ignition YAMAHA TDM 900 2003 Owners Manual

INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock ...................................................................3-1
Indicator and warning lights ...............................................................3-2
Speedometer unit ..............................................................................3-4
Tachometer unit .................................................................................3-5
Coolant temperature gauge ...............................................................3-6
Anti-theft alarm (optional) ..................................................................3-7
Handlebar switches ...........................................................................3-7
Clutch lever ........................................................................................3-9
Shift pedal ..........................................................................................3-9
Brake lever ........................................................................................3-9
Brake pedal .....................................................................................3-10
Fuel tank cap ...................................................................................3-10
Fuel ..................................................................................................3-11
Fuel tank breather hose ...................................................................3-12
Catalytic converter ...........................................................................3-12
Seat .................................................................................................3-13
Storage compartment ......................................................................3-14
Adjusting the front fork .....................................................................3-14
Adjusting the shock absorber assembly ..........................................3-16
Luggage strap holders .....................................................................3-18
Sidestand .........................................................................................3-18
Ignition circuit cut-off system ...........................................................3-19
3
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3-1
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Main switch/steering lockMain switch/steering lockThe main switch/steering lock con-
trols the ignition and lighting systems,
and is used to lock the steering. The
various positions are described
below.
EAU04926
ON
All electrical circuits are supplied with
power; the meter lighting, taillight and
auxiliary light come on, and the
engine can be started. The key can-
not be removed.
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INSTRUMENT AND CONTROL FUNCTIONS
3
NOTE:
The headlight comes on automatical-
ly when the engine is started and
stays on until the key is turned to
“OFF”.
EAU00038
OFF
All electrical systems are off. The key
can be removed.
EAU00040
LOCK
The steering is locked, and all electri-
cal systems are off. The key can be
removed.
To lock the steering
1. Turn the handlebars all the way
to the left.
2. Push the key in from the “OFF”
position, and then turn it to
“LOCK” while still pushing it.
3. Remove the key.
To unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
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3-9
INSTRUMENT AND CONTROL FUNCTIONS
3
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Clutch leverClutch leverThe clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the han-
dlebar grip. To engage the clutch,
release the lever. The lever should
be pulled rapidly and released slowly
for smooth clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-19 for an explanation of the ignition
circuit cut-off system.)
1. Clutch lever
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Shift pedalShift pedalThe shift pedal is located on the left
side of the engine and is used in
combination with the clutch lever
when shifting the gears of the
6-speed constant-mesh transmission
equipped on this motorcycle.
1. Shift pedal
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Brake leverBrake leverThe brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the han-
dlebar grip.
The brake lever is equipped with a
position adjusting dial.
1. Brake lever
2. Brake lever position adjusting dial
3. Arrow mark
a. Distance between brake lever and
handlebar grip
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3-18
INSTRUMENT AND CONTROL FUNCTIONS
3
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This shock absorber contains
highly pressurized nitrogen gas.
For proper handling, read and
understand the following informa-
tion before handling the shock
absorber. The manufacturer can-
not be held responsible for proper-
ty damage or personal injury that
may result from improper han-
dling.
8Do not tamper with or attempt
to open the gas cylinder.
8Do not subject the shock
absorber to an open flame or
other high heat sources, other-
wise it may explode due to
excessive gas pressure.
8Do not deform or damage the
gas cylinder in any way, as
this will result in poor damp-
ing performance.
8Always have a Yamaha dealer
service the shock absorber.
EAU00324
Luggage strap holdersLuggage strap holdersThere are four luggage strap holders
below the passenger seat, two of
which can be turned out for easier
access.
1. Luggage strap holder (×4)
EAU00330
SidestandSidestandThe sidestand is located on the left
side of the frame. Raise the side-
stand or lower it with your foot while
holding the motorcycle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain situ-
ations. (See further down for an
explanation of the ignition circuit cut-
off system.)
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3-19
INSTRUMENT AND CONTROL FUNCTIONS
3
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w
The motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up),
otherwise the sidestand could con-
tact the ground and distract the
operator, resulting in a possible
loss of control. Yamaha’s ignition
circuit cut-off system has been
designed to assist the operator in
fulfilling the responsibility of rais-
ing the sidestand before starting
off. Therefore, check this system
regularly as described below and
have a Yamaha dealer repair it if it
does not function properly.
EAU03720
Ignition circuit cut-off
system
Ignition circuit cut-off systemThe ignition circuit cut-off system
(comprising the sidestand switch,
clutch switch and neutral switch) has
the following functions.
8It prevents starting when the
transmission is in gear and the
sidestand is up, but the clutch
lever is not pulled.
8It prevents starting when the
transmission is in gear and the
clutch lever is pulled, but the
sidestand is still down.
8It cuts the running engine when
the transmission is in gear and
the sidestand is moved down.
Periodically check the operation of
the ignition circuit cut-off system
according to the following procedure.
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w
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
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4-2
PRE-OPERATION CHECKS
4
Throttle grip•Make sure that operation is smooth.
•Check cable free play.
•If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-18, 6-29
Control cables•Make sure that operation is smooth.
•Lubricate if necessary.6-29
Drive chain•Check chain slack.
•Adjust if necessary.
•Check chain condition.
•Lubricate if necessary.6-27–6-29
Wheels and tires•Check for damage.
•Check tire condition and tread depth.
•Check air pressure.
•Correct if necessary.6-18–6-22
Brake and shift pedals•Make sure that operation is smooth.
•Lubricate pedal pivoting points if necessary.6-30
Brake and clutch levers•Make sure that operation is smooth.
•Lubricate lever pivoting points if necessary.6-30
Sidestand•Make sure that operation is smooth.
•Lubricate pivot if necessary.6-30
Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.
•Tighten if necessary.—
Instruments, lights, signals
and switches•Check operation.
•Correct if necessary.3-2–3-3, 3-7–3-8, 6-35–6-38
Sidestand switch•Check operation of ignition circuit cut-off system.
•If system is defective, have Yamaha dealer check vehicle.3-18–3-20 ITEM CHECKS PAGE
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5-1
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OPERATION AND IMPORTANT RIDING POINTS
5
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8Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or func-
tion that you do not thorough-
ly understand.
8Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
8Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU03951
Starting the engineStarting the engineIn order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
8The transmission is in the neutral
position.
8The transmission is in gear with
the clutch lever pulled and the
sidestand up.
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w
8Before starting the engine,
check the function of the igni-
tion circuit cut-off system
according to the procedure
described on page 3-20.
8Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch
is set to “#”.
ECA00083
cC
The oil level warning light and
engine trouble warning light
should come on for a few seconds,
then go off. If a warning light does
not go off, see pages 3-2 and 3-3
for the corresponding warning
light circuit check.
2. Shift the transmission into the
neutral position.
NOTE:
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.
3. Start the engine by pushing the
start switch.
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6-34
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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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.
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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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6-43
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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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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