2003 YAMAHA TDM 900 wheel bolts

4-2
PRE-OPERATION CHECKS
4
Throttle grip•Make sure that operation is smooth.
•Check cable free play.
•If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-18, 6-29
Control cables•Make sure that operation is smooth.
•Lubricate if necessary.6-29
Drive chain•Check chain slack.
•Adjust if necessary.
•Check chain condition.
•Lubricate if necessary.6-27–6-29
Wheels and tires•Check for damage.
•Check tire condition and tread depth.
•Check air pressure.
•Correct if necessary.6-18–6-22
Brake and shift pedals•Make sure that operation is smooth.
•Lubricate pedal pivoting points if necessary.6-30
Brake and clutch levers•Make sure that operation is smooth.
•Lubricate lever pivoting points if necessary.6-30
Sidestand•Make sure that operation is smooth.
•Lubricate pivot if necessary.6-30
Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.
•Tighten if necessary.—
Instruments, lights, signals
and switches•Check operation.
•Correct if necessary.3-2–3-3, 3-7–3-8, 6-35–6-38
Sidestand switch•Check operation of ignition circuit cut-off system.
•If system is defective, have Yamaha dealer check vehicle.3-18–3-20 ITEM CHECKS PAGE
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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
5PS-28199-E1 8/29/02 9:16 AM Page 48

6-39
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01617
Front wheelWheel (front)
To remove the front wheelRemovingEW000122
w
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
ECA00046
cC
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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6-40
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04376
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.
EAU04455
Rear wheel
Wheel (rear)To remove the rear wheelRemovingEW000122
w
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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6-41
PERIODIC MAINTENANCE AND MINOR REPAIR
61. Remove the drive chain cover by
removing the quick fasteners and
the bolts.
4. Remove the axle nut.
5. Loosen the locknut on each side
of the swingarm.
6. Turn the drive chain slack adjust-
ing bolts fully in direction a.
7. Push the wheel forward, tighten
the caliper bracket bolt, and then
remove the drive chain from the
rear sprocket.
NOTE:
The drive chain does not need to be
disassembled in order to remove and
install the rear wheel.
1. Bolt
2. Brake caliper bracket
2. Loosen the axle nut and the
brake caliper bracket bolt.
3. Lift the rear wheel off the ground
according to the procedure on
page 6-38.
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
5PS-28199-E1 8/29/02 9:17 AM Page 86

6-42
PERIODIC MAINTENANCE AND MINOR REPAIR
6 8. Pull the wheel axle out, and then
remove the wheel.
ECA00119
cC
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake caliper pistons will be forced
out.
7. Install the drive chain cover by
installing the bolts and quick fas-
teners.
NOTE:
To install a quick fastener, push the
pin back so that it will protrude from
the fastener head, and then insert the
fastener and push the protruding pin
in until it is flush with the fastener
head.
EAU04456
To install the rear wheelInstalling1. Install the wheel by inserting the
wheel axle from the right hand
side.
NOTE:
Make sure that there is enough
space between the brake pads
before installing the wheel.
2. Install the drive chain onto the
rear sprocket.
3. Loosen the brake caliper bracket
bolt.
4. Adjust the drive chain slack.
(See page 6-27 for drive chain
slack adjustment procedures.)
5. Install the axle nut, and then
lower the rear wheel so that it is
on the ground.
6. Tighten the axle nut and the
brake caliper bracket bolt to the
specified torques.Tightening torques:
Axle nut:
150 Nm (15.0 m·kgf)
Brake caliper bracket bolt:
40 Nm (4.0 m·kgf)
1. Quick fastener
2. Pin
After removalBefore installation
5PS-28199-E1 8/29/02 9:17 AM Page 87