light YAMAHA TDM 900 2003 User Guide

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 ............................6-8
Coolant ...............................................................6-11
Replacing 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 ...................................................................6-18
Cast wheels ........................................................6-22
Adjusting the clutch lever free play .....................6-22
Adjusting the brake pedal position .....................6-23
Adjusting the rear brake light switch ...................6-24
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 ................................................6-27
Lubricating the drive chain .................................6-28
Checking and lubricating the cables ...................6-29
Checking and lubricating the throttle grip
and cable .........................................................6-29Checking and lubricating the brake and
shift pedals ......................................................6-30
Checking and lubricating the brake and
clutch levers ....................................................6-30
Checking and lubricating the sidestand ..............6-30
Lubricating the rear suspension .........................6-31
Checking the front fork .......................................6-31
Checking the steering .........................................6-32
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 .........................6-37
Replacing a turn signal light bulb .......................6-37
Supporting the motorcycle ..................................6-38
Front wheel .........................................................6-39
Rear wheel .........................................................6-40
Troubleshooting ..................................................6-43
Troubleshooting charts .......................................6-44
6
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03884
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
9Replace the brake hoses every four years and if cracked or damaged.
22 Engine oil•Change.
•Check oil level and vehicle for oil leakage.√√√√√ √
23 Engine oil filter element•Replace.√√√
24
*Cooling system•Check coolant level and vehicle for coolant leakage.√√√√ √
•Change.Every 3 years
25
*Front and rear brake
switches•Check operation.√√√√√ √
26 Moving parts and cables•Lubricate.√√√√ √
27
*Throttle grip housing
and cable•Check operation and free play.
•Adjust the throttle cable free play if necessary.
•Lubricate the throttle grip housing and cable.√√√√ √
28
*Air induction system•Check the air cut-off valve, reed valve, and hose for
damage.
•Replace the entire air induction system if necessary.√√√√ √
29
*Muffler and exhaust pipe•Check the screw clamp for looseness.√√√√√
30
*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
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6-7
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01880
Checking the spark plugsSpark plugs, checkingThe spark plugs are important engine
components, which should be
checked periodically, preferably by a
Yamaha dealer. Since heat and
deposits will cause any spark plug to
slowly erode, they should be
removed and checked in accordance
with the periodic maintenance and
lubrication chart. In addition, the con-
dition of the spark plugs can reveal
the condition of the engine.
The porcelain insulator around the
center electrode of each spark plug
should be a medium-to-light tan (the
ideal color when the motorcycle is rid-
den normally), and all spark plugs
installed in the engine should have
the same color. If any spark plug
shows a distinctly different color, the
engine could be defective. Do not
attempt to diagnose such problems
yourself. Instead, have a Yamaha
dealer check the motorcycle.Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
a. Spark plug gap
If a spark plug shows signs of elec-
trode erosion and excessive carbon
or other deposits, it should be
replaced.
Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification.
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf)
Specified spark plug:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
Spark plug gap:
0.8–0.9 mm
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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 specified torque as
soon as possible.
3. Wait a few minutes until the oil
settles, remove the oil filler cap,
wipe the dipstick clean, insert it
back into the oil filler hole (with-
out 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.
1. Oil filler cap
EAU04619
Engine oil and oil filter
element
Engine oil and oil filter elementThe engine oil level should be
checked before each ride. In addition,
the oil must be changed and the oil
filter element replaced at the intervals
specified in the periodic maintenance
and lubrication 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
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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
ECA00133
cC
8In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives.
Do not use oils with a diesel
specification of “CD” or oils of
a higher quality than specified.
In addition, do not use oils
labeled “ENERGY CONSERV-
ING II” or higher.
8Make sure that no foreign
material enters the crankcase.
9. Start the engine, and then let it
idle for several minutes while
checking it for oil leakage. If oil is
leaking, immediately turn the
engine off and check for the
cause.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.2. Check the coolant level in the
coolant reservoir.
NOTE:
The coolant should be between the
minimum and maximum level marks.
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
EAU04879
CoolantCoolantThe coolant level should be checked
before each ride. In addition, the
coolant must be changed at the inter-
vals specified in the periodic mainte-
nance and lubrication chart.
To check the coolant level
Checking1. Place the motorcycle on the cen-
terstand.
NOTE:
8The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
8Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EW000109
w
A soft or spongy feeling in the
brake pedal can indicate the pres-
ence of air in the hydraulic system.
If there is air in the hydraulic sys-
tem, have a Yamaha dealer bleed
the system before operating the
motorcycle. Air in the hydraulic
system will diminish the braking
performance, which may result in
loss of control and an accident.
