2003 YAMAHA TDM 900 torque

6-1
EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. The most important
points of inspection, adjustment, and
lubrication are explained on the fol-
lowing pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a
general guide under normal riding
conditions. However, DEPENDING
ON THE WEATHER, TERRAIN,
GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTE-
NANCE INTERVALS MAY NEED TO
BE SHORTENED.
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If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you.
NOTE:
If you do not have the tools or experi-
ence required for a particular job,
have a Yamaha dealer perform it for
you.
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Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle
unsafe for use. Consult a Yamaha
dealer before attempting any
changes.
EAU01299
Owner’s tool kitTool kitThe owner’s tool kit is located inside
the storage compartment under the
seat. (See page 3-13 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 pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be nec-
essary to perform certain mainte-
nance work correctly.
1. Owner’s tool kit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01880
Checking the spark plugsSpark plugs, checkingThe 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 maintenance and
lubrication chart. In addition, the con-
dition of the spark plugs can reveal
the condition of the engine.
The porcelain insulator around the
center electrode of each spark plug
should be a medium-to-light tan (the
ideal color when the motorcycle is rid-
den normally), and all spark plugs
installed in the engine should have
the same color. If any spark plug
shows a distinctly different color, the
engine could be defective. Do not
attempt to diagnose such problems
yourself. Instead, have a Yamaha
dealer check the motorcycle.Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
a. Spark plug gap
If a spark plug shows signs of elec-
trode 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.
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf)
Specified spark plug:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
Spark plug gap:
0.8–0.9 mm
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PERIODIC MAINTENANCE AND MINOR REPAIR
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 specified torque as
soon as possible.
3. Wait a few minutes until the oil
settles, remove the oil filler cap,
wipe the dipstick clean, insert it
back into the oil filler hole (with-
out 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.
1. Oil filler cap
EAU04619
Engine oil and oil filter
element
Engine oil and oil filter elementThe engine oil level should be
checked before each ride. In addition,
the oil must be changed and the oil
filter element replaced at the intervals
specified in the periodic maintenance
and lubrication 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
positioned 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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6 4. Remove the oil filter element
cover by removing the bolts.
1. Engine oil drain bolt B
2. Oil filter element cover
3. Bolt (×5)
7. Install the engine oil drain bolts,
and then tighten them to the
specified torques.
8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil
filler cap. 5. Remove and replace the oil filter
element and O-rings.
6. Install the oil filter element cover
by installing the bolts, then tight-
ening them to the specified
torque.
NOTE:
Make sure that the O-rings are prop-
erly seated.
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 8. Remove the coolant reservoir
bolt.
9. Pull the coolant reservoir upward
and away from the motorcycle.
10. Drain the remaining coolant from
the coolant reservoir by opening
the cap, then turning the reser-
voir upside down.
11. Install the coolant reservoir by
placing it in the original position,
then installing the bolt.
12. After the coolant is completely
drained, thoroughly flush the
cooling system with clean tap
water.
1. Bolt
2. Coolant reservoir
13. Install the coolant drain bolts,
and then tighten them to the
specified torque.
NOTE:
Check the washers for damage and
replace them if necessary.
14. Pour the recommended coolant
into the radiator until it is full. Tightening torque:
Coolant drain bolt:
10 Nm (1.0 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:
0.25 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
NOTE:
Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same
position for proper wheel alignment.
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Improper drive chain slack will
overload 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.
1. Bolt
2. Brake caliper bracket
EAU03006
Lubricating the drive chainDrive chain, lubricatingThe drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly
wear out, especially when riding in
dusty or wet areas. Service the drive
chain as follows.
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The drive chain must be lubricated
after washing the motorcycle or
riding in the rain.
1. Clean the drive chain with
kerosene and a small soft brush.
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To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents.
3. Tighten the locknuts, and then
tighten the axle nut and the
brake caliper bracket bolt to the
specified torques.
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
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To install the front wheelInstalling1. 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
installing the bolts.
NOTE:
Make sure that there is enough
space between the brake pads
before installing 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 speci-
fied torques.
EAU04455
Rear wheel
Wheel (rear)To remove the rear wheelRemovingEW000122
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8It is advisable to have a
Yamaha dealer service the
wheel.
8Securely support the motorcy-
cle so that there is no danger
of it falling over.
1. Bolt (×2)
2. Quick fastener (×3)7. Push down hard on the handle-
bar several times to check for
proper fork operation. 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)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6 8. Pull the wheel axle out, and then
remove the wheel.
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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.
7. Install the drive chain cover by
installing the bolts and quick fas-
teners.
NOTE:
To install a quick fastener, push the
pin back so that it will protrude from
the fastener head, and then insert the
fastener and push the protruding pin
in until it is flush with the fastener
head.
EAU04456
To install the rear wheelInstalling1. 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 installing 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 adjustment 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.Tightening torques:
Axle nut:
150 Nm (15.0 m·kgf)
Brake caliper bracket bolt:
40 Nm (4.0 m·kgf)
1. Quick fastener
2. Pin
After removalBefore installation
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