2002 YAMAHA TDM 900 fuel
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OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EAU03952
Tips for reducing fuel
consumption Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
Thoroughly warm up the engine.
Shift up swiftly, and avoid high en-
gine speeds during acceleration.
Do not rev the engine while shift-
ing 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 traf-
fic lights or at railroad crossings).
EAU01128
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1,600 km. For this rea-
son, you should read the following ma-
terial carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,600 km. The various parts in the en-
gine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full-throttle oper-
ation or any condition that might result
in engine overheating must be avoided.
EAU04315
0–1,000 km
Avoid prolonged operation above
4,000 r/min.
1,000–1,600 km
Avoid prolonged operation above
6,000 r/min.
ECA00058
CAUTION:_ After 1,000 km of operation, the en-
gine oil must be changed, and the
oil filter element replaced. _1,600 km and beyond
The vehicle can now be operated nor-
mally.
EC000053
CAUTION:_
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.
_
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Page 47 of 110
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_
CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel lineCheck fuel hoses for cracks or damage.√√√√ √
2 Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.Every 40,000 km
4 Air filter elementReplace.√
5ClutchCheck operation.
Adjust.√√√√√
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
9*WheelsCheck runout and for damage.√√√√
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
10
*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearingsCheck bearing for looseness or damage.√√√√
12*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50,000 km
13 Drive chainCheck 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 bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20,000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.√√√√ √
16 SidestandCheck operation.
Lubricate.√√√√ √
17*Sidestand switchCheck operation.√√√√√ √
18*Front forkCheck operation and for oil leakage.√√√√
19*Shock absorber
assemblyCheck operation and shock absorber for oil leakage.√√√√
20*Rear suspension relay
arm and connecting arm
pivoting pointsCheck operation.√√√√
Lubricate with lithium-soap-based grease.√√
21*Electronic fuel injectionAdjust engine idling speed and synchronization.√√√√√ √
22 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
23 Engine oil filter elementReplace.√√√
24*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
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Page 58 of 110
PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
EC000080
CAUTION:_
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
_
EW000067
WARNING
_ Never attempt to remove the radia-
tor cap when the engine is hot. _
NOTE:_
The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.
If the engine overheats, see page
6-44 for further instructions.
_
EAU04461
To change the coolant
1. Place the motorcycle on a level
surface and let the engine cool if
necessary.
2. Remove the seat. (See page 3-11
for seat removal and installation
procedures.)
3. Remove cowling B and panel B.
(See pages 6-5 and 6-6 for cowl-
ing and panel removal and instal-
lation procedures.)
4. Remove the fuel tank bolts, and
then lift the fuel tank to position it
away from the coolant reservoir.
(Do not disconnect the fuel hos-
es!)
5. Place a container under the en-
gine to collect the used coolant.
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Page 60 of 110
PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
613. Install the coolant drain bolts, and
then tighten them to the specified
torque.
NOTE:_ Check the washers for damage and re-
place them if necessary. _14. Pour the recommended coolant
into the radiator until it is full.
EC000080
CAUTION:_
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
_15. Install the radiator cap, start the
engine, let it idle for several min-
utes, and then turn it off.
16. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radia-
tor, and then install the radiator
cap and the cap retaining bolt.
17. Check the coolant level in the res-
ervoir. If necessary, remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the cap.
18. Install the fuel tank. Tightening torque:
Coolant drain bolt:
7 Nm (0.7 m·kgf)
Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Coolant quantity:
Total amount:
1.7 L
Coolant reservoir capacity:
0.3 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6
EWA00052
WARNING
_
Before installing the fuel tank,
make sure that the fuel hoses
are not damaged. If any fuel
hose is damaged, do not start
the engine but have a Yamaha
dealer replace the hose, other-
wise fuel may leak.
Make sure that the fuel hoses
are properly connected and
routed, and not pinched.
Be sure to place the fuel tank
breather hose in the original po-
sition.
_19. Install the panel, the cowling, and
the seat.
20. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
EAU04431*
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the seat. (See page 3-11
for seat removal and installation
procedures.)
2. Remove cowlings A and B as well
as panels A and B. (See pages 6-5
and 6-6 for cowling and panel re-
moval and installation proce-
dures.)3. Remove the fuel tank bolts, and
then lift the fuel tank away from the
air filter case.
4. Remove the air filter case cover by
removing the screws.
5. Pull the air filter element out.1. Bolt (× 2 on each side)
1. Air filter case cover
2. Screw (× 8)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
66. Insert a new air filter element into
the air filter case.
EC000082*
CAUTION:_
Make sure that the air filter ele-
ment is properly seated in the
air filter case.
The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
pistons and/or cylinders may
become excessively worn.
_
7. Install the air filter case cover by
installing the screws.
8. Place the fuel tank in the original
position and install the bolts.
EWA00013
WARNING
_ Make sure that the fuel hose and
breather hose are properly connect-
ed and routed, and not pinched. Re-
place any damaged hoses. _9. Install the panels and cowlings.
10. Install the seat.
EAU00632
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Start the engine and warm it up for
several minutes at 1,000–
2,000 r/min while occasionally rev-
ving it to 4,000–5,000 r/min.NOTE:@ The engine is warm when it quickly re-
sponds to the throttle. @
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6 2. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di-
rection
a. To decrease the engine
idling speed, turn the screw in di-
rection
b.
NOTE:@ If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment. @
EAU00635
Adjusting the throttle cable
free play The throttle cable free play should
measure 3–5 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
EAU00637
Adjusting the valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Throttle stop screw
Engine idling speed:
1,100–1,200 r/min
a. Throttle cable free play
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