2003 YAMAHA TDM 900 coolant level

4-1
EAU01114
PRE-OPERATION CHECKS
4The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
EAU03439
Pre-operation check listPre-operation check list
ITEM CHECKS PAGE
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-10–3-12
Engine oil•Check oil level in engine.
•If necessary, add recommended oil to specified level.
•Check vehicle for oil leakage.6-8–6-11
Coolant•Check coolant level in reservoir.
•If necessary, add recommended coolant to specified level.
•Check cooling system for leakage.6-11–6-15
Front brake•Check 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.3-9–3-10, 6-24–6-26
Rear brake•Check 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.3-10, 6-23–6-26
Clutch•Check operation.
•Lubricate cable if necessary.
•Check lever free play.
•Adjust if necessary.3-9, 6-22–6-23
5PS-28199-E1 8/29/02 9:16 AM Page 36

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 ............................6-8
Coolant ...............................................................6-11
Replacing 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 ...................................................................6-18
Cast wheels ........................................................6-22
Adjusting the clutch lever free play .....................6-22
Adjusting the brake pedal position .....................6-23
Adjusting the rear brake light switch ...................6-24
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 ................................................6-27
Lubricating the drive chain .................................6-28
Checking and lubricating the cables ...................6-29
Checking and lubricating the throttle grip
and cable .........................................................6-29Checking and lubricating the brake and
shift pedals ......................................................6-30
Checking and lubricating the brake and
clutch levers ....................................................6-30
Checking and lubricating the sidestand ..............6-30
Lubricating the rear suspension .........................6-31
Checking the front fork .......................................6-31
Checking the steering .........................................6-32
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 .........................6-37
Replacing a turn signal light bulb .......................6-37
Supporting the motorcycle ..................................6-38
Front wheel .........................................................6-39
Rear wheel .........................................................6-40
Troubleshooting ..................................................6-43
Troubleshooting charts .......................................6-44
6
5PS-28199-E1 8/29/02 9:16 AM Page 45

6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03884
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
9Replace the brake hoses every four years and if cracked or damaged.
22 Engine oil•Change.
•Check oil level and vehicle for oil leakage.√√√√√ √
23 Engine oil filter element•Replace.√√√
24
*Cooling system•Check coolant level and vehicle for coolant leakage.√√√√ √
•Change.Every 3 years
25
*Front and rear brake
switches•Check operation.√√√√√ √
26 Moving parts and cables•Lubricate.√√√√ √
27
*Throttle grip housing
and cable•Check operation and free play.
•Adjust the throttle cable free play if necessary.
•Lubricate the throttle grip housing and cable.√√√√ √
28
*Air induction system•Check the air cut-off valve, reed valve, and hose for
damage.
•Replace the entire air induction system if necessary.√√√√ √
29
*Muffler and exhaust pipe•Check the screw clamp for looseness.√√√√√
30
*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
5PS-28199-E1 8/29/02 9:16 AM Page 49

6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
6
ECA00133
cC
8In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives.
Do not use oils with a diesel
specification of “CD” or oils of
a higher quality than specified.
In addition, do not use oils
labeled “ENERGY CONSERV-
ING II” or higher.
8Make sure that no foreign
material 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.2. Check the coolant level in the
coolant reservoir.
NOTE:
The coolant should be between the
minimum and maximum level marks.
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
EAU04879
CoolantCoolantThe coolant level should be checked
before each ride. In addition, the
coolant must be changed at the inter-
vals specified in the periodic mainte-
nance and lubrication chart.
To check the coolant level
Checking1. Place the motorcycle on the cen-
terstand.
NOTE:
8The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
8Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
5PS-28199-E1 8/29/02 9:16 AM Page 56

6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. If the coolant is at or below the
minimum level mark, remove
panel B (See page 6-6 for panel
removal and installation proce-
dures.), remove the reservoir
cap, add coolant to the maximum
level mark, and then install the
reservoir cap and the panel.
1. Coolant reservoir cap
EW000067
w
Never attempt to remove the radia-
tor cap when the engine is hot.
NOTE:
8The radiator fan is automatically
switched on or off according to
the coolant temperature in the
radiator.
8If the engine overheats, see
page 6-45 for further instructions.
EC000080
cC
8If 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.
8If water has been used instead
of coolant, replace it with
coolant as soon as possible,
otherwise the engine may not
be sufficiently cooled and the
cooling system will not be pro-
tected against frost and corro-
sion.
8If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possi-
ble, otherwise the effective-
ness of the coolant will be
reduced.
Coolant reservoir capacity
(up to the maximum level mark):
0.25 L
5PS-28199-E1 8/29/02 9:16 AM Page 57

6-13
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04461
To change the coolantChanging1. Place the motorcycle on a level
surface and let the engine cool if
necessary.
2. Remove the seat. (See page
3-13 for seat removal and instal-
lation procedures.)
3. Remove cowling B and panel B.
(See pages 6-5 and 6-6 for cowl-
ing and panel removal and instal-
lation procedures.)
4. Remove the fuel tank bolts, and
then lift the fuel tank to position it
away from the coolant reservoir.
(Do not disconnect the fuel
hoses!)
5. Place a container under the
engine to collect the used
coolant.7. Remove the coolant drain bolts
to drain the cooling system.
11
1. Coolant drain bolt (×2)
6. Remove the radiator cap retain-
ing bolt and the radiator cap.
EW000067
w
Never attempt to remove the radia-
tor cap when the engine is hot.
1. Radiator cap retaining bolt
2. Radiator cap
5PS-28199-E1 8/29/02 9:16 AM Page 58

6-15
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EC000080
cC
8If 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.
8If water has been used instead
of coolant, replace it with
coolant as soon as possible,
otherwise the engine may not
be sufficiently cooled and the
cooling system will not be pro-
tected against frost and corro-
sion.
8If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possi-
ble, otherwise the effective-
ness of the coolant will be
reduced.
EWA00052
w
8Before installing the fuel tank,
make sure that the fuel hoses
are not damaged. If any fuel
hose is damaged, do not start
the engine but have a Yamaha
dealer replace the hose, other-
wise fuel may leak.
8Make sure that the fuel hoses
are properly connected and
routed, and not pinched.
8Be sure to place the fuel tank
breather hose in the original
position.
19. Install the panel, the cowling,
and the seat.
20. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a
Yamaha dealer check the cool-
ing system. 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 suffi-
cient coolant until it reaches the
top of the radiator, and then
install the radiator cap and the
cap retaining bolt.
17. Check the coolant level in the
reservoir. If necessary, remove
the coolant reservoir cap, add
coolant to the maximum level
mark, and then install the cap.
18. Install the fuel tank.
5PS-28199-E1 8/29/02 9:16 AM Page 60

6-45
6Engine overheating
EW000070
w
8Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
8After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the
hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the
cap.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
Wait until the
engine has cooled.Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.
The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.
Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.
5PS-28199-E1 8/29/02 9:17 AM Page 90