2002 YAMAHA TDM 900 oil

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

INSTRUMENT AND CONTROL FUNCTIONS
3-2
3
EAU01590
(Parking)
The steering is locked, and the taillight
and auxiliary light are on, but all other
electrical systems are off. The key can
be removed.
The steering must be locked before the
key can be turned to “”.
ECA00043
CAUTION:_ Do not use the parking position for
an extended length of time, other-
wise the battery may discharge. _
EAU03034
Indicator and warning lights
EAU04478
Fuel level warning symbol “”
This fuel level warning symbol starts
flashing when the fuel level drops be-
low approximately 3.5 L.
EAU04121
Turn signal indicator lights “”
and “”
The corresponding indicator light flash-
es when the turn signal switch is
pushed to the left or right.
EAU00063
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU00061
Neutral indicator light “”
This indicator light comes on when the
transmission is in the neutral position.
1. Fuel level warning symbol “”
2. Left turn signal indicator light “”
3. High beam indicator light “”
4. Neutral indicator light “”
5. Engine trouble warning light “”
6. Right turn signal indicator light “”
7. Oil level warning light “”
U5PSE0.book Page 2 Thursday, December 13, 2001 4:29 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-3
3
EAU04238
Engine trouble warning light “”
This warning light comes on or flashes
when an electrical circuit monitoring
the engine is defective. When this oc-
curs, have a Yamaha dealer check the
self-diagnosis system.NOTE:_ This warning light comes on for a few
seconds when the key is turned to
“ON”, but this does not indicate a mal-
function. _
EAU04301
Oil level warning light “”
This warning light comes on when the
engine oil level is low.
The electrical circuit of the warning light
can be checked according to the fol-
lowing procedure.
1. Turn the key to “ON”.
2. If the warning light does not come
on for a few seconds, then go off,
have a Yamaha dealer check the
electrical circuit.
NOTE:_ Even if the oil level is sufficient, the
warning light may flicker when riding on
a slope or during sudden acceleration
or deceleration, but this is not a mal-
function. _
EAU04428*
Speedometer unit The speedometer unit is equipped with
the following:

a digital speedometer (which
shows riding speed)


an odometer (which shows the to-
tal distance traveled)


two tripmeters (which show the
distance traveled since they were
last set to zero)


a fuel reserve tripmeter (which
shows the distance traveled on the
fuel reserve)
1. Speedometer
2. Odometer/tripmeter
3.“SELECT” button
4.“RESET” button
5. Fuel gauge
U5PSE0.book Page 3 Thursday, December 13, 2001 4:29 PM

4-1
4
EAU01114
4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03439
Pre-operation check list
CO-01E
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-9–3-10
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-9
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-12–6-13
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-24–6-26
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-23–6-26
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-22
Throttle gripMake sure that operation is smooth.
Check free play.
If necessary, have Yamaha dealer make adjustment or lubricate.6-18
U5PSE0.book Page 1 Thursday, December 13, 2001 4:29 PM

5-1
5
EAU00372
5-OPERATION AND IMPORTANT RIDING POINTS
EAU00373
WARNING
@

Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.


Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.


Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
@
EAU03951
Starting the engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.


The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
WARNING
_

Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-19.


Never ride with the sidestand
down.
_1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
ECA00083
CAUTION:_ The oil level warning light and en-
gine trouble warning light should
come on for a few seconds, then go
off. If a warning light does not go off,
see pages 3-2 and 3-3 for the corre-
sponding warning light circuit
check. _2. Shift the transmission into the neu-
tral position.NOTE:_ When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir-
cuit. _3. Start the engine by pushing the
start switch.
U5PSE0.book Page 1 Thursday, December 13, 2001 4:29 PM

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

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
U5PSE0.book Page 1 Thursday, December 13, 2001 4:29 PM