2003 YAMAHA TDM 900 check engine

3-3
INSTRUMENT AND CONTROL FUNCTIONS
3
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Oil level warning light “7”Oil level warning lightThis warning light comes on when
the engine oil level is low.
The electrical circuit of the warning
light can be checked by turning the
key to “ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical
circuit.
NOTE:
Even if the oil level is sufficient, the
warning light may flicker when riding
on a slope or during sudden acceler-
ation or deceleration, but this is not a
malfunction.
1. Fuel level warning symbol “ ”
2. Left turn signal indicator light “4”
3. High beam indicator light “&”
4. Neutral indicator light “N”
5. Engine trouble indicator light “ ”
6. Right turn signal indicator light “6”
7. Oil level warning light “
7”
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Turn signal indicator lights “4”
and “6”
Turn signal indicator lightsThe corresponding indicator light
flashes when the turn signal switch is
pushed to the left or right.
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High beam indicator light “&”High beam indicator lightThis indicator light comes on when
the high beam of the headlight is
switched on.
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Neutral indicator light “N”Neutral indicator lightThis indicator light comes on when
the transmission is in the neutral
position.
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Engine trouble warning light “”Engine trouble warning lightThis warning light comes on or flash-
es when an electrical circuit monitor-
ing the engine is defective. When this
occurs, have a Yamaha dealer check
the self-diagnosis system.
The electrical circuit of the warning
light can be checked by turning the
key to “ON”. If the warning light does
not come on for a few seconds, then
go off, have a Yamaha dealer check
the electrical circuit.
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3-5
INSTRUMENT AND CONTROL FUNCTIONS
3
NOTE:
After resetting the fuel reserve trip-
meter, the display will return to
“TRIP 1”, unless a different mode had
been previously selected; in that
case, the display automatically
returns to the prior mode.
Fuel gauge
The fuel gauge indicates the amount
of fuel in the fuel tank. The display
segments of the fuel gauge disap-
pear towards “E” (Empty) as the fuel
level decreases. When only one seg-
ment is left near “E”, refuel as soon
as possible.Self-diagnosis device
This model is equipped with a self-
diagnosis device for various electrical
circuits.
If any of those circuits are defective,
the odometer/tripmeter will indicate a
two-digit error code (e.g., 11, 12, 13).
If the odometer/tripmeter indicates
such an error code, note the code
number, and then have a Yamaha
dealer check the motorcycle.
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If the odometer/tripmeter indicates
an error code, the motorcycle
should be checked as soon as
possible in order to avoid engine
damage.
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Tachometer unitTachometer unitThe electric tachometer allows the
rider to monitor the engine speed and
keep it within the ideal power range.
When the key is turned to “ON”, the
tachometer needle will move to
9,500 r/min and back to zero r/min in
order to test the electrical circuit.
1. Tachometer
2. Tachometer red zone
3. Clock
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3-12
INSTRUMENT AND CONTROL FUNCTIONS
3
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Use only unleaded gasoline. The
use of leaded gasoline will cause
severe damage to internal engine
parts, such as the valves and pis-
ton rings, as well as to the exhaust
system.
Your Yamaha engine has been
designed to use regular unleaded
gasoline with a research octane num-
ber of 91 or higher. If knocking (or
pinging) occurs, use a gasoline of a
different brand or premium unleaded
fuel. Use of unleaded fuel will extend
spark plug life and reduce mainte-
nance costs.EAU02955
Fuel tank breather hoseFuel tank breather hoseBefore operating the motorcycle:
8Check the fuel tank breather
hose connection.
8Check the fuel tank breather
hose for cracks or damage, and
replace it if damaged.
8Make sure that the end of the
fuel tank breather hose is not
blocked, and clean it if neces-
sary.
1. Fuel tank breather hose
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Catalytic converterCatalytic converterThis motorcycle is equipped with a
catalytic converter in the muffler.
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The exhaust system is hot after
operation. Make sure that the
exhaust system has cooled down
before doing any maintenance
work.
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3-19
INSTRUMENT AND CONTROL FUNCTIONS
3
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The motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up),
otherwise the sidestand could con-
tact the ground and distract the
operator, resulting in a possible
loss of control. Yamaha’s ignition
circuit cut-off system has been
designed to assist the operator in
fulfilling the responsibility of rais-
ing the sidestand before starting
off. Therefore, check this system
regularly as described below and
have a Yamaha dealer repair it if it
does not function properly.
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Ignition circuit cut-off
system
Ignition circuit cut-off systemThe ignition circuit cut-off system
(comprising the sidestand switch,
clutch switch and neutral switch) has
the following functions.
8It prevents starting when the
transmission is in gear and the
sidestand is up, but the clutch
lever is not pulled.
8It prevents starting when the
transmission is in gear and the
clutch lever is pulled, but the
sidestand is still down.
8It cuts the running engine when
the transmission is in gear and
the sidestand is moved down.
Periodically check the operation of
the ignition circuit cut-off system
according to the following procedure.
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If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
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3-20
INSTRUMENT AND CONTROL FUNCTIONS
3
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
#”.
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
NOTE:
This check is most reliable if performed with
a warmed-up engine.
YES
YES NO
The system is OK. The motorcycle can be ridden.
YES NO
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4-1
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PRE-OPERATION CHECKS
4The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
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Pre-operation check listPre-operation check list
ITEM CHECKS PAGE
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-10–3-12
Engine oil•Check oil level in engine.
•If necessary, add recommended oil to specified level.
•Check vehicle for oil leakage.6-8–6-11
Coolant•Check coolant level in reservoir.
•If necessary, add recommended coolant to specified level.
•Check cooling system for leakage.6-11–6-15
Front brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-9–3-10, 6-24–6-26
Rear brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-10, 6-23–6-26
Clutch•Check operation.
•Lubricate cable if necessary.
•Check lever free play.
•Adjust if necessary.3-9, 6-22–6-23
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5-1
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OPERATION AND IMPORTANT RIDING POINTS
5
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8Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or func-
tion that you do not thorough-
ly understand.
8Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
8Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
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Starting the engineStarting the engineIn order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
8The transmission is in the neutral
position.
8The transmission is in gear with
the clutch lever pulled and the
sidestand up.
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8Before starting the engine,
check the function of the igni-
tion circuit cut-off system
according to the procedure
described on page 3-20.
8Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch
is set to “#”.
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The oil level warning light and
engine trouble warning light
should come on for a few seconds,
then go off. If a warning light does
not go off, see pages 3-2 and 3-3
for the corresponding warning
light circuit check.
2. Shift the transmission into the
neutral position.
NOTE:
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.
3. Start the engine by pushing the
start switch.
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5-4
OPERATION AND IMPORTANT RIDING POINTS
5
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0–1,000 km
Avoid prolonged operation above
4,000 r/min.
1,000–1,600 km
Avoid prolonged operation above
6,000 r/min.
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After 1,000 km of operation, the
engine oil must be changed, and
the oil filter element replaced.
1,600 km and beyond
The vehicle can now be operated
normally.
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8Keep the engine speed out of
the tachometer red zone.
8If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehi-
cle.
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ParkingParkingWhen parking, stop the engine, and
then remove the key from the main
switch.
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8Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely
to touch them.
8Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
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