2003 YAMAHA TDM 900 service

3-18
INSTRUMENT AND CONTROL FUNCTIONS
3
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This shock absorber contains
highly pressurized nitrogen gas.
For proper handling, read and
understand the following informa-
tion before handling the shock
absorber. The manufacturer can-
not be held responsible for proper-
ty damage or personal injury that
may result from improper han-
dling.
8Do not tamper with or attempt
to open the gas cylinder.
8Do not subject the shock
absorber to an open flame or
other high heat sources, other-
wise it may explode due to
excessive gas pressure.
8Do not deform or damage the
gas cylinder in any way, as
this will result in poor damp-
ing performance.
8Always have a Yamaha dealer
service the shock absorber.
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Luggage strap holdersLuggage strap holdersThere are four luggage strap holders
below the passenger seat, two of
which can be turned out for easier
access.
1. Luggage strap holder (×4)
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SidestandSidestandThe sidestand is located on the left
side of the frame. Raise the side-
stand or lower it with your foot while
holding the motorcycle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain situ-
ations. (See further down for an
explanation of the ignition circuit cut-
off system.)
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6-1
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. The most important
points of inspection, adjustment, and
lubrication are explained on the fol-
lowing pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a
general guide under normal riding
conditions. However, DEPENDING
ON THE WEATHER, TERRAIN,
GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTE-
NANCE INTERVALS MAY NEED TO
BE SHORTENED.
EW000060
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If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you.
NOTE:
If you do not have the tools or experi-
ence required for a particular job,
have a Yamaha dealer perform it for
you.
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Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle
unsafe for use. Consult a Yamaha
dealer before attempting any
changes.
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Owner’s tool kitTool kitThe owner’s tool kit is located inside
the storage compartment under the
seat. (See page 3-13 for seat
removal procedures.)
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to
assist you in the performance of pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be nec-
essary to perform certain mainte-
nance work correctly.
1. Owner’s tool kit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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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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6-28
PERIODIC MAINTENANCE AND MINOR REPAIR
6
NOTE:
Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same
position for proper wheel alignment.
EC000096
cC
Improper drive chain slack will
overload the engine as well as
other vital parts of the motorcycle
and can lead to chain slippage or
breakage. To prevent this from
occurring, keep the drive chain
slack within the specified limits.
1. Bolt
2. Brake caliper bracket
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Lubricating the drive chainDrive chain, lubricatingThe drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly
wear out, especially when riding in
dusty or wet areas. Service the drive
chain as follows.
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The drive chain must be lubricated
after washing the motorcycle or
riding in the rain.
1. Clean the drive chain with
kerosene and a small soft brush.
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To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents.
3. Tighten the locknuts, and then
tighten the axle nut and the
brake caliper bracket bolt to the
specified torques.
Tightening torque:
Axle nut:
150 Nm (15.0 m·kgf)
Brake caliper bracket bolt:
40 Nm (4.0 m·kgf)
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6-38
PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
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cC
Do not overtighten the screw, oth-
erwise the lens may break.
1. Turn signal light bulb
To service the rear wheel
Raise the rear wheel off the ground
by using a motorcycle stand or, if a
motorcycle stand is not available, by
placing a jack either under each side
of the frame in front of the rear wheel
or under each side of the swingarm.EAU01579
Supporting the motorcycleSupporting the motorcycleSince this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and
rear wheel or performing other main-
tenance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed
under the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcy-
cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing
a jack under the frame in front of
the rear wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
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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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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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To install the front wheelInstalling1. Lift the wheel up between the
fork legs.
2. Insert the wheel axle.
3. Lower the front wheel so that it is
on the ground.
4. Install the brake calipers by
installing the bolts.
NOTE:
Make sure that there is enough
space between the brake pads
before installing the brake calipers
onto the brake discs.
5. Install the brake hose holders by
installing the bolts.
6. Tighten the wheel axle, the front
wheel axle pinch bolt and the
brake caliper bolts to the speci-
fied torques.
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Rear wheel
Wheel (rear)To remove the rear 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. Bolt (×2)
2. Quick fastener (×3)7. Push down hard on the handle-
bar several times to check for
proper fork operation. Tightening torques:
Wheel axle:
72 Nm (7.2 m·kgf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf)
Brake caliper bolt:
40 Nm (4.0 m·kgf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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TroubleshootingTroubleshootingAlthough Yamaha motorcycles
receive a thorough inspection before
shipment from the factory, trouble
may occur during operation. Any
problem in the fuel, compression, or
ignition systems, for example, can
cause poor starting and loss of
power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcy-
cle require any repair, take it to a
Yamaha dealer, whose skilled techni-
cians have the necessary tools,
experience, and know-how to service
the motorcycle properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life
and can lead to expensive repair
bills.
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