2002 YAMAHA TDM 900 lock

INSTRUMENT AND CONTROL FUNCTIONS
3-11
3
EAU02925
Seat To remove the seat
Insert the key into the seat lock, turn it
counterclockwise, and then pull the
seat off.To install the seat
Insert the projections on the front of the
seat into the seat holder, push the rear
of the seat down to lock it in place, and
then remove the key.
NOTE:_ Make sure that the seat is properly se-
cured before riding. _
EAU04292
Storage compartment This storage compartment is designed
to hold an optional genuine Yamaha U-
LOCK. (Other locks may not fit.) When
placing a U-LOCK in the storage com-
partment, securely fasten it with the
straps. When the U-LOCK is not in the
storage compartment, be sure to se-
cure the straps to prevent losing them.
1. Seat lock
2. Unlock.
1. Projection (× 2)
2. Seat holder (× 2)
1. U-LOCK (optional)
2. Strap
U5PSE0.book Page 11 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EAU00692
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10–15 mm as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.
1. Loosen the locknut at the clutch le-
ver.
2. To increase the clutch lever free
play, turn the adjusting bolt in di-
rection
a. To decrease the clutch
lever free play, turn the adjusting
bolt in direction
b.
3. Tighten the locknut.
NOTE:@ If the specified free play cannot be ob-
tained as described above or if the
clutch does not operate correctly, have
a Yamaha dealer check the internal
clutch mechanism. @
1. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play
U5PSE0.book Page 22 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU03294
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake sys-
tem for leakage.Observe these precautions:


When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Minimum level markFront brake
1. Minimum level mark
Recommended brake fluid: DOT 4Rear brake
U5PSE0.book Page 25 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU04372
To adjust the drive chain slack
1. Loosen the axle nut, the brake cal-
iper bracket bolt and the locknut
on each side of the swingarm.
2. To tighten the drive chain, turn the
adjusting bolt on each side of the
swingarm in direction
a. To loos-
en the drive chain, turn the adjust-
ing bolt on each side of the
swingarm in direction
b, and then
push the rear wheel forward.
NOTE:_ Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same posi-
tion for proper wheel alignment. _
EC000096
CAUTION:_ Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits. _
3. Tighten the locknuts, and then
tighten the axle nut and the brake
caliper bracket bolt to the specified
torques.
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
1. Bolt
2. Brake caliper bracket
Tightening torque:
Axle nut:
150 Nm (15.0 m·kgf)
Brake caliper bracket bolt:
40 Nm (4.0 m·kgf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6
EC000102
CAUTION:@

Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.


To charge a sealed-type (MF)
battery, a special (constant-
voltage) battery charger is re-
quired. Using a conventional
battery charger will damage the
battery. If you do not have ac-
cess to a sealed-type (MF) bat-
tery charger, have a Yamaha
dealer charge your battery.
@
EAU04482*
Replacing the fuses The main fuse and the fuse box, which
contains the fuses for the individual cir-
cuits, are located under the seat. (See
page 3-11 for seat removal and instal-
lation procedures.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
EC000103
CAUTION:_ Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire. _
1. Backup fuse (odometer and clock)
2. Radiator fan fuse
3. Turn signal and hazard light fuse
4. Ignition fuse
5. Signaling system fuse
6. Headlight fuse
7. Spare fuse (× 4)
8. Parking lighting fuse
9. Electronic Fuel Injection System fuse
10. Main fuse
Specified fuses:
Main fuse: 40 A
Headlight fuse: 15 A
Signaling system fuse: 7.5 A
Radiator fan fuse: 20 A
Ignition fuse: 10 A
Backup fuse (odometer
and clock): 5 A
Turn signal and hazard
light fuse: 10 A
Parking lighting fuse: 5 A
Electronic Fuel Injection
System fuse: 10 A
U5PSE0.book Page 34 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6
EC000105
CAUTION:_ 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 af-
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner. _4. Install the headlight bulb cover,
and then connect the coupler.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU04411
Replacing a tail/brake light
bulb 1. Remove the seat. (See page 3-11
for seat removal and installation
procedures.)
2. Remove the socket (together with
the bulb) by turning it counter-
clockwise.
3. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
4. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.5. Install the socket (together with
the bulb) by turning it clockwise.
6. Install the seat.
1. Do not touch this area.
1. Socket
U5PSE0.book Page 36 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
6
EAU03497
Replacing a turn signal light
bulb 1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.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
CAUTION:@ Do not overtighten the screw, other-
wise the lens may break. @
EAU01579
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte-
nance 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 un-
der the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
1. Screw
2. Turn signal light lens
1. Turn signal light bulb
U5PSE0.book Page 37 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-40
6 1. Remove the drive chain cover by
removing the quick fasteners and
the bolts.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 6-39.4. 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. Quick fastener
2. Pin
After removal
Before installation
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
1. Bolt
2. Brake caliper bracket
U5PSE0.book Page 40 Thursday, December 13, 2001 4:29 PM