engine oil YAMAHA TDM 900 2004 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2004, Model line: TDM 900, Model: YAMAHA TDM 900 2004Pages: 92, PDF Size: 4.5 MB
Page 6 of 92
TABLE OF CONTENTS
SAFETY INFORMATION ............. 1-1
DESCRIPTION ............................. 2-1
Left view ..................................... 2-1
Right view................................... 2-2
Controls and instruments ........... 2-3
INSTRUMENT AND CONTROL
FUNCTIONS ................................ 3-1
Immobilizer system ................... 3-1
Main switch/steering lock .......... 3-2
Indicator and warning lights ...... 3-3
Speedometer unit ...................... 3-5
Tachometer unit ........................ 3-6
Coolant temperature gauge ...... 3-7
Anti-theft alarm (optional) .......... 3-8
Handlebar switches ................... 3-8
Clutch lever ............................... 3-9
Shift pedal ............................... 3-10
Brake lever .............................. 3-10
Brake pedal ............................. 3-11
Fuel tank cap ........................... 3-11
Fuel ......................................... 3-12
Fuel tank breather hose .......... 3-13
Catalytic converter .................. 3-13
Seat ......................................... 3-13
Storage compartment .............. 3-14
Adjusting the front fork ............ 3-15Adjusting the shock absorber
assembly ............................... 3-16
Luggage strap holders ............ 3-18
Sidestand ................................ 3-18
Ignition circuit cut-off system ... 3-19
PRE-OPERATION CHECKS ....... 4-1
Pre-operation check list ............ 4-2
OPERATION AND IMPORTANT
RIDING POINTS ........................... 5-1
Starting the engine .................... 5-1
Shifting ...................................... 5-2
Tips for reducing fuel
consumption ............................ 5-3
Engine break-in ......................... 5-3
Parking ...................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR ............................ 6-1
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 .......... 6-6
Engine oil and oil filter
element ................................... 6-7Coolant .................................... 6-10
Replacing the air filter
element ................................. 6-14
Adjusting the engine idling
speed .................................... 6-15
Adjusting the throttle cable free
play ....................................... 6-16
Adjusting the valve
clearance .............................. 6-16
Tires ........................................ 6-16
Cast wheels ............................ 6-19
Adjusting the clutch lever free
play ....................................... 6-20
Adjusting the brake pedal
position .................................. 6-21
Adjusting the rear brake light
switch .................................... 6-21
Checking the front and rear
brake pads ............................ 6-22
Checking the brake fluid
level ....................................... 6-22
Changing the brake fluid ......... 6-23
Drive chain slack ..................... 6-24
Lubricating the drive chain ...... 6-25
Checking and lubricating the
cables .................................... 6-26
Checking and lubricating the
throttle grip and cable ........... 6-26
Page 12 of 92
2-1
1
2
3
4
5
6
7
8
9
DESCRIPTION
EAU10410
Left view
12
345678
9 9 10 11 12 13 1412
345678
9 9 10 11 12 13 14
1. Front fork spring preload adjusting bolt (page 3-15)
2. Front fork damping adjusting screw (page 3-15)
3. Air filter element (page 6-14)
4. Shock absorber assembly compression damping force adjusting
knob (page 3-16)
5. Battery (page 6-29)
6. Fuses (page 6-30)
7. Storage compartment (page 3-14)8. Grab bar
9. Luggage strap holder (page 3-18)
10. Seat lock (page 3-13)
11. Shock absorber assembly rebound damping force adjusting knob
(page 3-16)
12. Shock absorber assembly spring preload adjusting ring (page 3-16)
13. Shift pedal (page 3-10)
14. Engine oil drain bolt A (page 6-7)
Page 13 of 92
DESCRIPTION
2-2
2
3
4
5
6
7
8
9
EAU10420
Right view
1234
5
6 7 8 9 10
1. Owner’s tool kit (page 6-1)
2. Coolant reservoir (page 6-10)
3. Throttle stop screw (page 6-15)
4. Front brake fluid reservoir (page 6-22)
5. Radiator cap (page 6-10)
6. Engine oil filler cap (page 6-7)
7. Engine oil filter element (page 6-7)
8. Engine oil drain bolt B (page 6-7)9. Brake pedal (page 3-11)
10. Rear brake fluid reservoir (page 6-22)
Page 17 of 92
INSTRUMENT AND CONTROL FUNCTIONS
3-3
2
34
5
6
7
8
9
left or right.
1. Push the key in from the “OFF” po-
sition, and then turn it to “LOCK”
while still pushing it.
2. Remove the key.
To unlock the steering
Push the key into the main switch, and
then turn it to “OFF” while still pushing
it.
WARNING
EWA10060
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving,
otherwise the electrical systems will
be switched off, which may result inloss of control or an accident. Make
sure that the vehicle is stopped be-
fore turning the key to “OFF” or
“LOCK”.
EAU10910
(Parking)
The steering is locked, the taillights and
auxiliary lights are on, and the hazard
light can be turned on, but all other
electrical systems are off. The key can
be removed.
The steering must be locked before the
key can be turned to “ ”.
CAUTION:
ECA11020
Do not use the parking position for
an extended length of time, other-
wise the battery may discharge.
EAU11001
Indicator and warning lights
EAU11030
Turn signal indicator lights “” and
“”
The corresponding indicator light flash-
es when the turn signal switch is
pushed to the left or right.
