torque YAMAHA TDM 900 2004 Owners Manual

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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17240
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation 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.
WARNING

EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealer
do it for you.
EAU17520
Owner’s tool kit
The owner’s tool kit is located inside the
storage compartment under the seat.
(See page 3-13.)
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.
WARNING

EWA10350
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
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PERIODIC MAINTENANCE AND MINOR REPAIR
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Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
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.
EAU19830
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 vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:

Make sure that the vehicle is positioned
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), Specified spark plug:
NGK/DPR8EA-9
DENSO/X24EPR-U9
1. Spark plug gap
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
1

Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf,
12.7 ft·lbf)

PERIODIC MAINTENANCE AND MINOR REPAIR
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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 byinstalling the bolts, then tightening
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.
8. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
1. Engine oil drain bolt A
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1. Engine oil drain bolt B
2. Oil filter element cover
3. Bolt
1. Oil filter element
2. O-ring
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Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torques:
Engine oil drain bolt A:
35 Nm (3.5 m·kgf, 25 ft·lbf)
Engine oil drain bolt B:
35 Nm (3.5 m·kgf, 25 ft·lbf)

PERIODIC MAINTENANCE AND MINOR REPAIR
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3. Remove cowling B and panel B.
(See page 6-5.)
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 hoses!)
5. Place a container under the engine
to collect the used coolant.
6. Remove the radiator cap retaining
bolt and the radiator cap.
WARNING

EWA10380
Never attempt to remove the radiator
cap when the engine is hot.
7. Remove the coolant drain bolts todrain the cooling system.
8. Remove the coolant reservoir bolt.
9. Pull the coolant reservoir upward
and away from the vehicle.
10. Drain the remaining coolant fromthe coolant reservoir by opening
the cap, then turning the reservoir
upside down.
11. Install the coolant reservoir by
placing it in the original position,
then installing the bolt.
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. Radiator cap retaining bolt
2. Radiator cap
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1. Coolant drain bolt
1. Bolt
2. Coolant reservoir
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Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)

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tion for proper wheel alignment.
CAUTION:

ECA10570
Improper drive chain slack will over-
load 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.
3. Tighten the locknuts, and then
tighten the axle nut and the brake
caliper bracket bolt to the specified
torques.
EAU23020
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.
CAUTION:

ECA10580
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.
CAUTION:

ECA11120
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.
CAUTION:

ECA11110
Do not use engine oil or any other lu-
bricants for the drive chain, as they
may contain substances that could
damage the O-rings.
Tightening torque:
Axle nut:
150 Nm (15.0 m·kgf,
108.5 ft·lbf)
Brake caliper bracket bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)

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EAU24360
Front wheel
EAU24550
To remove the front wheel
WARNING

EWA10820

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

Securely support the motorcy-
cle 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 groundaccording to the procedure on
page 6-34.
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.
CAUTION:

ECA11050
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut.
EAU25020
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 wheel
axle pinch bolt and the brake cali-
per bolts to the specified torques.
1. Wheel axle
2. Front wheel axle pinch bolt
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1. Brake hose holder
2. Bolt
3. Brake caliper
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Tightening torques:
Wheel axle:
72 Nm (7.2 m·kgf, 52 ft·lbf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf, 14.5 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)

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3. Lift the rear wheel off the ground
according to the procedure on
page 6-34.
4. Remove the axle nut.
5. Loosen the locknut on each side of
the swingarm.
6. Turn the drive chain slack adjust-
ing bolts fully in direction (a).
7. Push the wheel forward, tighten
the caliper bracket bolt, 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.
8. Pull the wheel axle out, and thenremove the wheel.
CAUTION:

ECA11510
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake caliper pistons will be forced
out.
EAU25681
To install the rear wheel
1. Install the wheel by inserting the
wheel axle from the right hand
side.
NOTE:

Make sure that there is enough space
between the brake pads before install-
ing the wheel.
2. Install the drive chain onto the rear
sprocket.
3. Loosen the brake caliper bracket
bolt.
4. Adjust the drive chain slack. (See
page 6-24.)
5. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.6. Tighten the axle nut and the brake
caliper bracket bolt to the specified
torques.
7. Install the drive chain cover by in-
stalling the bolts and quick fasten-
ers.
NOTE:

To install a quick fastener, push the pin
Tightening torques:
Axle nut:
150 Nm (15.0 m·kgf,
108.5 ft·lbf)
Brake caliper bracket bolt:
40 Nm (4.0 m·kgf, 29.0 ft·lbf)
1. Quick fastener (after removal)
2. Quick fastener (before installation)
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