2003 YAMAHA TDM 900 fuel filter

6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03685
Periodic maintenance and lubrication chartPeriodic maintenance and lubrication chartNOTE:
8The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line•Check fuel hoses for cracks or damage.√√√√ √
2 Spark plugs•Check condition.
•Clean and regap.√√
•Replace.√√
3
*Valves•Check valve clearance.
•Adjust.Every 40,000 km
4 Air filter element•Replace.√
5 Clutch•Check operation.
•Adjust.√√√√√
6
*Front brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
7
*Rear brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
8
*Brake hoses•Check for cracks or damage.√√√√ √
•Replace. (See NOTE on page 6-4.)Every 4 years
9
*Wheels•Check runout and for damage.√√√√
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6-16
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04973
Replacing the air filter
element
Air filter element, replacingThe air filter element should be
replaced at the intervals specified in
the periodic maintenance and lubrica-
tion chart. Replace the air filter ele-
ment more frequently if you are riding
in unusually wet or dusty areas.
1. Remove the seat. (See page
3-13 for seat removal and instal-
lation procedures.)
2. Remove cowlings A and B as
well as panels A and B. (See
pages 6-5 and 6-6 for cowling
and panel removal and installa-
tion procedures.)
1. Bolt (×2)
6. Insert a new air filter element into
the air filter case.
EC000082
cC
8Make sure that the air filter ele-
ment is properly seated in the
air filter case.
8The engine should never be
operated without the air filter
element installed, otherwise
the pistons and/or cylinders
may become excessively
worn.
1. Air filter element
3. Remove the fuel tank bolts, and
then lift the fuel tank away from
the air filter case.
4. Remove the air filter case cover
by removing the screws.
5. Pull the air filter element out.
1. Air filter case cover
2. Screw (×8)
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6-17
PERIODIC MAINTENANCE AND MINOR REPAIR
67. Install the air filter case cover by
installing the screws.
8. Place the fuel tank in the original
position and install the bolts.
EWA00067
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 and the fuel
tank overflow hose in the orig-
inal position.
9. Install the panels and cowlings.
10. Install the seat.Check the engine idling speed and, if
necessary, adjust it to specification
by turning the throttle stop screw. To
increase the engine idling speed, turn
the screw in direction a. To
decrease the engine idling speed,
turn the screw in direction b.
NOTE:
If the specified idling speed cannot
be obtained as described above,
have a Yamaha dealer make the
adjustment.
1. Throttle stop screw
EAU04578
Adjusting the engine idling
speed
Engine idling speedThe engine idling speed must be
checked and, if necessary, adjusted
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
The engine should be warm before
making this adjustment.
NOTE:
The engine is warm when it quickly
responds to the throttle.
Engine idling speed:
1,100–1,200 r/min
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8
8-1
EAU01038
SPECIFICATIONS
SpecificationsSpecifications
Model TDM900
Dimensions
Overall length 2,180 mm
Overall width 800 mm
Overall height 1,290 mm
Seat height 825 mm
Wheelbase 1,485 mm
Ground clearance 160 mm
Minimum turning radius 2,900 mm
Basic weight (with oil and full
fuel tank)221 kg
Engine
Engine type Liquid-cooled 4-stroke, DOHC
Cylinder arrangement Forward-inclined parallel
2-cylinder
Displacement 897 cm
3
Bore ×Stroke 92.0 ×67.5 mm
Compression ratio 10.4:1
Starting system Electric starter
Lubrication system Dry sumpEngine oil
Type
Recommended engine oil
classification API Service SE, SF, SG type
or higher
cC
In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not mix any chemical additives. Do
not use oils with a diesel specification of “CD” or oils of a
higher quality than specified. In addition, do not use oils
labeled “ENERGY CONSERVING II” or higher.
Capacity
Without oil filter element
removal 3.8 L
With oil filter element removal 3.9 L
Total amount (dry engine) 4.7 L
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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

INDEX
Checking ............................................6-27
Drive chain, lubricating .........................6-28
E
Engine break-in ......................................5-3
Engine idling speed ..............................6-17
Engine oil and oil filter element ..............6-8
F
Front and rear brake pads, checking ....6-24
Front fork, adjusting ..............................3-14
Front fork, checking ..............................6-31
Fuel ......................................................3-11
Fuel consumption, tips for reducing .......5-3
Fuel tank breather hose .......................3-12
Fuel tank cap ........................................3-10
Fuses, replacing ...................................6-34
H
Handlebar switches ................................3-7
Dimmer switch .....................................3-7
Engine stop switch ...............................3-8
Hazard switch ......................................3-8
Horn switch ..........................................3-8
Pass switch ..........................................3-7
Start switch ..........................................3-8
Turn signal switch ................................3-8
Headlight bulb, replacing ......................6-35
I
Identification numbers ............................9-1
Ignition circuit cut-off system ................3-19Indicator and warning lights ....................3-2
Fuel level warning symbol ...................3-2
Turn signal indicator lights ...................3-3
High beam indicator light .....................3-3
Neutral indicator light ...........................3-3
Engine trouble warning light ................3-3
Oil level warning light ...........................3-3
K
Key identification number .......................9-1
L
Luggage strap holders ..........................3-18
M
Main switch/steering lock .......................3-1
Model label .............................................9-2
P
Parking ...................................................5-4
Part locations ..........................................2-1
Periodic maintenance and lubrication
chart .....................................................6-2
Pre-operation check list ..........................4-1
R
Rear brake light switch, adjusting .........6-24
Rear suspension, lubricating ................6-31
S
Seat ......................................................3-13
Shift pedal ..............................................3-9A
Air filter element, replacing ...................6-16
Anti-theft alarm (optional) .......................3-7
B
Battery ..................................................6-33
Brake and clutch levers, checking
and lubricating ...................................6-30
Brake and shift pedals, checking
and lubricating ...................................6-30
Brake fluid level, checking ....................6-25
Brake fluid, changing ............................6-26
Brake lever .............................................3-9
Brake pedal ..........................................3-10
Brake pedal position, adjusting ............6-23
C
Cables, checking and lubricating ..........6-29
Care ........................................................7-1
Catalytic converter ................................3-12
Clutch lever ............................................3-9
Clutch lever free play, adjusting ...........6-22
Conversion table ....................................8-5
Coolant .................................................6-11
Checking ............................................6-11
Changing ...........................................6-13
Coolant temperature gauge ....................3-6
Cowlings and panels, removing
and installing ........................................6-5
D
Drive chain slack ..................................6-27
Adjusting ............................................6-27
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