following order: ODOTRIP 1TRIP 2CLOCK ODO To reset a tripmeter, select it by pushing the SELECT button, and then push the RESET button for at least one second. The tripmeters can be used to estimate the distance that can be traveled with a full tank of fuel. This information will enable you to plan future fuel stops. Clock mode To change the display to the clock mode, push both the SELECT and RESET buttons. To change the display back to the odometer mode, push the SELECT button.
E_4tx.book Page 4 Wednesday, October 4, 2000 4:28 PM
To set the clock 1. Push both the SELECT and RESET buttons for at least two seconds. 2. When the hour digits start flashing, push the RESET button to set the hours. 3. Push the SELECT button to change the minutes. 4. When the minute digits start flashing, push the RESET button to set the minutes. 5. Push the SELECT button to start the clock. NOTE: After setting the clock, be sure to push the SELECT button before turning the key to OFF, otherwise the clock will not be set.

EAU00103

Self-diagnosis device
This model is equipped with a self-diagnosis device for the throttle position sensor circuit. If the throttle position sensor circuit is defective, the tachometer will repeatedly display the following error code:

CB-10E

1. Tachometer 2. Tachometer red zone

EAU00101

0 r/min for 3 seconds
3,000 r/min for 2.5 seconds
Current engine speed for 3 seconds

Drive chain

Wheels and tires

6-196-22

Brake and shift pedals Brake and clutch levers Sidestand Chassis fasteners Instruments, lights, signals and switches Sidestand switch

6-30 6-31 6-31 3-17

NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved.

EWA00033

WARNING If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the motorcycle.
OPERATION AND IMPORTANT RIDING POINTS
Starting a cold engine... 5-1 Starting a warm engine... 5-2 Shifting.... 5-3 Recommended shift points (for Switzerland only).. 5-3 Tips for reducing fuel consumption... 5-4 Engine break-in... 5-4 Parking.... 5-5

EAU00373 EAU03827*

EAU00372

EC000035

WARNING q Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. q Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time. Always make sure that there is adequate ventilation. q Before starting out, make sure that the sidestand is up. If the sidestand is not raised completely, it could contact the ground and distract the operator, resulting in a possible loss of control.

Starting the engine

In order for the ignition circuit cut-off system to enable starting, one of the following conditions must be met: q The transmission is in the neutral position. q The transmission is in gear with the clutch lever pulled and the sidestand up.

EW000054

CAUTION: If the fuel level warning light comes on, check the fuel level, and, if necessary, refuel as soon as possible.

2. Shift the transmission into the neutral position. NOTE: When the transmission is in the neutral position, the neutral indicator light should be on, otherwise have a Yamaha dealer check the electrical circuit.
WARNING Before starting the engine, check the function of the ignition circuit cut-off system according to the procedure described on page 3-19. q Never ride with the sidestand down.
1. Turn the key to ON and make sure that the engine stop switch is set to .
3. Turn the starter (choke) on and completely close the throttle. (See page 3-10 for starter (choke) operation.) 4. Start the engine by pushing the start switch.
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 preserve the battery. Do not crank the engine more than 10 seconds on any one attempt.
soon 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 after 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

EAU01258

Starting a warm engine

Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm.

ECA00022

CAUTION: q The coolant temperature warning 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. q If the coolant temperature warning light remains on after starting, immediately stop the engine, and then have a Yamaha dealer check the electrical circuit. q If the fuel level warning light remains on after starting, stop the engine, and then check the fuel level. If necessary, refuel as
CAUTION: For maximum engine life, never accelerate 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.

EC000048 EAU02941

1. Shift pedal N. Neutral position

EAU00423

Shifting

EC000052* EAU00460

CAUTION: After 1,000 km of operation, the engine oil must be changed and the oil filter element replaced.

Parking

When parking, stop the engine, and then remove the key from the main switch.

EW000058

1,000 km and beyond The vehicle can now be operated normally.

