maintenance YAMAHA TDM 900 2003 Owners Manual

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TABLE OF CONTENTS
1 GIVE SAFETY THE RIGHT OF WAY
2 DESCRIPTION
3 INSTRUMENT AND CONTROL FUNCTIONS
4 PRE-OPERATION CHECKS
5 OPERATION AND IMPORTANT RIDING POINTS
6 PERIODIC MAINTENANCE AND MINOR REPAIR
7 MOTORCYCLE CARE AND STORAGE
8 SPECIFICATIONS
9 CONSUMER INFORMATION
INDEX
9
8
7
6
5
4
3
2
1
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1-1
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QGIVE SAFETY THE RIGHT OF WAYSafety information
1Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and free-
dom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.
Regular care and maintenance are essential for preserving value and operating condition of your
motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders—more than car drivers—must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passen-
gers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic
materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum pro-
tective wear, however, should not encourage carelessness. Although full-coverage helmets and suits,
in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable.
Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is
even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensive-
ly—avoiding all dangers, including those caused by others.
Enjoy your ride!
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3-12
INSTRUMENT AND CONTROL FUNCTIONS
3
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cC
Use only unleaded gasoline. The
use of leaded gasoline will cause
severe damage to internal engine
parts, such as the valves and pis-
ton rings, as well as to the exhaust
system.
Your Yamaha engine has been
designed to use regular unleaded
gasoline with a research octane num-
ber of 91 or higher. If knocking (or
pinging) occurs, use a gasoline of a
different brand or premium unleaded
fuel. Use of unleaded fuel will extend
spark plug life and reduce mainte-
nance costs.EAU02955
Fuel tank breather hoseFuel tank breather hoseBefore operating the motorcycle:
8Check the fuel tank breather
hose connection.
8Check the fuel tank breather
hose for cracks or damage, and
replace it if damaged.
8Make sure that the end of the
fuel tank breather hose is not
blocked, and clean it if neces-
sary.
1. Fuel tank breather hose
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Catalytic converterCatalytic converterThis motorcycle is equipped with a
catalytic converter in the muffler.
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The exhaust system is hot after
operation. Make sure that the
exhaust system has cooled down
before doing any maintenance
work.
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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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6-1
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. The most important
points of inspection, adjustment, and
lubrication are explained on the fol-
lowing pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a
general guide under normal riding
conditions. However, DEPENDING
ON THE WEATHER, TERRAIN,
GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTE-
NANCE INTERVALS MAY NEED TO
BE SHORTENED.
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w
If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you.
NOTE:
If you do not have the tools or experi-
ence required for a particular job,
have a Yamaha dealer perform it for
you.
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w
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle
unsafe for use. Consult a Yamaha
dealer before attempting any
changes.
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Owner’s tool kitTool kitThe owner’s tool kit is located inside
the storage compartment under the
seat. (See page 3-13 for seat
removal procedures.)
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to
assist you in the performance of pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be nec-
essary to perform certain mainte-
nance work correctly.
1. Owner’s tool kit
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6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Periodic maintenance and lubrication chartPeriodic maintenance and lubrication chartNOTE:
8The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line•Check fuel hoses for cracks or damage.√√√√ √
2 Spark plugs•Check condition.
•Clean and regap.√√
•Replace.√√
3
*Valves•Check valve clearance.
•Adjust.Every 40,000 km
4 Air filter element•Replace.√
5 Clutch•Check operation.
•Adjust.√√√√√
6
*Front brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
7
*Rear brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
8
*Brake hoses•Check for cracks or damage.√√√√ √
•Replace. (See NOTE on page 6-4.)Every 4 years
9
*Wheels•Check runout and for damage.√√√√
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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
6
10*Tires•Check tread depth and for damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.√√√√ √
11
*Wheel bearings•Check bearing for looseness or damage.√√√√
12
*Swingarm•Check operation and for excessive play.√√√√
•Lubricate with lithium-soap-based grease. Every 50,000 km
13 Drive chain•Check chain slack.
•Make sure that the rear wheel is properly aligned.
•Clean and lubricate.Every 1,000 km and after washing
the motorcycle or riding in the rain
14
*Steering bearings•Check bearing play and steering for roughness.√√√√√
•Lubricate with lithium-soap-based grease.Every 20,000 km
15
*Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.√√√√ √
16 Sidestand•Check operation.
•Lubricate.√√√√ √
17
*Sidestand switch•Check operation.√√√√√ √
18
*Front fork•Check operation and for oil leakage.√√√√
19
*Shock absorber
assembly•Check operation and shock absorber for oil leakage.√√√√
20
*
Rear suspension relay
arm and connecting arm
pivoting points•Check operation.√√√√
•Lubricate with lithium-soap-based grease.√√
21
*Electronic fuel injection•Adjust engine idling speed and synchronization.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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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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6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Removing and installing
cowlings and panels
Cowlings and panels, removing and installingThe cowlings and panels shown
above need to be removed to per-
form some of the maintenance jobs
described in this chapter. Refer to
this section each time a cowling or
panel needs to be removed and
installed.
1. Cowling A
2. Panel A
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Cowlings A and B
To remove one of the cowlings
Remove the cowling screws and the
quick fastener, and then pull the
cowling off as shown.
NOTE:
The quick fastener is removed by
pushing the center pin in with a
screwdriver, and then pulling the fas-
tener out.
1. Screw (×6)
2. Quick fastener1. Cowling B
2. Panel B
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6-6
PERIODIC MAINTENANCE AND MINOR REPAIR
6 To install the cowling
Place the cowling in the original posi-
tion, and then install the screws and
the quick fastener.
NOTE:
To install the quick fastener, push the
center pin out so that it will protrude
from the fastener head, insert the fas-
tener into the cowling, and then push
the protruding pin in until it is flush
with the fastener head.
1. Quick fastener
2. Pin
To install the panel
1. Place the panel in the original
position, and then install the
screw.
2. Install the seat and the cowling.
1. Panel B
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Panels A and B
To remove one of the panels
1. Remove the corresponding cowl-
ing A or B. (See page 6-5 for
cowling removal and installation
procedures.)
2. Remove the seat. (See page
3-13 for seat removal and instal-
lation procedures.)
3. Remove the screw, and then
take the panel off.
1. Screw
After removalBefore installation
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