2003 YAMAHA TDM 900 check engine

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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
10*Tires•Check tread depth and for damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.√√√√ √
11
*Wheel bearings•Check bearing for looseness or damage.√√√√
12
*Swingarm•Check operation and for excessive play.√√√√
•Lubricate with lithium-soap-based grease. Every 50,000 km
13 Drive chain•Check 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 bearings•Check bearing play and steering for roughness.√√√√√
•Lubricate with lithium-soap-based grease.Every 20,000 km
15
*Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.√√√√ √
16 Sidestand•Check operation.
•Lubricate.√√√√ √
17
*Sidestand switch•Check operation.√√√√√ √
18
*Front fork•Check operation and for oil leakage.√√√√
19
*Shock absorber
assembly•Check operation and shock absorber for oil leakage.√√√√
20
*
Rear suspension relay
arm and connecting arm
pivoting points•Check operation.√√√√
•Lubricate with lithium-soap-based grease.√√
21
*Electronic fuel injection•Adjust engine idling speed and synchronization.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
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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
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6-7
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
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.
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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
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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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