EC000053

CAUTION: q Keep the engine speed out of the tachometer red zone. q If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle.
WARNING Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them. q Do not park on a slope or on soft ground, otherwise the motorcycle may overturn.
PERIODIC MAINTENANCE AND MINOR REPAIR
Owners tool kit..6-1 Periodic maintenance and lubrication chart.6-2 Removing and installing cowlings and panels..6-5 Checking the spark plugs.6-7 Engine oil and oil filter element..6-9 Coolant..6-11 Cleaning the air filter element..6-15 Adjusting the carburetors..6-18 Adjusting the engine idling speed..6-18 Adjusting the throttle cable free play.6-19 Adjusting the valve clearance..6-19 Tires..6-19 Adjusting the clutch lever free play..6-23 Adjusting the brake pedal position.6-23 Adjusting the rear brake light switch.6-24 Checking the front and rear brake pads.6-25 Checking the brake fluid level..6-25 Changing the brake fluid.6-26 Drive chain slack..6-27 Lubricating the drive chain..6-29 Checking and lubricating the cables.6-29 Checking and lubricating the throttle grip and cable... 6-30 Checking and lubricating the brake and shift pedals.. 6-30 Checking and lubricating the brake and clutch levers.. 6-31 Checking and lubricating the sidestand. 6-31 Lubricating the rear suspension. 6-32 Checking the front fork.. 6-32 Checking the steering.. 6-33 Checking the wheel bearings.. 6-33 Battery... 6-34 Replacing the fuses.. 6-35 Replacing a headlight bulb.. 6-36 Replacing the tail/brake light bulb. 6-37 Replacing a turn signal light bulb.. 6-38 Supporting the motorcycle.. 6-39 Front wheel.. 6-39 Rear wheel... 6-41 Troubleshooting.. 6-43 Troubleshooting charts.. 6-44

ODOMETER READING ( 1,000 km) 20 Every 40,000 km

ANNUAL CHECK

* Fuel line * Fuel filter

Spark plugs

* Valves
Air filter element Clutch
* Front brake * Rear brake
Whenever worn to the limit
Whenever worn to the limit
NO. ITEM CHECK OR MAINTENANCE JOB Check for cracks or damage. Replace. (See NOTE on page 6-4.) Check runout and for damage. Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. Check bearing for looseness or damage. Check operation and for excessive play. Lubricate with molybdenum disulfide grease. Check chain slack. Make sure that the rear wheel is properly aligned. Clean and lubricate. Check bearing play and steering for roughness. Lubricate with lithium-soap-based grease. Make sure that all nuts, bolts and screws are properly tightened. Check operation. Lubricate. Check operation. Check operation and for oil leakage. Check operation and shock absorber for oil leakage. Check operation. ODOMETER READING ( 1,000 km) 20 30 40 ANNUAL CHECK
* Brake hose * Wheels * Tires * Wheel bearings * Swingarm

Every 4 years

Every 50,000 km Every 1,000 km and after washing the motorcycle or riding in the rain.
* Steering bearings * Chassis fasteners

Every 20,000 km

* Sidestand switch * Front fork *
Rear shock absorber assembly Rear suspension relay
* arm and connecting arm Lubricate with molybdenum disulfide grease. pivoting points
NO. 28 ITEM CHECK OR MAINTENANCE JOB Check starter (choke) operation. Adjust engine idling speed and synchronization. Change. ODOMETER READING ( 1,000 km) 1 10 20 Every 3 years

EAU03541

ANNUAL CHECK

* Carburetors

Engine oil filter element Replace.
* Cooling system * switches

Front and rear brake

Check coolant level and vehicle for coolant leakage. Change. Check operation.
Moving parts and cables Lubricate.

* switches

Lights, signals and
Check operation. Adjust headlight beam.
NOTE: q The air filter needs more frequent service if you are riding in unusually wet or dusty areas. q Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged.

