2002 YAMAHA TDM 900 Brake pads

6
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 ............................ 6-9
Coolant .............................................................. 6-12
Cleaning 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 ................................................................... 6-19
Adjusting the clutch lever free play .................... 6-22
Adjusting the brake pedal position ..................... 6-23
Adjusting the rear brake light switch .................. 6-23
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 ................................................ 6-26
Lubricating the drive chain ................................. 6-28
Checking and lubricating the cables .................. 6-28Checking and lubricating the throttle grip and
cable ............................................................... 6-29
Checking and lubricating the brake and
shift pedals ...................................................... 6-29
Checking and lubricating the brake and
clutch levers .................................................... 6-29
Checking and lubricating the sidestand ............ 6-30
Lubricating the rear suspension ........................ 6-30
Checking the front fork ...................................... 6-31
Checking the steering ....................................... 6-31
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 ........................ 6-36
Replacing a turn signal light bulb ...................... 6-37
Supporting the motorcycle ................................ 6-37
Front wheel ....................................................... 6-38
Rear wheel ........................................................ 6-39
Troubleshooting ................................................. 6-42
Troubleshooting charts ...................................... 6-43
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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
6-24
6
EAU00715
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart. Each brake pad is
provided with a wear indicator, which
allows you to check the brake pad wear
without having to disassemble the
brake. To check the brake pad wear, check
the position of the wear indicator while
applying the brake. If a brake pad has
worn to the point that the wear indicator
almost touches the brake disc, have a
Yamaha dealer replace the brake pads
as a set. 1. Brake pad wear indicator grooveFront brake
1. Brake pad wear indicator grooveRear brake
U5PSE0.book Page 24 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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6 To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU01617
Front wheel To remove the front wheel
EW000122
WARNING
_

It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Loosen the front wheel axle pinch
bolt, then the brake caliper bolts.
2. Loosen the wheel axle with a 19-mm
hexagon wrench.3. Lift the front wheel off the ground
according to the procedure on
page 6-37.
4. Remove the brake hose holders
by removing the bolts.
5. Remove the brake calipers by re-
moving the bolts.
6. Pull the wheel axle out, and then
remove the wheel.
ECA00046
CAUTION:_ Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut. _
1. Wheel axle
2. Front wheel axle pinch bolt
1. Bolt (× 2)
2. Brake caliper
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6
EAU04376
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Lower the front wheel so that it is
on the ground.
4. Install the brake calipers by install-
ing the bolts.NOTE:_ Make sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs. _5. Install the brake hose holders by
installing the bolts.
6. Tighten the wheel axle, the front
wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.7. Push down hard on the handlebar
several times to check for proper
fork operation.
EAU04455
Rear wheel To remove the rear wheel
EW000122
WARNING
_

It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no danger
of it falling over.
_
Tightening torques:
Wheel axle:
72 Nm (7.2 m·kgf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf)
Brake caliper bolt:
40 Nm (4.0 m·kgf)
1. Bolt (× 2)
2. Quick fastener (× 3)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-41
68. Pull the wheel axle out, and then
remove the wheel.
ECA00119
CAUTION:_ Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake caliper pistons will be forced
out. _
EAU04456
To install the rear wheel
1. Install the wheel by inserting the
wheel axle from the right hand
side.NOTE:_ Make sure that there is enough space
between the brake pads before install-
ing the wheel. _2. Install the drive chain onto the rear
sprocket.
3. Loosen the brake caliper bracket
bolt.
4. Adjust the drive chain slack. (See
page 6-27 for drive chain slack ad-
justment procedures.)
5. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.
6. Tighten the axle nut and the brake
caliper bracket bolt to the specified
torques.7. Install the drive chain cover by in-
stalling the bolts and quick fasten-
ers.
NOTE:_ To install a quick fastener, push the pin
back so that it will protrude from the
fastener head, and then insert the fas-
tener and push the protruding pin in un-
til it is flush with the fastener head. _
Tightening torques:
Axle nut:
150 Nm (15.0 m·kgf)
Brake caliper bracket bolt:
40 Nm (4.0 m·kgf)
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10-INDEXAAir filter element, cleaning ...................... 6-16
Anti-theft alarm ........................................3-6BBattery ................................................... 6-33
Brake and clutch levers, checking and
lubricating ............................................ 6-29
Brake and shift pedals, checking and
lubricating ............................................ 6-29
Brake fluid, changing ............................. 6-26
Brake fluid level, checking...................... 6-25
Brake lever...............................................3-8
Brake light switch (rear), adjusting ......... 6-23
Brake pads, checking............................. 6-24
Brake pedal..............................................3-8
Brake pedal position, adjusting .............. 6-23CCables, checking and lubricating............ 6-28
Care.........................................................7-1
Clutch lever ..............................................3-7
Clutch lever free play, adjusting ............. 6-22
Conversion table ......................................8-5
Coolant .................................................. 6-12
Changing .......................................... 6-13
Checking .......................................... 6-12
Coolant temperature gauge .....................3-5
Cowlings and panels, removing and
installing ................................................6-5DDimmer switch .........................................3-6
Drive chain, lubricating ........................... 6-28
Drive chain slack ................................... 6-26
Adjusting .......................................... 6-27
Checking .......................................... 6-26EEngine break-in ....................................... 5-4
Engine oil and oil filter element ................ 6-9
Engine stop switch................................... 3-7
Engine trouble warning light .................... 3-3FFront fork, adjusting ............................... 3-13
Front fork, checking ............................... 6-31
Fuel ......................................................... 3-9
Fuel consumption, tips for reducing ......... 5-4
Fuel level warning symbol ....................... 3-2
Fuel tank breather hose
(Germany only) ................................... 3-10
Fuel tank cap ........................................... 3-9
Fuses, replacing .................................... 6-34HHandlebar switches ................................. 3-6
Hazard switch .......................................... 3-6
Headlight bulb, replacing ....................... 6-35
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-6IIdentification numbers ............................. 9-1
Idling speed, adjusting ........................... 6-17
Ignition circuit cut-off system.................. 3-18
Indicator and warning lights ..................... 3-2
KKey identification number .........................9-1LLight switch ..............................................3-7
Luggage strap holders ...........................3-17MMain switch/steering lock .........................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-2OOil level warning light ...............................3-3PParking.....................................................5-5
Part locations ...........................................2-1
Pass switch ..............................................3-6
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list ............................4-1RRear suspension, lubricating ..................6-30SSafety information ....................................1-1
Seat .......................................................3-11
Shifting .....................................................5-3
Shift pedal ................................................3-8
Shift points (for Switzerland only) .............5-3
Shock absorber assembly, adjusting ......3-15
Sidestand ...............................................3-17
U5PSE0.book Page 1 Thursday, December 13, 2001 4:29 PM