2003 YAMAHA TDM 900 wheel

6-32
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00794
Checking the steeringSteering, checkingWorn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine
to raise the front wheel off the
ground.
EW000115
w
Securely support the motorcycle
so that there is no danger of it
falling over.
EAU01144
Checking the wheel bearingsWheel bearings, checkingThe front and rear wheel bearings
must be checked at the intervals
specified in the periodic maintenance
and lubrication chart. If there is play
in the wheel hub or if the wheel does
not turn smoothly, have a Yamaha
dealer check the wheel bearings.
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any
free play can be felt, have a
Yamaha dealer check or repair
the steering.
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6-38
PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
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Do not overtighten the screw, oth-
erwise the lens may break.
1. Turn signal light bulb
To service the rear wheel
Raise the rear wheel off the ground
by using a motorcycle stand or, if a
motorcycle 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.EAU01579
Supporting the motorcycleSupporting the motorcycleSince this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and
rear wheel or performing other main-
tenance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed
under the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcy-
cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing
a jack under the frame in front of
the rear wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
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6-39
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01617
Front wheelWheel (front)
To remove the front wheelRemovingEW000122
w
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. Loosen the front wheel axle
pinch bolt, then the brake caliper
bolts.
1. Wheel axle
2. Front wheel axle pinch bolt
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Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut.
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 6-38.
4. Remove the brake hose holders
by removing the bolts.
5. Remove the brake calipers by
removing the bolts.
6. Pull the wheel axle out, and then
remove the wheel.
1
3
2
1. Brake hose holder
2. Bolt (×2)
3. Brake caliper
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6-40
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04376
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
w
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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6-41
PERIODIC MAINTENANCE AND MINOR REPAIR
61. Remove the drive chain cover by
removing the quick fasteners and
the bolts.
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. Bolt
2. Brake caliper bracket
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 6-38.
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
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6-42
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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7
7-1
EAU04454
MOTORCYCLE CARE AND STORAGE
CareCareWhile the open design of a motorcy-
cle reveals the attractiveness of the
technology, it also makes it more vul-
nerable. Rust and corrosion can
develop even if high-quality compo-
nents are used. A rusty exhaust pipe
may go unnoticed on a car, however,
it detracts from the overall appear-
ance of a motorcycle. Frequent and
proper care does not only comply
with the terms of the warranty, but it
will also keep your motorcycle looking
good, extend its life and optimize its
performance.Before cleaning
1. Cover the muffler outlets with
plastic bags after the engine has
cooled down.
2. Make sure that all caps and cov-
ers as well as all electrical cou-
plers and connectors, including
the spark plug caps, are tightly
installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such
products onto seals, gaskets,
sprockets, the drive chain and
wheel axles. Always rinse the dirt
and degreaser off with water.Cleaning
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8Avoid using strong acidic
wheel cleaners, especially on
spoked wheels. If such prod-
ucts are used on hard-to-
remove dirt, do not leave the
cleaner on the affected area
any longer than instructed.
Also, thoroughly rinse the area
off with water, immediately dry
it, and then apply a corrosion
protection spray.
8Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent
and water to clean plastic.
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7
7-2
MOTORCYCLE CARE AND STORAGE
8Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abra-
sive cleaning products, sol-
vent or thinner, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or elec-
trolyte.
8Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the
following areas: seals (of
wheel and swingarm bearings,
fork and brakes), electric com-
ponents (couplers, connec-
tors, instruments, switches
and lights), breather hoses
and vents.8For motorcycles equipped
with a windshield: Do not use
strong cleaners or hard
sponges as they will cause
dulling or scratching. Some
cleaning compounds for plas-
tic may leave scratches on the
windshield. Test the product
on a small hidden part of the
windshield to make sure that it
does not leave any marks. If
the windshield is scratched,
use a quality plastic polishing
compound after washing.After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottle-
brush for hard-to-reach areas.
Stubborn dirt and insects will come
off more easily if the area is covered
with a wet cloth for a few minutes
before cleaning.
After riding in the rain, near the sea
or on salt-sprayed roads
Since sea salt or salt sprayed on
roads during winter are extremely
corrosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads.
NOTE:
Salt sprayed on roads in the winter
may remain well into spring.
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