2002 YAMAHA TDM 900 oil level

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
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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

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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
10
*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearingsCheck bearing for looseness or damage.√√√√
12*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50,000 km
13 Drive chainCheck chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate.Every 1,000 km and after washing
the motorcycle or riding in the rain
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20,000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.√√√√ √
16 SidestandCheck operation.
Lubricate.√√√√ √
17*Sidestand switchCheck operation.√√√√√ √
18*Front forkCheck operation and for oil leakage.√√√√
19*Shock absorber
assemblyCheck operation and shock absorber for oil leakage.√√√√
20*Rear suspension relay
arm and connecting arm
pivoting pointsCheck operation.√√√√
Lubricate with lithium-soap-based grease.√√
21*Electronic fuel injectionAdjust engine idling speed and synchronization.√√√√√ √
22 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
23 Engine oil filter elementReplace.√√√
24*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
U5PSE0.book Page 3 Thursday, December 13, 2001 4:29 PM

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
U5PSE0.book Page 9 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