Tightening torque: Spark plug: 18 Nm (1.8 mkg) NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/41/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.

a. Spark plug gap

To install a spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. Spark plug gap: 0.80.9 mm 2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque.
4. Install the spark plug cap. 5. Install the cowling. 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 element replaced at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Place the motorcycle on a level surface and hold it in an upright position. 6 NOTE: Make sure that the motorcycle is positioned straight up when checking the oil level. A slight tilt to the side can result in a false reading.
1. Engine oil level check window 2. Maximum level mark 3. Minimum level mark

1. Engine oil tank cap

3. Check the oil level through the check window located on the right side of the engine oil tank. NOTE: q The engine oil tank is located behind the cylinders. q The engine oil should be between the minimum and maximum level marks.
To change the engine oil (with or without oil filter element replacement) 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.
2. Start the engine, warm it up for 15 minutes, and then turn it off.
4. If the engine oil is below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level.
1. Engine oil drain bolt A
3. Remove the engine oil tank cap and drain bolts to drain the oil from the crankcase. NOTE: Skip steps 46 if the oil filter element is not being replaced.
1. Engine oil drain bolt B 2. Oil filter element cover 3. Bolt ( 5)

1. Oil filter element 2. O-ring ( 2)
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 tightening them to the specified torque. Tightening torque: Oil filter element cover bolt: 10 Nm (1.0 mkg) NOTE: Make sure that the O-rings are properly seated.
7. Install the engine oil drain bolts, and then tighten them to the specified torques.

EC000072 EAU03495

Tightening torques: Engine oil drain bolt A: 35 Nm (3.5 mkg) Engine oil drain bolt B: 30 Nm (3.0 mkg) 8. Add the specified amount of the recommended engine oil, and then install and tighten the oil tank cap. 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
CAUTION: q In order to prevent clutch slippage (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. q Make sure that no foreign material enters the crankcase.
The coolant level should be checked before each ride. In addition, the coolant 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: q The coolant level must be checked on a cold engine since the level varies with engine temperature. q 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.
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.

EC000080

1. Coolant reservoir 2. Maximum level mark 3. Minimum level mark

1. Coolant reservoir cap

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 removal and installation procedures.), 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. Coolant reservoir capacity: 0.3 L

7. 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.
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 installing the bolts.

EWA00013

WARNING Make sure that the fuel hose and breather hose are properly connected and routed, and not pinched. Replace any damaged hoses.
12. Install the panels and cowlings. 13. Install the seat.

EAU00630 EAU00632

Adjusting the carburetors
The carburetors are important parts of the engine and require very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. The adjustment described in the following section, however, may be serviced by the owner as part of routine maintenance.

EC000095

Adjusting the engine idling speed
The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Start the engine and warm it up for several minutes at 1,000 2,000 r/min while occasionally revving it to 4,0005,000 r/min. NOTE: The engine is warm when it quickly responds to the throttle.

1. Throttle stop screw

CAUTION: The carburetors have been set and extensively tested at the Yamaha factory. Changing these settings without sufficient technical knowledge may result in poor performance of or damage to the engine.
2. Check the engine idling speed and, if necessary, adjust it to specification by turning the throttle stop screw. To increase the engine idling speed, turn the screw in direction a. To decrease the engine idling speed, turn the screw in direction b. Engine idling speed: 1,0501,250 r/min NOTE: If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment.

E_4tx.book Page 26 Wednesday, October 4, 2000 4:28 PM
Rear brake Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. q Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. q Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. q As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.

