2004 YAMAHA TDM 900 check engine

OPERATION AND IMPORTANT RIDING POINTS
5-4
2
3
4
56
7
8
9

the oil filter element replaced.
1,600 km (1,000 mi) and beyond
The vehicle can now be operated nor-
mally.
CAUTION:

ECA10310

Keep the engine speed out of
the tachometer red zone.

If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-
cle.
EAU17211
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
WARNING

EWA10310

Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.

Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
CAUTION:

ECA10380
Never park in an area where there
are fire hazards such as grass or
other flammable materials.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
1
2
3
4
5
6
7
8
9

10

*
Tires

Check tread depth and for damage.

Replace if necessary.

Check air pressure.

Correct if necessary.
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11

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Wheel bearings

Check bearing for looseness or damage.
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12

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Swingarm

Check operation and for excessive play.
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Lubricate with lithium-soap-based grease. Every 50000 km
13

Drive chain

Check chain slack.

Make sure that the rear wheel is properly aligned.

Clean and lubricate.Every 1000 km and after washing the motorcycle or
riding in the rain
14

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Steering bearings

Check bearing play and steering for roughness.
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Lubricate with lithium-soap-based grease. Every 20000 km
15

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Chassis fasteners

Make sure that all nuts, bolts and screws are properly
tightened.
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16

Sidestand

Check operation.

Lubricate.
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17

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Sidestand switch

Check operation.
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18

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Front fork

Check operation and for oil leakage.
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19

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Shock absorber assem-
bly

Check operation and shock absorber for oil leakage.
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20

*
Rear suspension relay
arm and connecting arm
pivoting points

Check operation.
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Lubricate with lithium-soap-based grease.
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21

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Electronic fuel injection

Adjust engine idling speed and synchronization.
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22

Engine oil

Change.

Check oil level and vehicle for oil leakage.
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23

Engine oil filter element

Replace.
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24
*Cooling system
Check coolant level and vehicle for coolant leakage.√ √ √ √ √ Change. Every 3 years NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
2
3
4
5
67
8
9
To install the cowling
Place the cowling in the original posi-
tion, and then install the screws and the
quick fastener.NOTE:

To install the quick fastener, push the
center pin out so that it will protrude
from the fastener head, insert the fas-
tener into the cowling, and then push
the protruding pin in until it is flush with
the fastener head.
EAU19171
Panels A and B
To remove one of the panels
1. Remove the corresponding cowl-
ing A or B. (See page 6-5.)
2. Remove the seat. (See
page 3-13.)
3. Remove the screw, and then take
the panel off.To install the panel
1. Place the panel in the original po-
sition, and then install the screw.
2. Install the seat and the cowling.

EAU19641
Checking the spark plugs
The 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 mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal color
when the vehicle is ridden normally),
and all spark plugs installed in the en-
gine 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 deal-
er check the vehicle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.
1. Screw
1. Panel B
1
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
1
2
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5
6
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8
9
Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
NOTE:

If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
EAU19830
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:

Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.
2. Start the engine, warm it up for 15
minutes, and then turn it off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in and with the arrow
mark pointing upward as shown), Specified spark plug:
NGK/DPR8EA-9
DENSO/X24EPR-U9
1. Spark plug gap
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
1

Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf,
12.7 ft·lbf)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
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67
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and then remove it again to check
the oil level.
NOTE:

The engine oil should be between the
minimum and maximum level marks.
CAUTION:

ECA10010
Do not operate the vehicle until you
know that the engine oil level is suf-
ficient.
WARNING

EWA10360
Never remove the engine oil tank
cap after high-speed operation, oth-
erwise hot engine oil could spout
out and cause damage or injury. Al-
ways let the engine oil cool down
sufficiently before removing the oil
tank cap.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Install the oil filler cap.
NOTE:


The engine oil tank is located be-
hind the cylinders.

The engine oil should be between
the minimum and maximum level
marks.
To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolts to drain the oil from
the crankcase.
1. Engine oil filler cap
1

1. Engine oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
1
2
3
4

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
2
3
4
5
67
8
9
CAUTION:

ECA11620

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

Make sure that no foreign mate-
rial enters the crankcase.
9. Start the engine, and then let it idlefor several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU20101
To check the coolant level
1. Place the vehicle on the center-
stand.
NOTE:


The coolant level must be checked
on a cold engine since the level
varies with engine temperature.

Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.
NOTE:

The coolant should be between the
minimum and maximum level marks. Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
3.80 L (4.02 US qt)
(3.34 Imp.qt)
With oil filter element replace-
ment:
3.90 L (4.12 US qt)
(3.43 Imp.qt)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
1
2
3
4
5
6
7
8
9
3. If the coolant is at or below the
minimum level mark, remove pan-
el B (See page 6-5.), remove the
reservoir cap, add coolant to the
maximum level mark, and then in-
stall the reservoir cap and the pan-
el.
CAUTION:

ECA10470

If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.

If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-ing system will not be protected
against frost and corrosion.

If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
WARNING

EWA10380
Never attempt to remove the radiator
cap when the engine is hot.
NOTE:


The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.

If the engine overheats, see page
6-39 for further instructions.
EAU20450
To change the coolant
1. Place the vehicle on a level sur-
face and let the engine cool if nec-
essary.
2. Remove the seat. (See
page 3-13.)
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
1 2
3

1. Coolant reservoir cap
Coolant reservoir capacity (up to
the maximum level mark):
0.25 L (0.26 US qt)
(0.22 Imp.qt)
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
2
3
4
5
67
8
9
3. Remove cowling B and panel B.
(See page 6-5.)
4. Remove the fuel tank bolts, and
then lift the fuel tank to position it
away from the coolant reservoir.
(Do not disconnect the fuel hoses!)
5. Place a container under the engine
to collect the used coolant.
6. Remove the radiator cap retaining
bolt and the radiator cap.
WARNING

EWA10380
Never attempt to remove the radiator
cap when the engine is hot.
7. Remove the coolant drain bolts todrain the cooling system.
8. Remove the coolant reservoir bolt.
9. Pull the coolant reservoir upward
and away from the vehicle.
10. Drain the remaining coolant fromthe coolant reservoir by opening
the cap, then turning the reservoir
upside down.
11. Install the coolant reservoir by
placing it in the original position,
then installing the bolt.
12. After the coolant is completely
drained, thoroughly flush the cool-
ing system with clean tap water.
13. Install the coolant drain bolts, and
then tighten them to the specified
torque.
NOTE:

Check the washers for damage and re-
place them if necessary.
14. Pour the recommended coolant
into the radiator until it is full.
1. Radiator cap retaining bolt
2. Radiator cap
1
2

1. Coolant drain bolt
1. Bolt
2. Coolant reservoir
11
1
2

Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)