2003 YAMAHA TDM 900 maintenance

6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EW000080
w
8The front and rear tires should
be of the same make and
design, otherwise the handling
characteristics of the motorcy-
cle cannot be guaranteed.
8After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha Motor Co., Ltd.
8Always make sure that the
valve caps are securely
installed to prevent air pres-
sure leakage.
8Use only the tire valves and
valve cores listed below to
avoid tire deflation during a
high-speed ride.
EAU00684
w
This motorcycle is fitted with
super-high-speed tires. Note the
following points in order to make
the most efficient use of these
tires.
8Use only the specified replace-
ment tires. Other tires may run
the danger of bursting at
super high speeds.
8Brand-new tires can have a
relatively poor grip on certain
road surfaces until they have
been “broken in”. Therefore, it
is advisable before doing any
high-speed riding to ride con-
servatively for approximately
100 km after installing a new
tire.
8The tires must be warmed up
before a high-speed run.
8Always adjust the tire air pres-
sure according to the operat-
ing conditions.
FRONT
Manufacturer Size Model
Dunlop
120/70 ZR18 M/C (59W)D220FSTJ
Metzeler
120/70 ZR18 M/C (59W)MEZ4 FRONT
REAR
Manufacturer Size Model
Dunlop
160/60 ZR17 M/C (69W)D220STJ
Metzeler
160/60 ZR17 M/C (69W)MEZ4
FRONT & REAR
Tire air valve TR412
Valve core #9000A (original)
5PS-28199-E1 8/29/02 9:16 AM Page 66

6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03773
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.
EAU00694
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.
5PS-28199-E1 8/29/02 9:16 AM Page 67

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
EAU00712
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
5PS-28199-E1 8/29/02 9:16 AM Page 68

6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EW000109
w
A soft or spongy feeling in the
brake pedal can indicate the pres-
ence of air in the hydraulic system.
If there is air in the hydraulic sys-
tem, have a Yamaha dealer bleed
the system before operating the
motorcycle. Air in the hydraulic
system will diminish the braking
performance, which may result in
loss of control and an accident.
EAU00721
Checking the front and rear
brake pads
Front and rear brake pads, checkingThe front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU00713
Adjusting the rear brake light
switch
Rear brake light switch, adjustingThe rear brake light switch, which is
activated by the brake pedal, is prop-
erly adjusted when the brake light
comes on just before braking takes
effect. If necessary, adjust the brake
light switch as follows.
Turn the adjusting nut while holding
the rear brake light switch in place.
To make the brake light come on ear-
lier, turn the adjusting nut in direction
a. To make the brake light come on
later, turn the adjusting nut in direc-
tion b.
1. Brake light switch
2. Brake light switch adjusting nut
5PS-28199-E1 8/29/02 9:16 AM Page 69

6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00725
Front brake pads
Each front brake pad is provided with
a wear indicator groove, which allows
you to check the brake pad wear
without having to disassemble the
brake. To check the brake pad wear,
check the wear indicator groove. If a
brake pad has worn to the point that
the wear indicator groove has almost
disappeared, have a Yamaha dealer
replace the brake pads as a set.
1
1. Brake pad wear indicator groove
EAU04856
Checking the brake fluid
level
Brake fluid level, checkingInsufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low
brake fluid level may indicate worn
brake pads and/or brake system
leakage. If the brake fluid level is low,
be sure to check the brake pads for
wear and the brake system for leak-
age.
1
1. Minimum level mark
EAU04510
Rear brake pads
Check each rear brake pad for dam-
age and measure the lining thick-
ness. If a brake pad is damaged or if
the lining thickness is less than
0.8 mm, have a Yamaha dealer
replace the brake pads as a set.
1
1. Lining thickness
Front brakeRear brakeFront brake
5PS-28199-E1 8/29/02 9:16 AM Page 70

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
EAU03985
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
5PS-28199-E1 8/29/02 9:16 AM Page 71

6-27
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00744
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
5PS-28199-E1 8/29/02 9:16 AM Page 72

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