2003 YAMAHA TDM 900 cooling

4-1
EAU01114
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.
EAU03439
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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6-4
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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6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. If the coolant is at or below the
minimum level mark, remove
panel B (See page 6-6 for panel
removal and installation proce-
dures.), remove the reservoir
cap, add coolant to the maximum
level mark, and then install the
reservoir cap and the panel.
1. Coolant reservoir cap
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w
Never attempt to remove the radia-
tor cap when the engine is hot.
NOTE:
8The radiator fan is automatically
switched on or off according to
the coolant temperature in the
radiator.
8If the engine overheats, see
page 6-45 for further instructions.
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cC
8If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
8If water has been used instead
of coolant, replace it with
coolant as soon as possible,
otherwise the engine may not
be sufficiently cooled and the
cooling system will not be pro-
tected against frost and corro-
sion.
8If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possi-
ble, otherwise the effective-
ness of the coolant will be
reduced.
Coolant reservoir capacity
(up to the maximum level mark):
0.25 L
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6-13
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04461
To change the coolantChanging1. Place the motorcycle on a level
surface and let the engine cool if
necessary.
2. Remove the seat. (See page
3-13 for seat removal and instal-
lation procedures.)
3. Remove cowling B and panel B.
(See pages 6-5 and 6-6 for cowl-
ing and panel removal and instal-
lation procedures.)
4. Remove the fuel tank bolts, and
then lift the fuel tank to position it
away from the coolant reservoir.
(Do not disconnect the fuel
hoses!)
5. Place a container under the
engine to collect the used
coolant.7. Remove the coolant drain bolts
to drain the cooling system.
11
1. Coolant drain bolt (×2)
6. Remove the radiator cap retain-
ing bolt and the radiator cap.
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w
Never attempt to remove the radia-
tor cap when the engine is hot.
1. Radiator cap retaining bolt
2. Radiator cap
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6-14
PERIODIC MAINTENANCE AND MINOR REPAIR
6 8. Remove the coolant reservoir
bolt.
9. Pull the coolant reservoir upward
and away from the motorcycle.
10. Drain the remaining coolant from
the coolant reservoir by opening
the cap, then turning the reser-
voir upside down.
11. Install the coolant reservoir by
placing it in the original position,
then installing the bolt.
12. After the coolant is completely
drained, thoroughly flush the
cooling system with clean tap
water.
1. Bolt
2. Coolant reservoir
13. Install the coolant drain bolts,
and then tighten them to the
specified torque.
NOTE:
Check the washers for damage and
replace them if necessary.
14. Pour the recommended coolant
into the radiator until it is full. Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf)
Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Coolant quantity:
Total amount:
1.7 L
Coolant reservoir capacity:
0.25 L
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6-15
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EC000080
cC
8If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
8If water has been used instead
of coolant, replace it with
coolant as soon as possible,
otherwise the engine may not
be sufficiently cooled and the
cooling system will not be pro-
tected against frost and corro-
sion.
8If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possi-
ble, otherwise the effective-
ness of the coolant will be
reduced.
EWA00052
w
8Before installing the fuel tank,
make sure that the fuel hoses
are not damaged. If any fuel
hose is damaged, do not start
the engine but have a Yamaha
dealer replace the hose, other-
wise fuel may leak.
8Make sure that the fuel hoses
are properly connected and
routed, and not pinched.
8Be sure to place the fuel tank
breather hose in the original
position.
19. Install the panel, the cowling,
and the seat.
20. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a
Yamaha dealer check the cool-
ing system. 15. Install the radiator cap, start the
engine, let it idle for several min-
utes, and then turn it off.
16. Remove the radiator cap to
check the coolant level in the
radiator. If necessary, add suffi-
cient coolant until it reaches the
top of the radiator, and then
install the radiator cap and the
cap retaining bolt.
17. Check the coolant level in the
reservoir. If necessary, remove
the coolant reservoir cap, add
coolant to the maximum level
mark, and then install the cap.
18. Install the fuel tank.
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6-45
6Engine overheating
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w
8Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
8After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the
hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the
cap.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
Wait until the
engine has cooled.Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.
The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.
Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.
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8
8-2
SPECIFICATIONS
Cooling system capacity
(total amount)1.7 L
Air filterOil-coated paper element
Fuel
Type REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity 20 L
Fuel reserve amount 3.5 L
Spark plug
Manufacturer/model NGK/DPR8EA-9 or
DENSO/X24EPR-U9
Gap 0.8–0.9 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 1.718
Secondary reduction system Chain drive
Secondary reduction ratio 2.625
Number of drive chain
sprocket teeth (front/rear) 16/42
Transmission type Constant mesh 6-speedOperation Left foot
Gear ratio 1st 2.750
2nd 1.947
3rd 1.545
4th 1.240
5th 1.040
6th 0.923
Chassis
Frame type Diamond
Caster angle 25.5°
Trail 114 mm
Tires
Front
Type Tubeless tire
Size 120/70 ZR18 M/C (59W)
Manufacturer/ Dunlop/D220FSTJ
model Metzeler/MEZ4 FRONT
Rear
Type Tubeless tire
Size 160/60 ZR17 M/C (69W)
Manufacturer/ Dunlop/D220STJ
model Metzeler/MEZ4
5PS-28199-E1 8/29/02 9:17 AM Page 99