2002 YAMAHA TDM 900 wheel bolts

PRE-OPERATION CHECKS
4-2
4
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-28
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-26
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-19–6-21
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-29
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-29
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-30
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-17 ITEM CHECKS PAGE
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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
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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
6-40
6 1. Remove the drive chain cover by
removing the quick fasteners and
the bolts.2. Loosen the axle nut and the brake
caliper bracket bolt.
3. Lift the rear wheel off the ground
according to the procedure on
page 6-39.4. Remove the axle nut.
5. Loosen the locknut on each side of
the swingarm.
6. Turn the drive chain slack adjust-
ing bolts fully in direction
a.
7. Push the wheel forward, tighten
the caliper bracket bolt and then
remove the drive chain from the
rear sprocket.
NOTE:_ The drive chain does not need to be
disassembled in order to remove and
install the rear wheel. _
1. Quick fastener
2. Pin
After removal
Before installation
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
1. Bolt
2. Brake caliper bracket
U5PSE0.book Page 40 Thursday, December 13, 2001 4:29 PM

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