warning YAMAHA TDM 900 2002 Owner's Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6 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.
EAU01617
Front wheel To remove the front wheel
EW000122
WARNING
_

It is advisable to have a Yamaha
dealer service the wheel.


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 brake caliper bolts.
2. Loosen the wheel axle with a 19-mm
hexagon wrench.3. Lift the front wheel off the ground
according to the procedure on
page 6-37.
4. Remove the brake hose holders
by removing the bolts.
5. Remove the brake calipers by re-
moving the bolts.
6. Pull the wheel axle out, and then
remove the wheel.
ECA00046
CAUTION:_ Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut. _
1. Wheel axle
2. Front wheel axle pinch bolt
1. Bolt (× 2)
2. Brake caliper
U5PSE0.book Page 38 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6
EAU04376
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Lower the front wheel so that it is
on the ground.
4. Install the brake calipers by install-
ing the bolts.NOTE:_ Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs. _5. Install the brake hose holders by
installing the bolts.
6. Tighten the wheel axle, the front
wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.7. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU04455
Rear wheel To remove the rear wheel
EW000122
WARNING
_

It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no danger
of it falling over.
_
Tightening torques:
Wheel axle:
72 Nm (7.2 m·kgf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf)
Brake caliper bolt:
40 Nm (4.0 m·kgf)
1. Bolt (× 2)
2. Quick fastener (× 3)
U5PSE0.book Page 39 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-43
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. @
CT-1AE
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.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
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.
DryWet
Open the throttle halfway and operate
the electric starter.
U5PSE0.book Page 43 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-44
6 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.


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.
_CT-2AENOTE:@ 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.
U5PSE0.book Page 44 Thursday, December 13, 2001 4:29 PM

MOTORCYCLE CARE AND STORAGE
7-3
71. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
CAUTION:_ Do not use warm water since it in-
creases the corrosive action of the
salt. _2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick-
el-plated, surfaces to prevent cor-
rosion.After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
EWA00001
WARNING
_

Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent.


Before operating the motor-
cycle, test its braking perfor-
mance and cornering behavior.
_
U5PSE0.book Page 3 Thursday, December 13, 2001 4:29 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
grounded. (This will limit spark-
ing 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. _
4. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
5. 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.
6. Cover the muffler outlets with plas-
tic bags to prevent moisture from
entering them.
7. 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 6-33.
NOTE:_ Make any necessary repairs before
storing the motorcycle. _
U5PSE0.book Page 5 Thursday, December 13, 2001 4:29 PM

SPECIFICATIONS
8-4
8
Electrical system
Ignition system T.C.I. (digital)
Charging system
Type A.C. magneto
Standard output 14 V, 31.5 A @ 5,000 r/min
Battery
Model GT12B-4
Voltage, capacity 12 V, 10 Ah
Headlight typeQuar tz bulb (halogen)
Bulb voltage, wattage × quantity
Headlight 12 V, 55 W × 2
Auxiliary light 12 V, 5 W × 1
Tail/brake light 12 V, 5/21 W × 2
Turn signal light 12 V, 10 W × 4
Meter lighting 12 V, 2 W × 2
Neutral indicator light 14 V, 1.2 W × 1
High beam indicator light 14 V, 1.4 W × 1
Turn signal indicator light 14 V, 1.2 W × 2
Oil level warning light L.E.D.
Engine trouble warning light 14 V, 1.4 W × 1Fuses
Main fuse 40 A
Headlight fuse 15 A
Signaling system fuse 7.5 A
Ignition fuse 10 A
Parking lighting fuse 5 A
Turn signal and hazard light
fuse 10 A
Backup fuse (odometer and
clock) 5 A
Radiator fan fuse 20 A
Electronic Fuel Injection
System fuse 10 A
U5PSE0.book Page 4 Thursday, December 13, 2001 4:29 PM

10-INDEXAAir filter element, cleaning ...................... 6-16
Anti-theft alarm ........................................3-6BBattery ................................................... 6-33
Brake and clutch levers, checking and
lubricating ............................................ 6-29
Brake and shift pedals, checking and
lubricating ............................................ 6-29
Brake fluid, changing ............................. 6-26
Brake fluid level, checking...................... 6-25
Brake lever...............................................3-8
Brake light switch (rear), adjusting ......... 6-23
Brake pads, checking............................. 6-24
Brake pedal..............................................3-8
Brake pedal position, adjusting .............. 6-23CCables, checking and lubricating............ 6-28
Care.........................................................7-1
Clutch lever ..............................................3-7
Clutch lever free play, adjusting ............. 6-22
Conversion table ......................................8-5
Coolant .................................................. 6-12
Changing .......................................... 6-13
Checking .......................................... 6-12
Coolant temperature gauge .....................3-5
Cowlings and panels, removing and
installing ................................................6-5DDimmer switch .........................................3-6
Drive chain, lubricating ........................... 6-28
Drive chain slack ................................... 6-26
Adjusting .......................................... 6-27
Checking .......................................... 6-26EEngine break-in ....................................... 5-4
Engine oil and oil filter element ................ 6-9
Engine stop switch................................... 3-7
Engine trouble warning light .................... 3-3FFront fork, adjusting ............................... 3-13
Front fork, checking ............................... 6-31
Fuel ......................................................... 3-9
Fuel consumption, tips for reducing ......... 5-4
Fuel level warning symbol ....................... 3-2
Fuel tank breather hose
(Germany only) ................................... 3-10
Fuel tank cap ........................................... 3-9
Fuses, replacing .................................... 6-34HHandlebar switches ................................. 3-6
Hazard switch .......................................... 3-6
Headlight bulb, replacing ....................... 6-35
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-6IIdentification numbers ............................. 9-1
Idling speed, adjusting ........................... 6-17
Ignition circuit cut-off system.................. 3-18
Indicator and warning lights ..................... 3-2
KKey identification number .........................9-1LLight switch ..............................................3-7
Luggage strap holders ...........................3-17MMain switch/steering lock .........................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-2OOil level warning light ...............................3-3PParking.....................................................5-5
Part locations ...........................................2-1
Pass switch ..............................................3-6
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list ............................4-1RRear suspension, lubricating ..................6-30SSafety information ....................................1-1
Seat .......................................................3-11
Shifting .....................................................5-3
Shift pedal ................................................3-8
Shift points (for Switzerland only) .............5-3
Shock absorber assembly, adjusting ......3-15
Sidestand ...............................................3-17
U5PSE0.book Page 1 Thursday, December 13, 2001 4:29 PM