2003 YAMAHA TDM 900 Owners Manual

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PERIODIC MAINTENANCE AND MINOR REPAIR
68Adjust the suspension and tire
air pressure with regard to the
load.
8Check the tire condition and
air pressure before each ride.
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Because loading has an enormous
impact on the handling, braking,
performance and safety character-
istics of your motorcycle, you
should keep the following precau-
tions in mind.
8NEVER OVERLOAD THE
MOTORCYCLE! Operation of
an overloaded motorcycle may
result in tire damage, loss of
control, or severe injury. Make
sure that the total weight of
rider, passenger, cargo, and
accessories does not exceed
the specified maximum load
for the vehicle.
8Do not carry along loosely
packed items, which can shift
during a ride.
8Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg
225 kPa
(2.25 kgf/cm2,
2.25 bar)250 kPa
(2.50 kgf/cm2,
2.50 bar)
90 kg–maximum225 kPa
(2.25 kgf/cm2,
2.25 bar)290 kPa
(2.90 kgf/cm2,
2.90 bar)
High-speed riding225 kPa
(2.25 kgf/cm2,
2.25 bar)250 kPa
(2.50 kgf/cm2,
2.50 bar)
Maximum load* 203 kg
* Total weight of rider, passenger, cargo and
accessories
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PERIODIC MAINTENANCE AND MINOR REPAIR
6 Tire inspection
The tires must be checked before
each ride. If the center tread depth
reaches the specified limit, if the tire
has a nail or glass fragments in it, or
if the sidewall is cracked, have a
Yamaha dealer replace the tire imme-
diately.
1. Tire sidewall
a. Tire tread depth
Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
1. Tire air valve
2. Valve core
3. Valve cap with seal
NOTE:
The tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.
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8Have a Yamaha dealer replace
excessively worn tires.
Besides being illegal, operat-
ing the motorcycle with exces-
sively worn tires decreases
riding stability and can lead to
loss of control.
8The replacement of all wheel
and brake related parts,
including the tires, should be
left to a Yamaha dealer, who
has the necessary profession-
al knowledge and experience.
Minimum tire tread depth
(front and rear)1.6 mm
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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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.
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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)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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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.
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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.
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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
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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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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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.
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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.
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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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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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
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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
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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
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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
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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
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