2003 YAMAHA TDM 900 spark plugs

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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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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6-7
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01880
Checking the spark plugsSpark plugs, checkingThe spark plugs are important engine
components, which should be
checked periodically, preferably by a
Yamaha dealer. Since heat and
deposits will cause any spark plug to
slowly erode, they should be
removed and checked in accordance
with the periodic maintenance and
lubrication chart. In addition, the con-
dition of the spark plugs can reveal
the condition of the engine.
The porcelain insulator around the
center electrode of each spark plug
should be a medium-to-light tan (the
ideal color when the motorcycle is rid-
den normally), and all spark plugs
installed in the engine should have
the same color. If any spark plug
shows a distinctly different color, the
engine could be defective. Do not
attempt to diagnose such problems
yourself. Instead, have a Yamaha
dealer check the motorcycle.Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
a. Spark plug gap
If a spark plug shows signs of elec-
trode erosion and excessive carbon
or other deposits, it should be
replaced.
Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification.
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf)
Specified spark plug:
DPR8EA-9 (NGK) or
X24EPR-U9 (DENSO)
Spark plug gap:
0.8–0.9 mm
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU02990
Troubleshooting chartsTroubleshooting chartsStarting problems or poor engine performanceEW000125
w
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.
1. FuelThere is enough fuel.
There is no fuel.Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.
2. CompressionThere is compression.
There is no compression.Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.
3. IgnitionWipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.
4. BatteryThe engine turns over
quickly.
The engine turns over
slowly.The battery is good.
Check the battery lead connections,
and charge the battery if necessary.
Dry
WetOpen the throttle halfway and operate
the electric starter.
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7
7-4
MOTORCYCLE CARE AND STORAGE
ECA00013
cC
8Apply spray oil and wax spar-
ingly and make sure to wipe
off any excess.
8Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
8Avoid using abrasive polish-
ing compounds as they will
wear away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
Storage
StorageShort-term
Always store your motorcycle in a
cool, dry place and, if necessary, pro-
tect it against dust with a porous
cover.
ECA00014
cC
8Storing the motorcycle in a
poorly ventilated room or cov-
ering it with a tarp, while it is
still wet, will allow water and
humidity to seep in and cause
rust.
8To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
3. Perform the following steps to
protect the cylinders, piston
rings, etc. from corrosion.
a. Remove the spark plug caps
and spark plugs.
b. Pour a teaspoonful of engine
oil into each spark plug bore.
c. Install the spark plug caps
onto the spark plugs, and then
place the spark plugs on the
cylinder head so that the elec-
trodes are grounded. (This will
limit sparking during the next
step.)
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7
7-5
MOTORCYCLE CARE AND STORAGE
d. Turn the engine over several
times with the starter. (This
will coat the cylinder walls with
oil.)
e. Remove the spark plug caps
from the spark plugs, and then
install the spark plugs and the
spark plug caps.
EWA00003
w
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turn-
ing the engine over.
4. Lubricate all control cables and
the pivoting points of all levers
and pedals as well as of the
sidestand/centerstand.5. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground.
Alternatively, turn the wheels a
little every month in order to pre-
vent the tires from becoming
degraded in one spot.
6. Cover the muffler outlets with
plastic bags to prevent moisture
from entering them.
7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a
month. Do not store the battery
in an excessively cold or warm
place [less than 0 °C or more
than 30 °C]. For more informa-
tion on storing the battery, see
page 6-34.
NOTE:
Make any necessary repairs before
storing the motorcycle.
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Shift points (for Switzerland only) ...........5-3
Shifting ...................................................5-2
Shock absorber assembly, adjusting ....3-16
Sidestand .............................................3-18
Sidestand, checking and lubricating .....6-30
Spark plugs, checking ............................6-7
Specifications .........................................8-1
Speedometer unit ...................................3-4
Starting the engine .................................5-1
Steering, checking ................................6-32
Storage ...................................................7-4
Storage compartment ...........................3-14
Supporting the motorcycle ....................6-38
T
Tachometer unit .....................................3-5
Tail/brake light bulb, replacing ..............6-37
Throttle cable free play, adjusting ........6-18
Throttle grip and cable, checking
and lubricating ...................................6-29
Tires .....................................................6-18
Tool kit ....................................................6-1
Troubleshooting ....................................6-43
Troubleshooting charts .........................6-44
Turn signal light bulb, replacing ............6-37
V
Valve clearance, adjusting ...................6-18
Vehicle identification number .................9-1W
Wheel (front)..........................................6-39
Installing .............................................6-40
Removing ...........................................6-39
Wheel (rear) .........................................6-40
Installing .............................................6-42
Removing ...........................................6-40
Wheel bearings, checking ....................6-32
Wheels .................................................6-22
INDEX
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