2003 YAMAHA TDM 900 transmission

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.
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High beam indicator light “&”High beam indicator lightThis indicator light comes on when
the high beam of the headlight is
switched on.
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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.
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3-9
INSTRUMENT AND CONTROL FUNCTIONS
3
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Clutch leverClutch leverThe clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the han-
dlebar grip. To engage the clutch,
release the lever. The lever should
be pulled rapidly and released slowly
for smooth clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-19 for an explanation of the ignition
circuit cut-off system.)
1. Clutch lever
EAU00157
Shift pedalShift pedalThe shift pedal is located on the left
side of the engine and is used in
combination with the clutch lever
when shifting the gears of the
6-speed constant-mesh transmission
equipped on this motorcycle.
1. Shift pedal
EAU00161
Brake leverBrake leverThe brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the han-
dlebar grip.
The brake lever is equipped with a
position adjusting dial.
1. Brake lever
2. Brake lever position adjusting dial
3. Arrow mark
a. Distance between brake lever and
handlebar grip
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3-19
INSTRUMENT AND CONTROL FUNCTIONS
3
EW000044
w
The motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up),
otherwise the sidestand could con-
tact the ground and distract the
operator, resulting in a possible
loss of control. Yamaha’s ignition
circuit cut-off system has been
designed to assist the operator in
fulfilling the responsibility of rais-
ing the sidestand before starting
off. Therefore, check this system
regularly as described below and
have a Yamaha dealer repair it if it
does not function properly.
EAU03720
Ignition circuit cut-off
system
Ignition circuit cut-off systemThe ignition circuit cut-off system
(comprising the sidestand switch,
clutch switch and neutral switch) has
the following functions.
8It prevents starting when the
transmission is in gear and the
sidestand is up, but the clutch
lever is not pulled.
8It prevents starting when the
transmission is in gear and the
clutch lever is pulled, but the
sidestand is still down.
8It cuts the running engine when
the transmission is in gear and
the sidestand is moved down.
Periodically check the operation of
the ignition circuit cut-off system
according to the following procedure.
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If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
5PS-28199-E1 8/29/02 9:16 AM Page 32

3-20
INSTRUMENT AND CONTROL FUNCTIONS
3
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
#”.
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
NOTE:
This check is most reliable if performed with
a warmed-up engine.
YES
YES NO
The system is OK. The motorcycle can be ridden.
YES NO
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5-1
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OPERATION AND IMPORTANT RIDING POINTS
5
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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.
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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 “#”.
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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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5-2
OPERATION AND IMPORTANT RIDING POINTS
5
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the
engine more than 10 seconds on any
one attempt.
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For maximum engine life, never
accelerate hard when the engine is
cold!
NOTE:
The engine is warm when it quickly
responds to the throttle.
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8Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long
distances. The transmission is
properly lubricated only when
the engine is running.
Inadequate lubrication may
damage the transmission.
8Always use the clutch while
changing gears to avoid dam-
aging the engine, transmis-
sion, and drive train, which are
not designed to withstand the
shock of forced shifting.
EAU00423
ShiftingShiftingShifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the
illustration.
NOTE:
To shift the transmission into the neu-
tral position, press the shift pedal
down repeatedly until it reaches the
end of its travel, and then slightly
raise it.
1. Shift pedal
N. Neutral position
5PS-28199-E1 8/29/02 9:16 AM Page 41

6-27
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00744
Drive chain slackDrive chain slackThe drive chain slack should be
checked before each ride and adjust-
ed if necessary.
To check the drive chain slack
Checking1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:
When checking and adjusting the
drive chain slack, the motorcycle
should be positioned straight up and
there should be no weight on it.EAU04372
To adjust the drive chain slackAdjusting1. Loosen the axle nut, the brake
caliper bracket bolt and the lock-
nut on each side of the
swingarm.
2. To tighten the drive chain, turn
the adjusting bolt on each side of
the swingarm in direction a. To
loosen the drive chain, turn the
adjusting bolt on each side of the
swingarm in direction b, and
then push the rear wheel for-
ward.
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
2. Shift the transmission into the
neutral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain,
and then measure the drive
chain slack as shown.
4. If the drive chain slack is incor-
rect, adjust it as follows.
a. Drive chain slack
Drive chain slack:
50–60 mm
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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
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