fuel YAMAHA TDM 900 2003 Owner's Manual

6-43
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03087
TroubleshootingTroubleshootingAlthough Yamaha motorcycles
receive a thorough inspection before
shipment from the factory, trouble
may occur during operation. Any
problem in the fuel, compression, or
ignition systems, for example, can
cause poor starting and loss of
power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcy-
cle require any repair, take it to a
Yamaha dealer, whose skilled techni-
cians have the necessary tools,
experience, and know-how to service
the motorcycle properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life
and can lead to expensive repair
bills.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU02990
Troubleshooting chartsTroubleshooting chartsStarting problems or poor engine performanceEW000125
w
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.
1. FuelThere 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. CompressionThere 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. IgnitionWipe 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. BatteryThe engine turns over
quickly.
The engine turns over
slowly.The battery is good.
Check the battery lead connections,
and charge the battery if necessary.
Dry
WetOpen the throttle halfway and operate
the electric starter.
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7
7-2
MOTORCYCLE CARE AND STORAGE
8Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abra-
sive cleaning products, sol-
vent or thinner, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or elec-
trolyte.
8Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the
following areas: seals (of
wheel and swingarm bearings,
fork and brakes), electric com-
ponents (couplers, connec-
tors, instruments, switches
and lights), breather hoses
and vents.8For motorcycles equipped
with a windshield: Do not use
strong cleaners or hard
sponges as they will cause
dulling or scratching. Some
cleaning compounds for plas-
tic may leave scratches on the
windshield. Test the product
on a small hidden part of the
windshield to make sure that it
does not leave any marks. If
the windshield is scratched,
use a quality plastic polishing
compound after washing.After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottle-
brush for hard-to-reach areas.
Stubborn dirt and insects will come
off more easily if the area is covered
with a wet cloth for a few minutes
before cleaning.
After riding in the rain, near the sea
or on salt-sprayed roads
Since sea salt or salt sprayed on
roads during winter are extremely
corrosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads.
NOTE:
Salt sprayed on roads in the winter
may remain well into spring.
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7
7-4
MOTORCYCLE CARE AND STORAGE
ECA00013
cC
8Apply spray oil and wax spar-
ingly and make sure to wipe
off any excess.
8Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
8Avoid using abrasive polish-
ing compounds as they will
wear away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
Storage
StorageShort-term
Always store your motorcycle in a
cool, dry place and, if necessary, pro-
tect it against dust with a porous
cover.
ECA00014
cC
8Storing the motorcycle in a
poorly ventilated room or cov-
ering it with a tarp, while it is
still wet, will allow water and
humidity to seep in and cause
rust.
8To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
3. Perform the following steps to
protect the cylinders, piston
rings, etc. from corrosion.
a. 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 elec-
trodes are grounded. (This will
limit sparking during the next
step.)
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8
8-1
EAU01038
SPECIFICATIONS
SpecificationsSpecifications
Model 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
Type
Recommended engine oil
classification API Service SE, SF, SG type
or higher
cC
In order to prevent clutch slippage (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 CONSERVING II” or higher.
