2003 YAMAHA TDM 900 steering

2-3
DESCRIPTION
2
1. Clutch lever (page 3-9)
2. Left handlebar switches (page 3-7)
3. Speedometer unit (page 3-4)
4. Main switch/steering lock (page 3-1)
5. Tachometer unit (page 3-5)6. Coolant temperature gauge (page 3-6)
7. Right handlebar switches (page 3-8)
8. Brake lever (page 3-9)
9. Throttle grip (page 6-18)
1 2 345 6 7 8 9
Controls and instruments
5PS-28199-E1 8/29/02 9:16 AM Page 12

INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock ...................................................................3-1
Indicator and warning lights ...............................................................3-2
Speedometer unit ..............................................................................3-4
Tachometer unit .................................................................................3-5
Coolant temperature gauge ...............................................................3-6
Anti-theft alarm (optional) ..................................................................3-7
Handlebar switches ...........................................................................3-7
Clutch lever ........................................................................................3-9
Shift pedal ..........................................................................................3-9
Brake lever ........................................................................................3-9
Brake pedal .....................................................................................3-10
Fuel tank cap ...................................................................................3-10
Fuel ..................................................................................................3-11
Fuel tank breather hose ...................................................................3-12
Catalytic converter ...........................................................................3-12
Seat .................................................................................................3-13
Storage compartment ......................................................................3-14
Adjusting the front fork .....................................................................3-14
Adjusting the shock absorber assembly ..........................................3-16
Luggage strap holders .....................................................................3-18
Sidestand .........................................................................................3-18
Ignition circuit cut-off system ...........................................................3-19
3
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3-1
EAU00029
Main switch/steering lockMain switch/steering lockThe main switch/steering lock con-
trols the ignition and lighting systems,
and is used to lock the steering. The
various positions are described
below.
EAU04926
ON
All electrical circuits are supplied with
power; the meter lighting, taillight and
auxiliary light come on, and the
engine can be started. The key can-
not be removed.
EAU00027
INSTRUMENT AND CONTROL FUNCTIONS
3
NOTE:
The headlight comes on automatical-
ly when the engine is started and
stays on until the key is turned to
“OFF”.
EAU00038
OFF
All electrical systems are off. The key
can be removed.
EAU00040
LOCK
The steering is locked, and all electri-
cal systems are off. The key can be
removed.
To lock the steering
1. Turn the handlebars all the way
to the left.
2. Push the key in from the “OFF”
position, and then turn it to
“LOCK” while still pushing it.
3. Remove the key.
To unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
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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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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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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
6
10*Tires•Check tread depth and for damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.√√√√ √
11
*Wheel bearings•Check bearing for looseness or damage.√√√√
12
*Swingarm•Check operation and for excessive play.√√√√
•Lubricate with lithium-soap-based grease. Every 50,000 km
13 Drive chain•Check chain slack.
•Make sure that the rear wheel is properly aligned.
•Clean and lubricate.Every 1,000 km and after washing
the motorcycle or riding in the rain
14
*Steering bearings•Check bearing play and steering for roughness.√√√√√
•Lubricate with lithium-soap-based grease.Every 20,000 km
15
*Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.√√√√ √
16 Sidestand•Check operation.
•Lubricate.√√√√ √
17
*Sidestand switch•Check operation.√√√√√ √
18
*Front fork•Check operation and for oil leakage.√√√√
19
*Shock absorber
assembly•Check operation and shock absorber for oil leakage.√√√√
20
*
Rear suspension relay
arm and connecting arm
pivoting points•Check operation.√√√√
•Lubricate with lithium-soap-based grease.√√
21
*Electronic fuel injection•Adjust engine idling speed and synchronization.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
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6-32
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00794
Checking the steeringSteering, checkingWorn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine
to raise the front wheel off the
ground.
EW000115
w
Securely support the motorcycle
so that there is no danger of it
falling over.
EAU01144
Checking the wheel bearingsWheel bearings, checkingThe front and rear wheel bearings
must be checked at the intervals
specified in the periodic maintenance
and lubrication chart. If there is play
in the wheel hub or if the wheel does
not turn smoothly, have a Yamaha
dealer check the wheel bearings.
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any
free play can be felt, have a
Yamaha dealer check or repair
the steering.
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9
9-1
EAU01039
CONSUMER INFORMATION
EAU02944
Identification numbersIdentification numbersRecord the key identification number,
vehicle identification number and
model label information in the spaces
provided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the
vehicle is stolen.
1. KEY IDENTIFICATION
NUMBER:
2. VEHICLE IDENTIFICATION
NUMBER:
3. MODEL LABEL INFORMATION:
EAU01043
Vehicle identification numberVehicle identification numberThe vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro-
vided.
NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motor-
cycle with the licensing authority in
your area.
1. Identification number
EAU01041
Key identification numberKey identification numberThe key identification number is
stamped into the key tag.
Record this number in the space pro-
vided and use it for reference when
ordering a new key.
1. Key identification number
1
6
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