2002 YAMAHA TDM 900 maintenance

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU01139
Removing and installing
cowlings and panels The cowlings and panels shown above
need to be removed to perform some
of the maintenance jobs described in
this chapter. Refer to this section each
time a cowling or panel needs to be re-
moved and installed.
EAU04039*
Cowling A and B
To remove one of the cowlingsRemove the screws and the quick fas-
tener, and then pull the cowling off as
shown.NOTE:_ The quick fastener is removed by push-
ing the center pin in with a screwdriver,
then pulling the fastener out. _To install the cowlingPlace the cowling in the original posi-
tion, and then install the screws and the
quick fastener.
1. Cowling A
2. Panel A
1. Cowling B
2. Panel B
1. Screw (× 6)
2. Quick fastener
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
NOTE:_

Make sure that the projection fits
into the grommet.


To install the quick fastener, push
the center pin out so that it will pro-
trude from the fastener head, in-
sert the fastener into the cowling,
and then push the protruding pin in
until it is flush with the fastener
head.
_
EAU03317
Panels A and B
To remove one of the panels1. Remove the corresponding cowl-
ing A or B. (See page 6-5 for cowl-
ing removal and installation
procedures.)
2. Remove the seat. (See page 3-11
for seat removal and installation
procedures.)
3. Remove the screw, and then take
the panel off.To install the panel
1. Place the panel in the original po-
sition, and then install the screw.
2. Install the seat and the cowling.
1. Quick fastener
2. Pin
After removal
Before installation
1. Screw
1. Panel B
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
EAU01880
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal col-
or when the motorcycle is ridden nor-
mally), and all spark plugs installed in
the engine should have the same color.
If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads. Specified spark plug:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
a. Spark plug gap
Spark plug gap:
0.8–0.9 mm
Tightening torque:
Spark plug:
18 Nm (1.8 m·kgf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
NOTE:_ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. _
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
EAU04429
Engine oil and oil filter
element The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _2. Start the engine, warm it up for
15 minutes, and then turn it off.3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in and with the arrow
mark pointing upward as shown),
and then remove it again to check
the oil level.
NOTE:_ The engine oil should be between the
minimum and maximum level marks. _
EC000000
CAUTION:_ Do not operate the motorcycle until
you know that the engine oil level is
sufficient. _
EW000065
WARNING
_ Never remove the engine oil tank
cap after high-speed operation, oth-
erwise hot engine oil could spout
out and cause damage or injury. Al-
ways let the engine oil cool down
sufficiently before removing the oil
tank cap. _
1. Oil filler cap
1. Oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Install the oil filler cap.
NOTE:_

The engine oil tank is located be-
hind the cylinders.


The engine oil should be between
the minimum and maximum level
marks.
_
To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolts to drain the oil from
the crankcase.NOTE:_ Skip steps 4–6 if the oil filter element is
not being replaced. _
4. Remove the oil filter element cover
by removing the bolts.
1. Engine oil drain bolt A
1. Engine oil drain bolt B
2. Oil filter element cover
3. Bolt (× 5)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
65. Remove and replace the oil filter
element and O-rings.
6. Install the oil filter element cover
by installing the bolts, then tighten-
ing them to the specified torque.
NOTE:_ Make sure that the O-rings are properly
seated. _7. Install the engine oil drain bolts,
and then tighten them to the spec-
ified torques.8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
EC000072
CAUTION:_

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of a higher
grade than “CD”. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign mate-
rial enters the crankcase.
_9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
1. Oil filter element
2. O-ring (× 2)Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf)
Tightening torques:
Engine oil drain bolt A:
35 Nm (3.5 m·kgf·)
Engine oil drain bolt B:
30 Nm (3.0 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
3.8 L
With oil filter element
replacement:
3.9 L
Total amount (dry engine):
4.7 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
EAU04298
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
To check the coolant level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:_

The coolant level must be checked
on a cold engine since the level
varies with engine temperature.


Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A slight
tilt to the side can result in a false
reading.
_
2. Check the coolant level in the
coolant reservoir.NOTE:_ The coolant should be between the
minimum and maximum level marks. _
3. If the coolant is at or below the
minimum level mark, remove
panel B (See page 6-6 for panel
removal and installation proce-
dures.), remove the reservoir cap,
add coolant to the maximum level
mark, and then install the reservoir
cap and the panel.
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
1. Coolant reservoir capCoolant reservoir capacity:
0.3 L
U5PSE0.book Page 12 Thursday, December 13, 2001 4:29 PM