EAU00721
Checking the front and rear
brake pads
Front and rear brake pads, checkingThe front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU00713
Adjusting the rear brake light
switch
Rear brake light switch, adjustingThe rear brake light switch, which is
activated by the brake pedal, is prop-
erly adjusted when the brake light
comes on just before braking takes
effect. If necessary, adjust the brake
light switch as follows.
Turn the adjusting nut while holding
the rear brake light switch in place.
To make the brake light come on ear-
lier, turn the adjusting nut in direction
a. To make the brake light come on
later, turn the adjusting nut in direc-
tion b.
1. Brake light switch
2. Brake light switch adjusting nut
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PERIODIC MAINTENANCE AND MINOR REPAIR
6 To store the battery
1. If the motorcycle will not be used
for more than one month,
remove the battery, fully charge
it, and then place it in a cool, dry
place.
2. If the battery will be stored for
more than two months, check it
at least once a month and fully
charge it if necessary.
3. Fully charge the battery before
installation.
4. After installation, make sure that
the battery leads are properly
connected to the battery termi-
nals.
EAU04880
Replacing the fusesFuses, replacingThe main fuse and the fuse box,
which contains the fuses for the indi-
vidual circuits, are located under the
seat. (See page 3-13 for seat
removal and installation procedures.)
If a fuse is blown, replace it as fol-
lows.
1. Turn the key to “OFF” and turn
off the electrical circuit in ques-
tion.
12 34 5 689 7
7
1. Odometer and clock fuse (backup fuse)
2. Radiator fan fuse
3. Turn signal light and hazard fuse
4. Ignition fuse
5. Signaling system fuse
6. Headlight fuse
7. Spare fuse (×5)
8. Electronic fuel injection system fuse
9. Main fuse
EC000102
cC
8Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.
8To charge a sealed-type (MF)
battery, a special (constant-
voltage) battery charger is
required. Using a conventional
battery charger will damage
the battery. If you do not have
access to a sealed-type (MF)
battery charger, have a
Yamaha dealer charge your
battery.
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PERIODIC MAINTENANCE AND MINOR REPAIR
62. Remove the blown fuse, and
then install a new fuse of the
specified amperage.
EC000103
cC
Do not use a fuse of a higher
amperage rating than recommend-
ed to avoid causing extensive
damage to the electrical system
and possibly a fire.
EAU04503
Replacing a headlight bulbHeadlight bulb, replacingThis motorcycle is equipped with
quartz bulb headlights. If a headlight
bulb burns out, replace it as follows.
1. Disconnect the headlight cou-
pler, and then remove the bulb
cover.
1. Headlight bulb holder
2. Headlight coupler
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system. Specified fuses:
Main fuse: 40 A
Headlight fuse: 15 A
Signaling system fuse: 10 A
Radiator fan fuse: 20 A
Ignition fuse: 10 A
Odometer and clock
fuse (backup fuse): 5 A
Turn signal light and
hazard fuse: 10 A
Electronic fuel
injection fuse: 10 A
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PERIODIC MAINTENANCE AND MINOR REPAIR
6 2. Unhook the headlight bulb hold-
er, and then remove the defec-
tive bulb.EW000119
w
Headlight bulbs get very hot.
Therefore, keep flammable prod-
ucts away from a lit headlight bulb,
and do not touch the bulb until it
has cooled down.
3. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
1
1. Headlight bulb holder
8Headlight lens
9Do not affix any type of tint-
ed film or stickers to the
headlight lens.
9Do not use a headlight bulb
of a wattage higher than
specified.
4. Install the headlight bulb cover,
and then connect the coupler.
5. Have a Yamaha dealer adjust
the headlight beam if necessary.
EC000104
cC
Take care not to damage the fol-
lowing parts:
8Headlight bulb
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the
bulb, and the bulb life will be
adversely affected. Thoroughly
clean off any dirt and fingerprints
on the headlight bulb using a cloth
moistened with alcohol or thinner.
a
a. Do not touch the glass part of the bulb.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04411
Replacing a tail/brake light
bulb
Tail/brake light bulb, replacing1. Remove the seat. (See page
3-13 for seat removal and instal-
lation procedures.)
2. Remove the socket (together
with the bulb) by turning it coun-
terclockwise.
3. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
4. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
1. Socket
EAU03497
Replacing a turn signal light
bulb
Turn signal light bulb, replacing1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
1. Screw
2. Turn signal light lens
5. Install the socket (together with
the bulb) by turning it clockwise.
6. Install the seat.
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