2002 YAMAHA TDM 900 torque

6-1
6
EAU00462
6-PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
EW000060
WARNING
@ If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you. @
EAU01299
Owner’s tool kit The owner’s tool kit is located inside
the storage compartment under the
seat. (See page 3-11 for seat removal
procedures.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:@ If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you. @
EW000063
WARNING
@ Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es. @
1. Owner’s tool kit
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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. _
U5PSE0.book Page 8 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
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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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU04372
To adjust the drive chain slack
1. Loosen the axle nut, the brake cal-
iper bracket bolt and the locknut
on each side of the swingarm.
2. To tighten the drive chain, turn the
adjusting bolt on each side of the
swingarm in direction
a. To loos-
en the drive chain, turn the adjust-
ing bolt on each side of the
swingarm in direction
b, and then
push the rear wheel forward.
NOTE:_ Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same posi-
tion for proper wheel alignment. _
EC000096
CAUTION:_ Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits. _
3. Tighten the locknuts, and then
tighten the axle nut and the brake
caliper bracket bolt to the specified
torques.
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
1. Bolt
2. Brake caliper bracket
Tightening torque:
Axle nut:
150 Nm (15.0 m·kgf)
Brake caliper bracket bolt:
40 Nm (4.0 m·kgf)
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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)
U5PSE0.book Page 41 Thursday, December 13, 2001 4:29 PM