2003 YAMAHA TDM 900 oil

2-1
EAU00026
DESCRIPTIONPart locations
2
1. Front fork spring preload adjusting bolt (page 3-15)
2. Front fork damping force adjusting
screw (page 3-15)
3. Air filter element (page 6-16)
4. Shock absorber assembly compression
damping force adjusting knob (page 3-17)
5. Battery (page 6-33)
6. Fuses (page 6-34)
7. Storage compartment (page 3-14)8. Grab bar
9. Luggage strap holders (page 3-18)
10. Seat lock (page 3-13)
11. Shock absorber assembly rebound
damping force adjusting knob (page 3-17)
12. Shock absorber assembly spring
preload adjusting ring (page 3-16)
13. Shift pedal (page 3-9)
14. Engine oil drain bolt A (page 6-9)
12
345678
9 9 10 11 12 13 1412
345678
9 9 10 11 12 13 14Left view
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2-2
DESCRIPTION
2
15. Tool kit (page 6-1)
16. Coolant reservoir (page 6-11)
17. Throttle stop screw (page 6-17)
18. Front brake master cylinder (page 6-25)
19. Radiator cap (page 6-13)20. Engine oil filler cap (page 6-8)
21. Engine oil filter element (page 6-10)
22. Engine oil drain bolt B (page 6-10)
23. Brake pedal (page 3-10)
24. Rear brake fluid reservoir (page 6-26)
915 16 17 18
19
20 21 22 23 249Right view
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3-2
INSTRUMENT AND CONTROL FUNCTIONS
3
EW000016
w
Never turn the key to “OFF” or
“LOCK” while the motorcycle is
moving, otherwise the electrical
systems will be switched off,
which may result in loss of control
or an accident. Make sure that the
motorcycle is stopped before turn-
ing the key to “OFF” or “LOCK”.
ab
a. Push.
b. Turn.
EAU03034
Indicator and warning lights
Indicator and warning lightsEAU04478
Fuel level warning symbol “”Fuel level warning symbolThis fuel level warning symbol starts
flashing when the fuel level drops
below approximately 3.5 L.
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”
EAU01590
.(Parking)
The steering is locked, and the tail-
light and auxiliary light are on, but all
other electrical systems are off. The
key can be removed.
The steering must be locked before
the key can be turned to “
.”.ECA00043
cC
Do not use the parking position for
an extended length of time, other-
wise the battery may discharge.
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3-3
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU04877
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”
EAU04121
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.
EAU00063
High beam indicator light “&”High beam indicator lightThis indicator light comes on when
the high beam of the headlight is
switched on.
EAU00061
Neutral indicator light “N”Neutral indicator lightThis indicator light comes on when
the transmission is in the neutral
position.
EAU04585
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.
5PS-28199-E1 8/29/02 9:16 AM Page 16

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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5-1
EAU00372
OPERATION AND IMPORTANT RIDING POINTS
5
EAU00373
w
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.
EAU03951
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.
EW000054
w
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 “#”.
ECA00083
cC
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
EAU04315
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.
ECA00058
cC
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.
EC000053
cC
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.
EAU00460
ParkingParkingWhen parking, stop the engine, and
then remove the key from the main
switch.
EW000058
w
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.
5PS-28199-E1 8/29/02 9:16 AM Page 43

PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .....................................................6-1
Periodic maintenance and lubrication chart .........6-2
Removing and installing cowlings and panels ......6-5
Checking the spark plugs .....................................6-7
Engine oil and oil filter element ............................6-8
Coolant ...............................................................6-11
Replacing the air filter element ...........................6-16
Adjusting the engine idling speed .......................6-17
Adjusting the throttle cable free play ..................6-18
Adjusting the valve clearance .............................6-18
Tires ...................................................................6-18
Cast wheels ........................................................6-22
Adjusting the clutch lever free play .....................6-22
Adjusting the brake pedal position .....................6-23
Adjusting the rear brake light switch ...................6-24
Checking the front and rear brake pads .............6-24
Checking the brake fluid level ............................6-25
Changing the brake fluid ....................................6-26
Drive chain slack ................................................6-27
Lubricating the drive chain .................................6-28
Checking and lubricating the cables ...................6-29
Checking and lubricating the throttle grip
and cable .........................................................6-29Checking and lubricating the brake and
shift pedals ......................................................6-30
Checking and lubricating the brake and
clutch levers ....................................................6-30
Checking and lubricating the sidestand ..............6-30
Lubricating the rear suspension .........................6-31
Checking the front fork .......................................6-31
Checking the steering .........................................6-32
Checking the wheel bearings .............................6-32
Battery ................................................................6-33
Replacing the fuses ............................................6-34
Replacing a headlight bulb .................................6-35
Replacing a tail/brake light bulb .........................6-37
Replacing a turn signal light bulb .......................6-37
Supporting the motorcycle ..................................6-38
Front wheel .........................................................6-39
Rear wheel .........................................................6-40
Troubleshooting ..................................................6-43
Troubleshooting charts .......................................6-44
6
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