2003 YAMAHA TDM 900 lock

3-11
INSTRUMENT AND CONTROL FUNCTIONS
32. Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.
NOTE:
The fuel tank cap cannot be closed
unless the key is in the lock. In addi-
tion, the key cannot be removed if the
cap is not properly closed and
locked.
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Make sure that the fuel tank cap is
properly closed before riding.
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FuelFuelMake sure that there is sufficient fuel
in the tank. Fill the fuel tank to the
bottom of the filler tube as shown.
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8Do not overfill the fuel tank,
otherwise it may overflow
when the fuel warms up and
expands.
8Avoid spilling fuel on the hot
engine.
1 2
1. Fuel tank filler tube
2. Fuel level
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cC
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted sur-
faces or plastic parts.
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Recommended fuel:
REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity:
Total amount:
20 L
Reserve amount:
3.5 L
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3-12
INSTRUMENT AND CONTROL FUNCTIONS
3
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cC
Use only unleaded gasoline. The
use of leaded gasoline will cause
severe damage to internal engine
parts, such as the valves and pis-
ton rings, as well as to the exhaust
system.
Your Yamaha engine has been
designed to use regular unleaded
gasoline with a research octane num-
ber of 91 or higher. If knocking (or
pinging) occurs, use a gasoline of a
different brand or premium unleaded
fuel. Use of unleaded fuel will extend
spark plug life and reduce mainte-
nance costs.EAU02955
Fuel tank breather hoseFuel tank breather hoseBefore operating the motorcycle:
8Check the fuel tank breather
hose connection.
8Check the fuel tank breather
hose for cracks or damage, and
replace it if damaged.
8Make sure that the end of the
fuel tank breather hose is not
blocked, and clean it if neces-
sary.
1. Fuel tank breather hose
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Catalytic converterCatalytic converterThis motorcycle is equipped with a
catalytic converter in the muffler.
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The exhaust system is hot after
operation. Make sure that the
exhaust system has cooled down
before doing any maintenance
work.
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3-13
INSTRUMENT AND CONTROL FUNCTIONS
3
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cC
The following precautions must be
observed to prevent a fire hazard
or other damages.
8Use only unleaded gasoline.
The use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.
8Never park the motorcycle
near possible fire hazards
such as grass or other materi-
als that easily burn.
8Do not allow the engine to idle
too long.
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Seat
SeatTo remove the seat
Insert the key into the seat lock, turn
it counterclockwise, and then pull the
seat off.
1 a
1. Seat lock
a. Unlock.
To install the seat
Insert the projections on the front of
the seat into the seat holder, push
the rear of the seat down to lock it in
place, and then remove the key.
NOTE:
Make sure that the seat is properly
secured before riding.
1. Projection (×2)
2. Seat holder (×2)
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3-14
INSTRUMENT AND CONTROL FUNCTIONS
3
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Storage compartmentStorage compartmentThis storage compartment is
designed to hold an optional genuine
Yamaha U-LOCK. (Other locks may
not fit.) When placing a U-LOCK in
the storage compartment, securely
fasten it with the straps. When the U-
LOCK is not in the storage compart-
ment, be sure to secure the straps to
prevent losing them.
1. U-LOCK (optional)
2. Strap
When storing the owner’s manual or
other documents in the storage com-
partment, be sure to wrap them in a
plastic bag so that they will not get
wet. When washing the motorcycle,
be careful not to let any water enter
the storage compartment.EAU04929
Adjusting the front forkFront fork, adjustingThis front fork is equipped with spring
preload adjusting bolts and damping
force adjusting screws.
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Always adjust both fork legs
equally, otherwise poor handling
and loss of stability may result.
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6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Cast wheelsWheelsTo maximize the performance, dura-
bility, and safe operation of your
motorcycle, note the following points
regarding the specified wheels.
8The wheel rims should be
checked for cracks, bends or
warpage before each ride. If any
damage is found, have a
Yamaha dealer replace the
wheel. Do not attempt even the
smallest repair to the wheel. A
deformed or cracked wheel must
be replaced.
8The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.
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Adjusting the clutch lever
free play
Clutch lever free play, adjustingThe clutch lever free play should
measure 10–15 mm as shown.
Periodically check the clutch lever
free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the clutch
lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in
direction a. To decrease the
clutch lever free play, turn the
adjusting bolt in direction b.
1
a2
a c
b
1. Locknut (clutch lever)
2. Clutch lever free play adjusting bolt
c. Clutch lever free play
8Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for
it to develop its optimal charac-
teristics.
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6-23
PERIODIC MAINTENANCE AND MINOR REPAIR
63. If the specified clutch lever free
play could be obtained as
described above, tighten the
locknut and skip the rest of the
procedure, otherwise proceed as
follows.
4. Fully turn the adjusting bolt at the
clutch lever in direction ato
loosen the clutch cable.
1
a2
a
1. Locknut (clutch lever)
2. Clutch lever free play adjusting bolt
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Adjusting the brake pedal
position
Brake pedal position, adjustingThe top of the brake pedal should be
positioned approximately 32 mm
below the top of the footrest as
shown. Periodically check the brake
pedal position and, if necessary,
have a Yamaha dealer adjust it.
a. Distance between brake pedal and footrest
5. Loosen the locknut at the
crankcase.
6. To increase the clutch lever free
play, turn the adjusting nut in
direction a. To decrease the
clutch lever free play, turn the
adjusting nut in direction b.
7. Tighten the locknut at the clutch
lever and the crankcase.
12
b
a
1. Locknut (crankcase)
2. Clutch lever free play adjusting nut
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6-26
PERIODIC MAINTENANCE AND MINOR REPAIR
6 Observe these precautions:
8When checking the fluid level,
make sure that the top of the
brake fluid reservoir is level.
8Use only the recommended qual-
ity brake fluid, otherwise the rub-
ber seals may deteriorate, caus-
ing leakage and poor braking
performance.
1
1. Minimum level mark
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Changing the brake fluidBrake fluid, changingHave a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addi-
tion, have the oil seals of the brake
master cylinder and caliper as well as
the brake hose replaced at the inter-
vals listed below or whenever they
are damaged or leaking.
8Oil seals: Replace every two
years.
8Brake hose: Replace every four
years. 8Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking perfor-
mance.
8Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock.
8Brake fluid may deteriorate paint-
ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
Rear brake
Recommended brake fluid:
DOT 4
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Drive chain slackDrive chain slackThe drive chain slack should be
checked before each ride and adjust-
ed if necessary.
To check the drive chain slack
Checking1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:
When checking and adjusting the
drive chain slack, the motorcycle
should be positioned straight up and
there should be no weight on it.EAU04372
To adjust the drive chain slackAdjusting1. Loosen the axle nut, the brake
caliper bracket bolt and the lock-
nut 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
loosen the drive chain, turn the
adjusting bolt on each side of the
swingarm in direction b, and
then push the rear wheel for-
ward.
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
2. Shift the transmission into the
neutral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain,
and then measure the drive
chain slack as shown.
4. If the drive chain slack is incor-
rect, adjust it as follows.
a. Drive chain slack
Drive chain slack:
50–60 mm
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