2003 YAMAHA TDM 900 Owners Manual

6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
6
10*Tires•Check tread depth and for damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.√√√√ √
11
*Wheel bearings•Check bearing for looseness or damage.√√√√
12
*Swingarm•Check operation and for excessive play.√√√√
•Lubricate with lithium-soap-based grease. Every 50,000 km
13 Drive chain•Check chain slack.
•Make sure that the rear wheel is properly aligned.
•Clean and lubricate.Every 1,000 km and after washing
the motorcycle or riding in the rain
14
*Steering bearings•Check bearing play and steering for roughness.√√√√√
•Lubricate with lithium-soap-based grease.Every 20,000 km
15
*Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.√√√√ √
16 Sidestand•Check operation.
•Lubricate.√√√√ √
17
*Sidestand switch•Check operation.√√√√√ √
18
*Front fork•Check operation and for oil leakage.√√√√
19
*Shock absorber
assembly•Check operation and shock absorber for oil leakage.√√√√
20
*
Rear suspension relay
arm and connecting arm
pivoting points•Check operation.√√√√
•Lubricate with lithium-soap-based grease.√√
21
*Electronic fuel injection•Adjust engine idling speed and synchronization.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03884
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
9Replace the brake hoses every four years and if cracked or damaged.
22 Engine oil•Change.
•Check oil level and vehicle for oil leakage.√√√√√ √
23 Engine oil filter element•Replace.√√√
24
*Cooling system•Check coolant level and vehicle for coolant leakage.√√√√ √
•Change.Every 3 years
25
*Front and rear brake
switches•Check operation.√√√√√ √
26 Moving parts and cables•Lubricate.√√√√ √
27
*Throttle grip housing
and cable•Check operation and free play.
•Adjust the throttle cable free play if necessary.
•Lubricate the throttle grip housing and cable.√√√√ √
28
*Air induction system•Check the air cut-off valve, reed valve, and hose for
damage.
•Replace the entire air induction system if necessary.√√√√ √
29
*Muffler and exhaust pipe•Check the screw clamp for looseness.√√√√√
30
*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
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6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01139
Removing and installing
cowlings and panels
Cowlings and panels, removing and installingThe cowlings and panels shown
above need to be removed to per-
form some of the maintenance jobs
described in this chapter. Refer to
this section each time a cowling or
panel needs to be removed and
installed.
1. Cowling A
2. Panel A
EAU04937
Cowlings A and B
To remove one of the cowlings
Remove the cowling screws and the
quick fastener, and then pull the
cowling off as shown.
NOTE:
The quick fastener is removed by
pushing the center pin in with a
screwdriver, and then pulling the fas-
tener out.
1. Screw (×6)
2. Quick fastener1. Cowling B
2. Panel B
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6-6
PERIODIC MAINTENANCE AND MINOR REPAIR
6 To install the cowling
Place the cowling in the original posi-
tion, and then install the screws and
the quick fastener.
NOTE:
To install the quick fastener, push the
center pin out so that it will protrude
from the fastener head, insert the fas-
tener into the cowling, and then push
the protruding pin in until it is flush
with the fastener head.
1. Quick fastener
2. Pin
To install the panel
1. Place the panel in the original
position, and then install the
screw.
2. Install the seat and the cowling.
1. Panel B
EAU03317
Panels A and B
To remove one of the panels
1. Remove the corresponding cowl-
ing A or B. (See page 6-5 for
cowling removal and installation
procedures.)
2. Remove the seat. (See page
3-13 for seat removal and instal-
lation procedures.)
3. Remove the screw, and then
take the panel off.
1. Screw
After removalBefore installation
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6-7
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01880
Checking the spark plugsSpark plugs, checkingThe spark plugs are important engine
components, which should be
checked periodically, preferably by a
Yamaha dealer. Since heat and
deposits will cause any spark plug to
slowly erode, they should be
removed and checked in accordance
with the periodic maintenance and
lubrication chart. In addition, the con-
dition of the spark plugs can reveal
the condition of the engine.
The porcelain insulator around the
center electrode of each spark plug
should be a medium-to-light tan (the
ideal color when the motorcycle is rid-
den normally), and all spark plugs
installed in the engine should have
the same color. If any spark plug
shows a distinctly different color, the
engine could be defective. Do not
attempt to diagnose such problems
yourself. Instead, have a Yamaha
dealer check the motorcycle.Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
a. Spark plug gap
If a spark plug shows signs of elec-
trode erosion and excessive carbon
or other deposits, it should be
replaced.
Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification.
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf)
Specified spark plug:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
Spark plug gap:
0.8–0.9 mm
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6-8
PERIODIC MAINTENANCE AND MINOR REPAIR
6
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4–1/2 turn past finger tight.
However, the spark plug should be
tightened to the specified torque as
soon as possible.
3. Wait a few minutes until the oil
settles, remove the oil filler cap,
wipe the dipstick clean, insert it
back into the oil filler hole (with-
out screwing it in and with the
arrow mark pointing upward as
shown), and then remove it
again to check the oil level.
NOTE:
The engine oil should be between the
minimum and maximum level marks.
1. Oil filler cap
EAU04619
Engine oil and oil filter
element
Engine oil and oil filter elementThe engine oil level should be
checked before each ride. In addition,
the oil must be changed and the oil
filter element replaced at the intervals
specified in the periodic maintenance
and lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:
Make sure that the motorcycle is
positioned straight up when checking
the oil level. A slight tilt to the side
can result in a false reading.
2. Start the engine, warm it up for
15 minutes, and then turn it off.
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6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EC000000
cC
Do not operate the motorcycle
until you know that the engine oil
level is sufficient.
1. Oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the
engine to collect the used oil.
3. Remove the engine oil filler cap
and drain bolts to drain the oil
from the crankcase.
NOTE:
Skip steps 4–6 if the oil filter element
is not being replaced.
1. Engine oil drain bolt A
EW000065
w
Never remove the engine oil tank
cap after high-speed operation,
otherwise hot engine oil could
spout out and cause damage or
injury. Always let the engine oil
cool down sufficiently before
removing the oil tank cap.
4. If the engine oil is below the min-
imum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
5. Install the oil filler cap.
NOTE:
8The engine oil tank is located
behind the cylinders.
8The engine oil should be
between the minimum and maxi-
mum level marks.
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6-10
PERIODIC MAINTENANCE AND MINOR REPAIR
6 4. Remove the oil filter element
cover by removing the bolts.
1. Engine oil drain bolt B
2. Oil filter element cover
3. Bolt (×5)
7. Install the engine oil drain bolts,
and then tighten them to the
specified torques.
8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil
filler cap. 5. Remove and replace the oil filter
element and O-rings.
6. Install the oil filter element cover
by installing the bolts, then tight-
ening them to the specified
torque.
NOTE:
Make sure that the O-rings are prop-
erly seated.
1. Oil filter element
2. O-ring (×2)
Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf)
Tightening torques:
Engine oil drain bolt A:
35 Nm (3.5 m·kgf)
Engine oil drain bolt B:
30 Nm (3.0 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
3.8 L
With oil filter element
replacement:
3.9 L
Total amount (dry engine):
4.7 L
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