2002 YAMAHA TDM 900 drain bolt

2-1
2
EAU00026
2-DESCRIPTION Left view1. Front fork spring preload adjusting bolt (page 3-13)
2. Front fork damping force adjusting screw (page 3-14)
3. Air filter element (page 6-16)
4. Shock absorber assembly spring
preload adjusting ring (page 3-15)
5. Battery (page 6-33)
6. Fuses (page 6-34)
7. Storage compartment (page 3-11)
8. Grab bar9. Luggage strap holder (page 3-17)
10. Seat lock (page 3-11)
11. Shock absorber assembly rebound
damping force adjusting knob (page 3-15)
12. Shock absorber assembly compression
damping force adjusting knob (page 3-16)
13. Shift pedal (page 3-8)
14. Engine oil drain bolt A (page 6-10)
U5PSE0.book Page 1 Thursday, December 13, 2001 4:29 PM

DESCRIPTION
2-2
2
Right view15. Tool kit (page 6-1)
16. Coolant reservoir (page 6-12)
17. Throttle stop screw (page 6-18)
18. Front brake master cylinder (page 6-25)
19. Radiator cap (page 6-14)20. Engine oil filler cap (page 6-9)
21. Engine oil filter element (page 6-11)
22. Engine oil drain bolt B (page 6-10)
23. Brake pedal (page 3-8)
24. Rear brake fluid reservoir (page 6-25)
U5PSE0.book Page 2 Thursday, December 13, 2001 4:29 PM

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)
U5PSE0.book Page 10 Thursday, December 13, 2001 4:29 PM

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
U5PSE0.book Page 11 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6 6. Remove the radiator cap retaining
bolt and the radiator cap.
EW000067
WARNING
_ Never attempt to remove the radia-
tor cap when the engine is hot. _
7. Remove the coolant drain bolts to
drain the cooling system.8. Remove the coolant reservoir bolt.
9. Pull the coolant reservoir upward
and away from the motorcycle.
10. Drain the remaining coolant from
the coolant reservoir by opening
the cap, then turning the reservoir
upside down.
11. Install the coolant reservoir by
placing it in the original position,
and then installing the bolt.
12. After the coolant is completely
drained, thoroughly flush the cool-
ing system with clean tap water.
1. Radiator cap retaining bolt
2. Radiator cap
1. Coolant drain bolt (× 2)
1. Bolt
2. Coolant reservoir
U5PSE0.book Page 14 Thursday, December 13, 2001 4:29 PM

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
U5PSE0.book Page 15 Thursday, December 13, 2001 4:29 PM