engine YAMAHA TDM 900 2002 Service Manual

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.
_
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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

8-1
8
EAU01038
8-SPECIFICATIONSSpecifications CS-01E
CS-01EModel TDM900
Dimensions
Overall length 2,180 mm
Overall width 800 mm
Overall height 1,290 mm
Seat height 825 mm
Wheelbase 1,485 mm
Ground clearance 160 mm
Minimum turning radius 2,900 mm
Basic weight (with oil and full
fuel tank)
221 kg
Engine
Engine type Liquid-cooled 4-stroke, DOHC
Cylinder arrangement Forward-inclined parallel
2-cylinder
Displacement 897 cm
3
Bore × stroke 92.0 × 67.5 mm
Compression ratio 10.4:1
Starting system Electric starter
Lubrication system Dry sumpEngine oil
Ty p e
Recommended engine oil
classification API Service SE, SF, SG or
higher
Quantity
Without oil filter element
replacement 3.8 L
With oil filter element
replacement 3.9 L
Total amount (dry engine) 4.7 L
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40
CAUTION:Be sure to use motor oils that do not contain anti-friction
modifiers. Passenger car motor oils (often labeled
“ENERGY CONSERVING II”) contain anti-friction additives
which will cause clutch and/or starter clutch slippage, result-
ing in reduced component life and poor engine performance.
U5PSE0.book Page 1 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
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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
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INDEX
Sidestand, checking and lubricating....... 6-30
Spark plugs, checking ............................. 6-7
Specifications .......................................... 8-1
Speedometer unit .................................... 3-3
Starting the engine .................................. 5-1
Start switch .............................................. 3-7
Steering, checking ................................. 6-31
Storage.................................................... 7-4
Storage compartment ............................ 3-11
Supporting the motorcycle ..................... 6-37TTachometer unit ...................................... 3-5
Tail/brake light bulb, replacing ............... 6-36
Throttle cable free play, adjusting .......... 6-18
Throttle grip and cable, checking and
lubricating............................................ 6-29
Tires ...................................................... 6-19
Tool kit..................................................... 6-1
Troubleshooting..................................... 6-42
Troubleshooting charts .......................... 6-43
Turn signal indicator lights ....................... 3-2
Turn signal light bulb, replacing ............. 6-37
Turn signal switch .................................... 3-6VValve clearance, adjusting ..................... 6-18
Vehicle identification number ................... 9-1WWheel bearings, checking...................... 6-32
Wheel (front).......................................... 6-38
Installing........................................... 6-39
Removing......................................... 6-38
Wheel (rear) .......................................... 6-39
Installing .......................................... 6-41
Removing ........................................ 6-39
U5PSE0.book Page 2 Thursday, December 13, 2001 4:29 PM