brake YAMAHA TDM 900 2002 Owners Manual

DESCRIPTION
2-2
2
Right view15. Tool kit (page 6-1)
16. Coolant reservoir (page 6-12)
17. Throttle stop screw (page 6-18)
18. Front brake master cylinder (page 6-25)
19. Radiator cap (page 6-14)20. Engine oil filler cap (page 6-9)
21. Engine oil filter element (page 6-11)
22. Engine oil drain bolt B (page 6-10)
23. Brake pedal (page 3-8)
24. Rear brake fluid reservoir (page 6-25)
U5PSE0.book Page 2 Thursday, December 13, 2001 4:29 PM

DESCRIPTION
2-3
2
Controls and instruments1. Clutch lever (page 3-7)
2. Left handlebar switches (page 3-6)
3. Speedometer unit (page 3-3)
4. Main switch/steering lock (page 3-1)
5. Tachometer (page 3-5)6. Coolant temperature gauge (page 3-5)
7. Right handlebar switches (page 3-7)
8. Brake lever (page 3-8)
9. Throttle grip (page 6-18)
U5PSE0.book Page 3 Thursday, December 13, 2001 4:29 PM

INSTRUMENT AND CONTROL FUNCTIONS
3
Main switch/steering lock .................................................................. 3-1
Indicator and warning lights ............................................................. 3-2
Speedometer unit .............................................................................. 3-3
Tachometer unit ................................................................................. 3-5
Coolant temperature gauge .............................................................. 3-5
Anti-theft alarm (optional) .................................................................. 3-6
Handlebar switches ........................................................................... 3-6
Clutch lever ....................................................................................... 3-7
Shift pedal ......................................................................................... 3-8
Brake lever ........................................................................................ 3-8
Brake pedal ....................................................................................... 3-8
Fuel tank cap ..................................................................................... 3-9
Fuel ................................................................................................... 3-9
Fuel tank breather hose (for Germany only) ................................... 3-10
Seat ................................................................................................. 3-11
Storage compartment ..................................................................... 3-11
Adjusting the front fork .................................................................... 3-13
Adjusting the shock absorber assembly .......................................... 3-15
Luggage strap holders .................................................................... 3-17
Sidestand ........................................................................................ 3-17
Ignition circuit cut-off system ........................................................... 3-18
U5PSE0.book Page 1 Thursday, December 13, 2001 4:29 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-8
3
EAU00157
Shift pedal The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 6-speed con-
stant-mesh transmission equipped on
this motorcycle.
EAU00161
Brake lever The brake lever is located at the right
handlebar grip. To apply the front brake,
pull the lever toward the handlebar grip.
The brake lever is equipped with a po-
sition adjusting dial. To adjust the dis-
tance between the brake lever and the
handlebar grip, turn the adjusting dial
while holding the lever pushed away
from the handlebar grip. Make sure that
the appropriate setting on the adjusting
dial is aligned with the arrow mark on
the brake lever.
EAU00162
Brake pedal The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
1. Shift pedal
1. Brake lever
2. Brake lever position adjusting dial
3. Arrow mark
a. Distance between brake lever and handlebar
grip
1. Brake pedal
U5PSE0.book Page 8 Thursday, December 13, 2001 4:29 PM

4-1
4
EAU01114
4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03439
Pre-operation check list
CO-01E
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-9–3-10
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-9
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-12–6-13
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-24–6-26
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-23–6-26
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-22
Throttle gripMake sure that operation is smooth.
Check free play.
If necessary, have Yamaha dealer make adjustment or lubricate.6-18
U5PSE0.book Page 1 Thursday, December 13, 2001 4:29 PM

PRE-OPERATION CHECKS
4-2
4
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-28
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-26
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-19–6-21
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-29
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-29
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-30
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-17 ITEM CHECKS PAGE
U5PSE0.book Page 2 Thursday, December 13, 2001 4:29 PM

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s 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 .............................................................. 6-12
Cleaning the air filter element ............................ 6-16
Adjusting the engine idling speed ...................... 6-17
Adjusting the throttle cable free play .................. 6-18
Adjusting the valve clearance ............................ 6-18
Tires ................................................................... 6-19
Adjusting the clutch lever free play .................... 6-22
Adjusting the brake pedal position ..................... 6-23
Adjusting the rear brake light switch .................. 6-23
Checking the front and rear brake pads ............. 6-24
Checking the brake fluid level ............................ 6-25
Changing the brake fluid .................................... 6-26
Drive chain slack ................................................ 6-26
Lubricating the drive chain ................................. 6-28
Checking and lubricating the cables .................. 6-28Checking and lubricating the throttle grip and
cable ............................................................... 6-29
Checking and lubricating the brake and
shift pedals ...................................................... 6-29
Checking and lubricating the brake and
clutch levers .................................................... 6-29
Checking and lubricating the sidestand ............ 6-30
Lubricating the rear suspension ........................ 6-30
Checking the front fork ...................................... 6-31
Checking the steering ....................................... 6-31
Checking the wheel bearings ............................ 6-32
Battery ............................................................... 6-33
Replacing the fuses .......................................... 6-34
Replacing a headlight bulb ................................ 6-35
Replacing a tail/brake light bulb ........................ 6-36
Replacing a turn signal light bulb ...................... 6-37
Supporting the motorcycle ................................ 6-37
Front wheel ....................................................... 6-38
Rear wheel ........................................................ 6-39
Troubleshooting ................................................. 6-42
Troubleshooting charts ...................................... 6-43
U5PSE0.book Page 1 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_

The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.


From 50,000 km, repeat the maintenance intervals starting from 10,000 km.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_
CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel lineCheck fuel hoses for cracks or damage.√√√√ √
2 Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.Every 40,000 km
4 Air filter elementReplace.√
5ClutchCheck operation.
Adjust.√√√√√
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
9*WheelsCheck runout and for damage.√√√√
U5PSE0.book Page 2 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU03884
NOTE:_

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
Replace the brake hoses every four years and if cracked or damaged.
_25
*Front and rear brake
switchesCheck operation.√√√√√ √
26 Moving parts and cablesLubricate.√√√√ √
27*Air induction systemCheck the air cut-off valve, read valve, and hose for
damage.
Replace the entire air induction system if necessary.√√√√ √
28*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
29*Muffler and exhaust pipeCheck the screw clamp for looseness.√√√√√ √
30*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
U5PSE0.book Page 4 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6 Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the side-
wall is cracked, have a Yamaha dealer
replace the tire immediately.
CE-08ENOTE:_ The tire tread depth limits may differ
from country to country. Always comply
with the local regulations. _
EW000079
WARNING
_

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
_
Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
1. Tire sidewall
a. Tire tread depthMinimum tire tread depth
(front and rear)1.6 mm
1. Tire air valve
2. Valve core
3. Valve cap with seal
U5PSE0.book Page 20 Thursday, December 13, 2001 4:29 PM