warning YAMAHA TDM 900 2002 User Guide

INSTRUMENT AND CONTROL FUNCTIONS
3-17
3
EAU00324
Luggage strap holders There are four luggage strap holders
below the passenger seat, two of which
can be turned out for easier access.
EAU00330
Sidestand The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
motorcycle upright.NOTE:@ The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.) @
EW000044
WARNING
@ The motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up), oth-
erwise the sidestand could contact
the ground and distract the opera-
tor, resulting in a possible loss of
control. Yamaha’s ignition circuit
cut-off system has been designed to
assist the operator in fulfilling the
responsibility of raising the side-
stand before starting off. Therefore,
check this system regularly as de-
scribed below and have a Yamaha
dealer repair it if it does not function
properly. @
1. Luggage strap holder (× 4)U5PSE0.book Page 17 Thursday, December 13, 2001 4:29 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-18
3
EAU03720
Ignition circuit cut-off system The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.

It prevents starting when the trans-
mission is in gear and the side-
stand is up, but the clutch lever is
not pulled.


It prevents starting when the trans-
mission is in gear and the clutch
lever is pulled, but the sidestand is
still down.


It cuts the running engine when
the transmission is in gear and the
sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
EW000045
WARNING
_ If a malfunction is noted, have a
Yamaha dealer check the system
before riding. _
U5PSE0.book Page 18 Thursday, December 13, 2001 4:29 PM

PRE-OPERATION CHECKS
4-3
4
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. _U5PSE0.book Page 3 Thursday, December 13, 2001 4:29 PM

5-1
5
EAU00372
5-OPERATION AND IMPORTANT RIDING POINTS
EAU00373
WARNING
@

Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.


Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.


Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
@
EAU03951
Starting the engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.


The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
WARNING
_

Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-19.


Never ride with the sidestand
down.
_1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
ECA00083
CAUTION:_ The oil level warning light and en-
gine trouble warning light should
come on for a few seconds, then go
off. If a warning light does not go off,
see pages 3-2 and 3-3 for the corre-
sponding warning light circuit
check. _2. Shift the transmission into the neu-
tral 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 cir-
cuit. _3. Start the engine by pushing the
start switch.
U5PSE0.book Page 1 Thursday, December 13, 2001 4:29 PM

OPERATION AND IMPORTANT RIDING POINTS
5-5
5
EAU00460
Parking When parking, stop the engine, and
then remove the key from the main
switch.
EW000058
WARNING
@

Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.


Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
@U5PSE0.book Page 5 Thursday, December 13, 2001 4:29 PM

6-1
6
EAU00462
6-PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
EW000060
WARNING
@ If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you. @
EAU01299
Owner’s tool kit The owner’s tool kit is located inside
the storage compartment under the
seat. (See page 3-11 for seat removal
procedures.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:@ If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you. @
EW000063
WARNING
@ Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es. @
1. Owner’s tool kit
U5PSE0.book Page 1 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
EAU04429
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. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in and with the arrow
mark pointing upward as shown),
and then remove it again to check
the oil level.
NOTE:_ The engine oil should be between the
minimum and maximum level marks. _
EC000000
CAUTION:_ Do not operate the motorcycle until
you know that the engine oil level is
sufficient. _
EW000065
WARNING
_ Never remove the engine oil tank
cap after high-speed operation, oth-
erwise hot engine oil could spout
out and cause damage or injury. Al-
ways let the engine oil cool down
sufficiently before removing the oil
tank cap. _
1. Oil filler cap
1. Oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
U5PSE0.book Page 9 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
EC000080
CAUTION:_

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.


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.


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. _
NOTE:_

The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.


If the engine overheats, see page
6-44 for further instructions.
_
EAU04461
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. Remove the fuel tank bolts, and
then lift the fuel tank to position it
away from the coolant reservoir.
(Do not disconnect the fuel hos-
es!)
5. Place a container under the en-
gine to collect the used coolant.
U5PSE0.book Page 13 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6 6. 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. _
7. Remove the coolant drain bolts to
drain the cooling system.8. Remove the coolant reservoir bolt.
9. Pull the coolant reservoir upward
and away from the motorcycle.
10. Drain the remaining coolant from
the coolant reservoir by opening
the cap, then turning the reservoir
upside down.
11. Install the coolant reservoir by
placing it in the original position,
and then installing the bolt.
12. After the coolant is completely
drained, thoroughly flush the cool-
ing system with clean tap water.
1. Radiator cap retaining bolt
2. Radiator cap
1. Coolant drain bolt (× 2)
1. Bolt
2. Coolant reservoir
U5PSE0.book Page 14 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6
EWA00052
WARNING
_

Before installing the fuel tank,
make sure that the fuel hoses
are not damaged. If any fuel
hose is damaged, do not start
the engine but have a Yamaha
dealer replace the hose, other-
wise fuel may leak.


Make sure that the fuel hoses
are properly connected and
routed, and not pinched.


Be sure to place the fuel tank
breather hose in the original po-
sition.
_19. Install the panel, the cowling, and
the seat.
20. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
EAU04431*
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, and
then lift the fuel tank away from the
air filter case.
4. Remove the air filter case cover by
removing the screws.
5. Pull the air filter element out.1. Bolt (× 2 on each side)
1. Air filter case cover
2. Screw (× 8)
U5PSE0.book Page 16 Thursday, December 13, 2001 4:29 PM