2003 YAMAHA TDM 900 lock

6-28
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.
EC000096
cC
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.
EC000097
cC
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.
ECA00053
cC
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)
5PS-28199-E1 8/29/02 9:16 AM Page 73

6-34
PERIODIC MAINTENANCE AND MINOR REPAIR
6 To store the battery
1. If the motorcycle will not be used
for more than one month,
remove the battery, fully charge
it, and then place it in a cool, dry
place.
2. If the battery will be stored for
more than two months, check it
at least once a month and fully
charge it if necessary.
3. Fully charge the battery before
installation.
4. After installation, make sure that
the battery leads are properly
connected to the battery termi-
nals.
EAU04880
Replacing the fusesFuses, replacingThe main fuse and the fuse box,
which contains the fuses for the indi-
vidual circuits, are located under the
seat. (See page 3-13 for seat
removal and installation procedures.)
If a fuse is blown, replace it as fol-
lows.
1. Turn the key to “OFF” and turn
off the electrical circuit in ques-
tion.
12 34 5 689 7
7
1. Odometer and clock fuse (backup fuse)
2. Radiator fan fuse
3. Turn signal light and hazard fuse
4. Ignition fuse
5. Signaling system fuse
6. Headlight fuse
7. Spare fuse (×5)
8. Electronic fuel injection system fuse
9. Main fuse
EC000102
cC
8Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.
8To charge a sealed-type (MF)
battery, a special (constant-
voltage) battery charger is
required. Using a conventional
battery charger will damage
the battery. If you do not have
access to a sealed-type (MF)
battery charger, have a
Yamaha dealer charge your
battery.
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6-35
PERIODIC MAINTENANCE AND MINOR REPAIR
62. Remove the blown fuse, and
then install a new fuse of the
specified amperage.
EC000103
cC
Do not use a fuse of a higher
amperage rating than recommend-
ed to avoid causing extensive
damage to the electrical system
and possibly a fire.
EAU04503
Replacing a headlight bulbHeadlight bulb, replacingThis motorcycle is equipped with
quartz bulb headlights. If a headlight
bulb burns out, replace it as follows.
1. Disconnect the headlight cou-
pler, and then remove the bulb
cover.
1. Headlight bulb holder
2. Headlight coupler
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system. Specified fuses:
Main fuse: 40 A
Headlight fuse: 15 A
Signaling system fuse: 10 A
Radiator fan fuse: 20 A
Ignition fuse: 10 A
Odometer and clock
fuse (backup fuse): 5 A
Turn signal light and
hazard fuse: 10 A
Electronic fuel
injection fuse: 10 A
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6-37
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04411
Replacing a tail/brake light
bulb
Tail/brake light bulb, replacing1. Remove the seat. (See page
3-13 for seat removal and instal-
lation procedures.)
2. Remove the socket (together
with the bulb) by turning it coun-
terclockwise.
3. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
4. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
1. Socket
EAU03497
Replacing a turn signal light
bulb
Turn signal light bulb, replacing1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
1. Screw
2. Turn signal light lens
5. Install the socket (together with
the bulb) by turning it clockwise.
6. Install the seat.
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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.
ECA00065
cC
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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6-41
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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6-45
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

8
8-4
SPECIFICATIONS
Electrical system
Ignition system T.C.I. (digital)
Charging system
Type A.C. magneto
Standard output 14 V, 31.5 A @ 5,000 r/min
Battery
Type GT12B-4
Voltage, capacity 12 V, 10 Ah
Headlight bulb typeHalogen
Bulb voltage, wattage ×quantity
Headlight 12 V, 55 W ×2
Auxiliary light 12 V, 5 W ×1
Tail/brake light 12 V, 5/21 W ×1
Front turn signal light 12 V, 10 W ×2
Rear turn signal light 12 V, 10 W ×2
Meter lighting 12 V, 2 W ×2
Neutral indicator light 12 V, 1.2 W ×1
High beam indicator light 12 V, 1.4 W ×1
Turn signal indicator light 12 V, 1.2 W ×2
Oil level warning light L.E.D. ×1
Engine trouble warning light 12 V, 1.4 W ×1Fuses
Main fuse 40 A
Headlight fuse 15 A
Signaling system fuse 10 A
Ignition fuse 10 A
Turn signal light and hazard
fuse 10 A
Odometer and clock fuse
(backup fuse) 5 A
Radiator fan fuse 20 A
Electronic fuel injection
system fuse 10 A
5PS-28199-E1 8/29/02 9:17 AM Page 101