2003 YAMAHA TDM 900 oil

6-31
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04282
Lubricating the rear
suspension
Rear suspension, lubricatingThe pivoting points of the rear sus-
pension must be lubricated at the
intervals specified in the periodic
maintenance and lubrication chart.
To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
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If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU02939
Checking the front forkFront fork, checkingThe condition and operation of the
front fork must be checked as follows
at the intervals specified in the peri-
odic maintenance and lubrication
chart.
To check the condition
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Securely support the motorcycle
so that there is no danger of it
falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
Recommended lubricant:
Lithium-soap-based grease
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6-36
PERIODIC MAINTENANCE AND MINOR REPAIR
6 2. Unhook the headlight bulb hold-
er, and then remove the defec-
tive bulb.EW000119
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Headlight bulbs get very hot.
Therefore, keep flammable prod-
ucts away from a lit headlight bulb,
and do not touch the bulb until it
has cooled down.
3. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
1
1. Headlight bulb holder
8Headlight lens
9Do not affix any type of tint-
ed film or stickers to the
headlight lens.
9Do not use a headlight bulb
of a wattage higher than
specified.
4. Install the headlight bulb cover,
and then connect the coupler.
5. Have a Yamaha dealer adjust
the headlight beam if necessary.
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Take care not to damage the fol-
lowing parts:
8Headlight bulb
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the
bulb, and the bulb life will be
adversely affected. Thoroughly
clean off any dirt and fingerprints
on the headlight bulb using a cloth
moistened with alcohol or thinner.
a
a. Do not touch the glass part of the bulb.
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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
7-3
MOTORCYCLE CARE AND STORAGE
1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
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Do not use warm water since it
increases the corrosive action of
the salt.
2. After drying the motorcycle,
apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, sur-
faces to prevent corrosion.After cleaning
1. Dry the motorcycle with a
chamois or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainless-
steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, includ-
ing chrome- and nickel-plated,
surfaces.
5. Use spray oil as a universal
cleaner to remove any remaining
dirt.
6. Touch up minor paint damage
caused by stones, etc.7. Wax all painted surfaces.
8. Let the motorcycle dry complete-
ly before storing or covering it.
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8Make sure that there is no oil
or wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild
detergent.
8Before operating the motorcy-
cle test its braking perfor-
mance and cornering behav-
ior.
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7
7-4
MOTORCYCLE CARE AND STORAGE
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8Apply spray oil and wax spar-
ingly and make sure to wipe
off any excess.
8Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
8Avoid using abrasive polish-
ing compounds as they will
wear away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
Storage
StorageShort-term
Always store your motorcycle in a
cool, dry place and, if necessary, pro-
tect it against dust with a porous
cover.
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8Storing the motorcycle in a
poorly ventilated room or cov-
ering it with a tarp, while it is
still wet, will allow water and
humidity to seep in and cause
rust.
8To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
3. Perform the following steps to
protect the cylinders, piston
rings, etc. from corrosion.
a. Remove the spark plug caps
and spark plugs.
b. Pour a teaspoonful of engine
oil into each spark plug bore.
c. Install the spark plug caps
onto the spark plugs, and then
place the spark plugs on the
cylinder head so that the elec-
trodes are grounded. (This will
limit sparking during the next
step.)
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7
7-5
MOTORCYCLE CARE AND STORAGE
d. Turn the engine over several
times with the starter. (This
will coat the cylinder walls with
oil.)
e. Remove the spark plug caps
from the spark plugs, and then
install the spark plugs and the
spark plug caps.
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To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turn-
ing the engine over.
4. Lubricate all control cables and
the pivoting points of all levers
and pedals as well as of the
sidestand/centerstand.5. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground.
Alternatively, turn the wheels a
little every month in order to pre-
vent the tires from becoming
degraded in one spot.
6. Cover the muffler outlets with
plastic bags to prevent moisture
from entering them.
7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a
month. Do not store the battery
in an excessively cold or warm
place [less than 0 °C or more
than 30 °C]. For more informa-
tion on storing the battery, see
page 6-34.
NOTE:
Make any necessary repairs before
storing the motorcycle.
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8
8-1
EAU01038
SPECIFICATIONS
SpecificationsSpecifications
Model TDM900
Dimensions
Overall length 2,180 mm
Overall width 800 mm
Overall height 1,290 mm
Seat height 825 mm
Wheelbase 1,485 mm
Ground clearance 160 mm
Minimum turning radius 2,900 mm
Basic weight (with oil and full
fuel tank)221 kg
Engine
Engine type Liquid-cooled 4-stroke, DOHC
Cylinder arrangement Forward-inclined parallel
2-cylinder
Displacement 897 cm
3
Bore ×Stroke 92.0 ×67.5 mm
Compression ratio 10.4:1
Starting system Electric starter
Lubrication system Dry sumpEngine oil
Type
Recommended engine oil
classification API Service SE, SF, SG type
or higher
cC
In order to prevent clutch slippage (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 CONSERVING II” or higher.
Capacity
Without oil filter element
removal 3.8 L
With oil filter element removal 3.9 L
Total amount (dry engine) 4.7 L
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8
8-2
SPECIFICATIONS
Cooling system capacity
(total amount)1.7 L
Air filterOil-coated paper element
Fuel
Type REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity 20 L
Fuel reserve amount 3.5 L
Spark plug
Manufacturer/model NGK/DPR8EA-9 or
DENSO/X24EPR-U9
Gap 0.8–0.9 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 1.718
Secondary reduction system Chain drive
Secondary reduction ratio 2.625
Number of drive chain
sprocket teeth (front/rear) 16/42
Transmission type Constant mesh 6-speedOperation Left foot
Gear ratio 1st 2.750
2nd 1.947
3rd 1.545
4th 1.240
5th 1.040
6th 0.923
Chassis
Frame type Diamond
Caster angle 25.5°
Trail 114 mm
Tires
Front
Type Tubeless tire
Size 120/70 ZR18 M/C (59W)
Manufacturer/ Dunlop/D220FSTJ
model Metzeler/MEZ4 FRONT
Rear
Type Tubeless tire
Size 160/60 ZR17 M/C (69W)
Manufacturer/ Dunlop/D220STJ
model Metzeler/MEZ4
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