1. Push.
2. Turn.
1. Fuel level warning light “ ”
2. Left turn signal indicator light “ ”
3. High beam indicator light “ ”
4. Neutral indicator light “ ”
5. Engine trouble warning light “ ”
6. Right turn signal indicator light “ ”
7. Oil level warning light “ ”
8. Immobilizer system indicator light “ ”
12345678
Page 18 of 92
INSTRUMENT AND CONTROL FUNCTIONS
3-4
1
2
3
4
5
6
7
8
9
EAU11060
Neutral indicator light “”
This indicator light comes on when the
transmission is in the neutral position.
EAU11080
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU11120
Oil level warning light “”
This warning light comes on when the
engine oil level is low.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
NOTE:
Even if the oil level is sufficient, the
warning light may flicker when riding on
a slope or during sudden acceleration
or deceleration, but this is not a mal-
function.
EAU11370
Fuel level warning symbol “”
This fuel level warning symbol starts
flashing when the fuel level drops be-
low approximately 3.5 L (0.92 US gal)
(0.77 Imp.gal) .
EAU11500
Engine trouble warning light “”
This warning light comes on or flashes
when an electrical circuit monitoring the
engine is defective. When this occurs,
have a Yamaha dealer check the
self-diagnosis system.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. If the warning light does not come
on for a few seconds, then go off, have
a Yamaha dealer check the electrical
circuit.
EAU32990
Immobilizer system indicator light
“”
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have aYamaha dealer check the electrical cir-
cuit.
When the key is turned to “OFF” and 30
seconds have passed, the indicator
light will start flashing indicating the im-
mobilizer system is enabled. After 24
hours have passed, the indicator light
will stop flashing, however the immobi-
lizer system is still enabled.
NOTE:
This model is also equipped with a
self-diagnosis device for the immobiliz-
er system. If the immobilizer system is
defective, the indicator light will start
flashing a pattern and the odometer/
tripmeter will display a 2-digit code
when the key is turned to “ON”. When
this occurs, have a Yamaha dealer
check the self-diagnosis system. How-
ever, if the indicator light slowly flashes
five times, and then quickly flashes two
times repeatedly, error code 52 will be
displayed. This error could be caused
by signal interference. If this occurs, try
the following.
1. Use the code re-registering key to
Page 36 of 92
PRE-OPERATION CHECKS
4-2
1
2
3
4
5
6
7
8
9
EAU15601
Pre-operation check list
ITEM CHECKS PAGE
Fuel
Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-12
Engine oil
Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-7
Coolant
Check coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-10
Front brake
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-22
Rear brake
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-21, 6-22
Clutch
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-20
Page 38 of 92
5-1
1
2
3
4
5
6
7
8
9
OPERATION AND IMPORTANT RIDING POINTS
EAU15950
WARNING
EWA10270
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
Never 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.
Before 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.
EAU16380
Starting the engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
The transmission is in the neutral
position.
The transmission is in gear with
the clutch lever pulled and the sid-
estand up.
WARNING
EWA10290
Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-19.
Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
CAUTION:
ECA11310
The oil level warning light and en-
gine trouble warning light should
come on for a few seconds, then gooff. If a warning light does not go off,
see page 3-3 for the corresponding
warning light circuit check.
2. Shift the transmission into the neu-
tral position.
NOTE:
When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a Yama-
ha dealer check the electrical circuit.
3. Start the engine by pushing the
start switch.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt.
CAUTION:
ECA11040
For maximum engine life, never ac-
celerate hard when the engine is
Page 40 of 92
OPERATION AND IMPORTANT RIDING POINTS
5-3
1
2
3
4
5
6
7
8
9
NOTE:
When shifting down two gears at a
time, reduce the speed accordingly
(e.g., down to 35 km/h (22 mi/h) when
shifting from 5th to 3rd gear).
EAU16810
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
Shift up swiftly, and avoid high en-
gine speeds during acceleration.
Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.
Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16841
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17100
0–1,000 km (0–600 mi)
Avoid prolonged operation above 4,000
r/min.
1,000–1,600 km (600–1,000 mi)
Avoid prolonged operation above 6,000
r/min.
CAUTION:
ECA11150
After 1,000 km (600 mi) of operation,
the engine oil must be changed, and Shift up points:
1st
→
2nd: 20 km/h (12 mi/h)
2nd
→
3rd: 30 km/h (19 mi/h)
3rd
→
4th: 40 km/h (25 mi/h)
4th
→
5th: 50 km/h (31 mi/h)
5th
→
6th: 60 km/h (37 mi/h)
Page 41 of 92
OPERATION AND IMPORTANT RIDING POINTS
5-4
2
3
4
56
7
8
9
the oil filter element replaced.
1,600 km (1,000 mi) and beyond
The vehicle can now be operated nor-
mally.
CAUTION:
ECA10310
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-
cle.
EAU17211
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
WARNING
EWA10310
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.
Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
CAUTION:
ECA10380
Never park in an area where there
are fire hazards such as grass or
other flammable materials.
Page 44 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
1
2
3
4
5
6
7
8
9
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 50000 km
13
Drive chain
Check chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate.Every 1000 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 20000 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 assem-
bly
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.
√
√
√
√
√
√
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 NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040