EAU03238

Changing the brake fluid
Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubrication chart. In addition, have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are damaged or leaking. q Oil seals: Replace every two years. q Brake hose: Replace every four years. 6
Observe these precautions: q When checking the fluid level, make sure that the top of the brake fluid reservoir is level. q Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Recommended brake fluid: DOT 4
E_4tx.book Page 27 Wednesday, October 4, 2000 4:28 PM

EAU00744

Drive chain slack
The drive chain slack should be checked before each ride and adjusted if necessary. To check the drive chain slack 1. Place the motorcycle on a level surface and hold it in an upright position. NOTE: When checking and adjusting the drive chain slack, the motorcycle should be positioned straight up and there should be no weight on it.

a. Drive chain slack

2. Shift the transmission into the neutral position. 3. Move the rear wheel by pushing the motorcycle to locate the tightest portion of the drive chain, and then measure the drive chain slack as shown. Drive chain slack: 4050 mm 4. If the drive chain slack is incorrect, adjust it as follows.

Axle nut Locknut Drive chain slack adjusting nut Alignment marks

EAU00765

To adjust the drive chain slack 1. Loosen the axle nut and the brake caliper bracket bolt. 2. Loosen the chain puller locknut at each end of the swingarm. 3. To tighten the drive chain, turn the adjusting nut at each end of the swingarm in direction a. To loosen the drive chain, turn the adjusting nut at each end of the swingarm in direction b, and then push the rear wheel forward.
E_4tx.book Page 28 Wednesday, October 4, 2000 4:28 PM
4. Tighten the locknuts, and then tighten the axle nut and the brake caliper bracket bolt to the specified torques. Tightening torques: Axle nut: 110 Nm (11.0 mkg) Brake caliper bracket bolt: 35 Nm (3.5 mkg)
1. Bolt 2. Brake caliper bracket
NOTE: Using the alignment marks on each side of the swingarm, make sure that both adjusting nuts are in the same position for proper wheel alignment.

EC000096

CAUTION: Improper drive chain slack will overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits.
E_4tx.book Page 29 Wednesday, October 4, 2000 4:28 PM

EAU03006

Lubricating the drive chain
The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows.

EC000097

2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant.

ECA00052

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 cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it. Recommended lubricant: Engine oil

EW000112

CAUTION: The drive chain must be lubricated after washing the motorcycle or riding in the rain.
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.

4. Pull the wheel axle out, and then remove the wheel.
To install the front wheel 1. Lift the wheel up between the fork legs. 2. Insert the wheel axle from the right-hand side. 3. Lower the front wheel so that it is on the ground. 4. Install the brake calipers by installing the bolts.
Tightening torques: Wheel axle: 58 Nm (5.8 mkg) Front wheel axle pinch bolt: 19 Nm (1.9 mkg) Brake caliper bolt: 40 Nm (4.0 mkg) 6. Push down hard on the handlebar several times to check for proper fork operation.
E_4tx.book Page 41 Wednesday, October 4, 2000 4:28 PM

EAU03830

Rear wheel

To remove the rear wheel

WARNING q It is advisable to have a Yamaha dealer service the wheel. q Securely support the motorcycle so that there is no danger of it falling over.
1. Axle nut 2. Locknut 3. Drive chain slack adjusting nut
1. Loosen the axle nut and the brake caliper bolts. 2. Lift the rear wheel off the ground according to the procedure on page 6-39.
Brake caliper Bolt ( 2) Bolt Brake caliper bracket
3. Loosen the brake caliper bracket bolt. 4. Remove the brake caliper by removing the bolts.
E_4tx.book Page 42 Wednesday, October 4, 2000 4:28 PM

