2003 YAMAHA TDM 900 ECU

3-13
INSTRUMENT AND CONTROL FUNCTIONS
3
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The following precautions must be
observed to prevent a fire hazard
or other damages.
8Use only unleaded gasoline.
The use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.
8Never park the motorcycle
near possible fire hazards
such as grass or other materi-
als that easily burn.
8Do not allow the engine to idle
too long.
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Seat
SeatTo remove the seat
Insert the key into the seat lock, turn
it counterclockwise, and then pull the
seat off.
1 a
1. Seat lock
a. Unlock.
To install the seat
Insert the projections on the front of
the seat into the seat holder, push
the rear of the seat down to lock it in
place, and then remove the key.
NOTE:
Make sure that the seat is properly
secured before riding.
1. Projection (×2)
2. Seat holder (×2)
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3-14
INSTRUMENT AND CONTROL FUNCTIONS
3
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Storage compartmentStorage compartmentThis storage compartment is
designed to hold an optional genuine
Yamaha U-LOCK. (Other locks may
not fit.) When placing a U-LOCK in
the storage compartment, securely
fasten it with the straps. When the U-
LOCK is not in the storage compart-
ment, be sure to secure the straps to
prevent losing them.
1. U-LOCK (optional)
2. Strap
When storing the owner’s manual or
other documents in the storage com-
partment, be sure to wrap them in a
plastic bag so that they will not get
wet. When washing the motorcycle,
be careful not to let any water enter
the storage compartment.EAU04929
Adjusting the front forkFront fork, adjustingThis front fork is equipped with spring
preload adjusting bolts and damping
force adjusting screws.
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Always adjust both fork legs
equally, otherwise poor handling
and loss of stability may result.
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6-19
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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6-21
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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6-31
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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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.
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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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6-32
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Checking the steeringSteering, checkingWorn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine
to raise the front wheel off the
ground.
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Securely support the motorcycle
so that there is no danger of it
falling over.
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Checking the wheel bearingsWheel bearings, checkingThe front and rear wheel bearings
must be checked at the intervals
specified in the periodic maintenance
and lubrication chart. If there is play
in the wheel hub or if the wheel does
not turn smoothly, have a Yamaha
dealer check the wheel bearings.
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any
free play can be felt, have a
Yamaha dealer check or repair
the steering.
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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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6-39
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Front wheelWheel (front)
To remove the front wheelRemovingEW000122
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8It is advisable to have a
Yamaha dealer service the
wheel.
8Securely support the motorcy-
cle so that there is no danger
of it falling over.
1. Loosen the front wheel axle
pinch bolt, then the brake caliper
bolts.
1. Wheel axle
2. Front wheel axle pinch bolt
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Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut.
2. Loosen the wheel axle with a
19-mm hexagon wrench.
3. Lift the front wheel off the ground
according to the procedure on
page 6-38.
4. Remove the brake hose holders
by removing the bolts.
5. Remove the brake calipers by
removing the bolts.
6. Pull the wheel axle out, and then
remove the wheel.
1
3
2
1. Brake hose holder
2. Bolt (×2)
3. Brake caliper
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