Capacity
Without oil filter element
removal 3.8 L
With oil filter element removal 3.9 L
Total amount (dry engine) 4.7 L
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8
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SPECIFICATIONS
Cooling system capacity
(total amount)1.7 L
Air filterOil-coated paper element
Fuel
Type REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity 20 L
Fuel reserve amount 3.5 L
Spark plug
Manufacturer/model NGK/DPR8EA-9 or
DENSO/X24EPR-U9
Gap 0.8–0.9 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 1.718
Secondary reduction system Chain drive
Secondary reduction ratio 2.625
Number of drive chain
sprocket teeth (front/rear) 16/42
Transmission type Constant mesh 6-speedOperation Left foot
Gear ratio 1st 2.750
2nd 1.947
3rd 1.545
4th 1.240
5th 1.040
6th 0.923
Chassis
Frame type Diamond
Caster angle 25.5°
Trail 114 mm
Tires
Front
Type Tubeless tire
Size 120/70 ZR18 M/C (59W)
Manufacturer/ Dunlop/D220FSTJ
model Metzeler/MEZ4 FRONT
Rear
Type Tubeless tire
Size 160/60 ZR17 M/C (69W)
Manufacturer/ Dunlop/D220STJ
model Metzeler/MEZ4
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8
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SPECIFICATIONS
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
Type GT12B-4
Voltage, capacity 12 V, 10 Ah
Headlight bulb typeHalogen
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 ×1
Front turn signal light 12 V, 10 W ×2
Rear turn signal light 12 V, 10 W ×2
Meter lighting 12 V, 2 W ×2
Neutral indicator light 12 V, 1.2 W ×1
High beam indicator light 12 V, 1.4 W ×1
Turn signal indicator light 12 V, 1.2 W ×2
Oil level warning light L.E.D. ×1
Engine trouble warning light 12 V, 1.4 W ×1Fuses
Main fuse 40 A
Headlight fuse 15 A
Signaling system fuse 10 A
Ignition fuse 10 A
Turn signal light and hazard
fuse 10 A
Odometer and clock fuse
(backup fuse) 5 A
Radiator fan fuse 20 A
Electronic fuel injection
system fuse 10 A
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INDEX
Checking ............................................6-27
Drive chain, lubricating .........................6-28
E
Engine break-in ......................................5-3
Engine idling speed ..............................6-17
Engine oil and oil filter element ..............6-8
F
Front and rear brake pads, checking ....6-24
Front fork, adjusting ..............................3-14
Front fork, checking ..............................6-31
Fuel ......................................................3-11
Fuel consumption, tips for reducing .......5-3
Fuel tank breather hose .......................3-12
Fuel tank cap ........................................3-10
Fuses, replacing ...................................6-34
H
Handlebar switches ................................3-7
Dimmer switch .....................................3-7
Engine stop switch ...............................3-8
Hazard switch ......................................3-8
Horn switch ..........................................3-8
Pass switch ..........................................3-7
Start switch ..........................................3-8
Turn signal switch ................................3-8
Headlight bulb, replacing ......................6-35
I
Identification numbers ............................9-1
Ignition circuit cut-off system ................3-19Indicator and warning lights ....................3-2
Fuel level warning symbol ...................3-2
Turn signal indicator lights ...................3-3
High beam indicator light .....................3-3
Neutral indicator light ...........................3-3
Engine trouble warning light ................3-3
Oil level warning light ...........................3-3
K
Key identification number .......................9-1
L
Luggage strap holders ..........................3-18
M
Main switch/steering lock .......................3-1
Model label .............................................9-2
P
Parking ...................................................5-4
Part locations ..........................................2-1
Periodic maintenance and lubrication
chart .....................................................6-2
Pre-operation check list ..........................4-1
R
Rear brake light switch, adjusting .........6-24
Rear suspension, lubricating ................6-31
S
Seat ......................................................3-13
Shift pedal ..............................................3-9A
Air filter element, replacing ...................6-16
Anti-theft alarm (optional) .......................3-7
B
Battery ..................................................6-33
Brake and clutch levers, checking
and lubricating ...................................6-30
Brake and shift pedals, checking
and lubricating ...................................6-30
Brake fluid level, checking ....................6-25
Brake fluid, changing ............................6-26
Brake lever .............................................3-9
Brake pedal ..........................................3-10
Brake pedal position, adjusting ............6-23
C
Cables, checking and lubricating ..........6-29
Care ........................................................7-1
Catalytic converter ................................3-12
Clutch lever ............................................3-9
Clutch lever free play, adjusting ...........6-22
Conversion table ....................................8-5
Coolant .................................................6-11
Checking ............................................6-11
Changing ...........................................6-13
Coolant temperature gauge ....................3-6
Cowlings and panels, removing
and installing ........................................6-5
D
Drive chain slack ..................................6-27
Adjusting ............................................6-27
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