EAU03501

1. Locknut 2. Drive chain slack adjusting nut
5. Loosen the locknut on each side of the swingarm. 6. Turn the drive chain slack adjusting nuts fully in direction a.
7. Push the wheel forward, and then remove the drive chain from the rear sprocket. NOTE: The drive chain does not need to be disassembled in order to remove and install the rear wheel.
To install the rear wheel 1. Install the wheel by inserting the wheel axle from the right-hand side. 2. Install the drive chain onto the rear sprocket, and then adjust the drive chain slack. (See page 6-27 for drive chain slack adjustment procedures.) 3. Install the brake caliper by installing the bolts. 4. Install the axle nut, and then lower the rear wheel so that it is on the ground. 5. Tighten the axle nut, the brake caliper bolts and the brake caliper bracket bolt to the specified torques. Tightening torques: Axle nut: 110 Nm (11.0 mkg) Brake caliper bolt: 40 Nm (4.0 mkg) Brake caliper bracket bolt: 35 Nm (3.5 mkg)
8. Remove the axle nut. 9. Pull the wheel axle out, and then remove the wheel.
E_4tx.book Page 43 Wednesday, October 4, 2000 4:28 PM

EAU03087

Troubleshooting
Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during 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 yourself. 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 replacement 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 44 Wednesday, October 4, 2000 4:28 PM

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.

1. Fuel

There is enough fuel. Check the fuel level in the fuel tank. There is no fuel. Supply fuel. Check the compression. The engine does not start. Check the compression.

2. Compression

There is compression. Operate the electric starter. There is no compression. Have a Yamaha dealer check the vehicle. Check the ignition.

3. Ignition

Wet Remove the spark plugs and check the electrodes. Dry
Wipe off with a dry cloth and correct the spark plug gaps, or replace the spark plugs.
Open the throttle halfway and operate the electric starter. The engine does not start. Check the battery.
Have a Yamaha dealer check the vehicle.

4. Battery

Operate the electric starter.
The engine turns over quickly. The engine turns over slowly.
The battery is good. Check the battery lead connections, and charge the battery if necessary.
The engine does not start. Have a Yamaha dealer check the vehicle.
E_4tx.book Page 45 Wednesday, October 4, 2000 4:28 PM

Engine overheating

EW000070
WARNING 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. q 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 hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
The coolant level is low. Check the cooling system for leakage.
There is leakage. There is no leakage.
Have a Yamaha dealer check and repair the cooling system.
Wait until the engine has cooled.
Check the coolant level in the reservoir and radiator. The coolant level is OK.

Add coolant. (See NOTE.)

Start the engine. If the engine overheats again, have a Yamaha dealer check and repair the cooling system.
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.
MOTORCYCLE CARE AND STORAGE
Care... 7-1 Storage.... 7-4
Before cleaning 1. Cover the muffler outlets with plastic bags after the engine has cooled down. 2. Make sure that all caps and covers as well as all electrical couplers and connectors, including the spark plug caps, are tightly installed. 3. Remove extremely stubborn dirt, like oil burnt onto the crankcase, with a degreasing agent and a brush, but never apply such products onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water. Cleaning

In order: 1971 Yamaha Minienduro JTYamaha YZHonda XRHonda XR200R 1982 Honda MB-Honda QA Honda CB750K 1983 Honda V45 Interceptor 1982 Honda FT500 Ascot-First road racer 1976 Honda TLYamaha RZ350-bought 1/27/Honda FT500 Ascot-parts bike 1984 Honda CRHonda CR250-I think? 1985 Honda Spree-pit bike 1983 Kawasaki GPZSuzuki GSXRHonda 500 Interceptor-Al Lambs Dallas Honda supplied race bike 1988 Suzuki GSXRKTM Duke 1998 Honda Valkyie Tourer 2001 Yamaha FZBMW R100S 2003 Yamaha FJRYamaha TTR125L 2001 Yamaha TTR125L 2002 Kawasaki 250 Ninja 2000 Honda XR650R 1978 SMW 280 GS 2001 KTM 400 EXC 2003 Yamaha YZ250F 1992 Yamaha TDMYamaha GTSKawasaki KLRMontesa 315R 2003 Gas Gas EC Suzuki V-Strom Gas Gas 450 FSE 1986 Honda TLR200 Reflex 1999 Honda XR400R 2003 Honda XR400R 2006 Kawasaki KLRKTM 250 EXC 2004 Yamaha TTR225