YAMAHA TDM 900 2003 Manual Online

6-35
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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6-36
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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6-37
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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6-38
PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
ECA00065
cC
Do not overtighten the screw, oth-
erwise the lens may break.
1. Turn signal light bulb
To service the rear wheel
Raise the rear wheel off the ground
by using a motorcycle stand or, if a
motorcycle stand is not available, by
placing a jack either under each side
of the frame in front of the rear wheel
or under each side of the swingarm.EAU01579
Supporting the motorcycleSupporting the motorcycleSince this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and
rear wheel or performing other main-
tenance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed
under the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcy-
cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing
a jack under the frame in front of
the rear wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
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6-39
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01617
Front wheelWheel (front)
To remove the front wheelRemovingEW000122
w
8It is advisable to have a
Yamaha dealer service the
wheel.
8Securely 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.
1. Wheel axle
2. Front wheel axle pinch bolt
ECA00046
cC
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut.
2. Loosen the wheel axle with a
19-mm hexagon wrench.
3. Lift the front wheel off the ground
according to the procedure on
page 6-38.
4. Remove the brake hose holders
by removing the bolts.
5. Remove the brake calipers by
removing the bolts.
6. Pull the wheel axle out, and then
remove the wheel.
1
3
2
1. Brake hose holder
2. Bolt (×2)
3. Brake caliper
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6-40
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04376
To install the front wheelInstalling1. 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
installing the bolts.
NOTE:
Make sure that there is enough
space between the brake pads
before installing the brake calipers
onto the brake discs.
5. Install the brake hose holders by
installing the bolts.
6. Tighten the wheel axle, the front
wheel axle pinch bolt and the
brake caliper bolts to the speci-
fied torques.
EAU04455
Rear wheel
Wheel (rear)To remove the rear wheelRemovingEW000122
w
8It is advisable to have a
Yamaha dealer service the
wheel.
8Securely support the motorcy-
cle so that there is no danger
of it falling over.
1. Bolt (×2)
2. Quick fastener (×3)7. Push down hard on the handle-
bar several times to check for
proper fork operation. Tightening torques:
Wheel axle:
72 Nm (7.2 m·kgf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf)
Brake caliper bolt:
40 Nm (4.0 m·kgf)
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6-41
PERIODIC MAINTENANCE AND MINOR REPAIR
61. Remove the drive chain cover by
removing the quick fasteners and
the bolts.
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.
1. Bolt
2. Brake caliper bracket
2. Loosen the axle nut and the
brake caliper bracket bolt.
3. Lift the rear wheel off the ground
according to the procedure on
page 6-38.
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
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6-42
PERIODIC MAINTENANCE AND MINOR REPAIR
6 8. Pull the wheel axle out, and then
remove the wheel.
ECA00119
cC
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.
7. Install the drive chain cover by
installing the bolts and quick fas-
teners.
NOTE:
To install a quick fastener, push the
pin back so that it will protrude from
the fastener head, and then insert the
fastener and push the protruding pin
in until it is flush with the fastener
head.
EAU04456
To install the rear wheelInstalling1. 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 installing 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 6-27 for drive chain
slack adjustment procedures.)
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.Tightening torques:
Axle nut:
150 Nm (15.0 m·kgf)
Brake caliper bracket bolt:
40 Nm (4.0 m·kgf)
1. Quick fastener
2. Pin
After removalBefore installation
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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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6-44
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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