Yamaha TDM 2002 Owner Manual U5PSE0

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    5PS-28199-E0

    OWNERS MANUAL

    TDM900

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    EAU03338

    Welcome to the Yamaha world of motorcycling!

    As the owner of a TDM900, you are benefiting from Yamahas vnewest technology regarding the design and manufacture of hig

    which have earned Yamaha a reputation for dependability.Please take the time to read this manual thoroughly, so as to enjoyyour TDM900. The owners manual does not only instruct youinspect and maintain your motorcycle, but also in how to safeguarers from trouble and injury.

    In addition, the many tips given in this manual will help keep yobest possible condition. If you have any further questions, do not your Yamaha dealer.

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    IMPORTANT MANUAL INFORMATIONParticularly important information is distinguished in this manual by the following notations:

    The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR INVOLVED!

    WARNING Failure to follow WARNING instructions could result in severe injury or deathmotorcycle operator, a bystander, or a person inspecting or repairing the mo

    cycle.

    CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage tmotorcycle.

    NOTE: A NOTE provides key information to make procedures easier or clearer.

    NOTE:@This manual should be considered a permanent part of this motorcycle and

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    IMPORTANT MANUA

    WARNING@

    PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFOTHIS MOTORCYCLE.@

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    IMPORTANT MANUAL INFORMATION

    EAU04229

    TDM900OWNERS MANUAL

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    TAB

    1 GIVE SAFETY THE RIGHT OF W

    2 DESCRIPTION

    3 INSTRUMENT AND CONTROL

    4 PRE-OPERATION CHECKS

    5 OPERATION AND IMPORTANT

    6 PERIODIC MAINTENANCE AN

    7 MOTORCYCLE CARE AND STO

    8 SPECIFICATIONS

    EAU00009

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    1

    1-GIVE SAFETY THE RIGHT OF WAYMotorcycles are fascinating vehicles, which can give you an unsurpassed freedom. However, they also impose certain limits, which you must accept; evdoes not ignore the laws of physics.

    Regular care and maintenance are essential for preserving value and operatmotorcycle. Moreover, what is true for the motorcycle is also true for the rdepends on being in good shape. Riding under the influence of medication, dcourse, out of the question. Motorcycle riders more than car drivers and physical best. Under the influence of even small amounts of alcohol, theredangerous risks.

    Protective clothing is as essential for the motorcycle rider as seat belts arpassengers. Always wear a complete motorcycle suit (whether made of lesynthetic materials with protectors), sturdy boots, motorcycle gloves and a

    Optimum protective wear, however, should not encourage carelessness. Ahelmets and suits, in particular, create an illusion of total safety and protecalways be vulnerable. Riders who lack critical self-control run the risk of gointake chances. This is even more dangerous in wet weather. The good motpredictably and defensively avoiding all dangers, including those caused

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    Left view .............................................................Right view............................................................Controls and instruments ....................................

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    Right view

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    DESCRIPTION

    2

    Controls and instruments

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    INSTRUMENT AND CONT

    Main switch/steering lock ..................................Indicator and warning lights .............................Speedometer unit ................................................Tachometer unit ...................................................Coolant temperature gauge ................................Anti-theft alarm (optional) ..................................Handlebar switches .............................................Clutch lever ........................................................Shift pedal ..........................................................Brake lever .........................................................Brake pedal .........................................................

    Fuel tank cap .......................................................Fuel .....................................................................Fuel tank breather hose (for Germany only) ......Seat .....................................................................Storage compartment .........................................

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    3

    3-INSTRUMENT AND CONTROL FUNCTIONS

    EAU00029

    Main switch/steering lockThe main switch/steering lock controlsthe ignition and lighting systems, and isused to lock the steering. The variouspositions are described below.

    EAU00036

    ONAll electrical systems are supplied with

    EAU00040

    LOCKThe steering is locked, and all electricalsystems are off. The key can be re-moved.

    To lock the steering1. Turn the handlebars all the way to

    the left.

    W@

    Never LOCKmovingsystemsmay reacciden

    1. Push.2. Turn.

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    INSTRUMENT AND CONTROL FUNCTIONS

    3

    EAU04238

    Engine trouble warning light

    This warning light comes on or flasheswhen an electrical circuit monitoringthe engine is defective. When this oc-curs, have a Yamaha dealer check theself-diagnosis system.

    NOTE:_This warning light comes on for a fewseconds when the key is turned toON, but this does not indicate a mal-function._

    EAU04301

    Oil level warning light This warning light comes on when theengine oil level is low.The electrical circuit of the warning lightcan be checked according to the fol-

    NOTE:_

    Even if the oil level is sufficient, thewarning light may flicker when riding ona slope or during sudden accelerationor deceleration, but this is not a mal-function._

    SpeedThe spethe follo

    a sh

    1. Speed2. Odom3. SELE4. RESE5. Fuel g

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    INSTRUMENT AND CONTROL FUNCTIONS

    3

    EAU04488

    Tachometer unitThe electric tachometer allows the riderto monitor the engine speed and keep itwithin the ideal power range.

    EC000003

    CAUTION:_

    Do not operate the engine in the ta-

    To set the clock:1. Push both the SELECT and

    RESET buttons for at least twoseconds.

    2. When the hour digits start flashing,push the RESET button to setthe hours.

    3. Push the SELECT button tochange the minutes.4. When the minute digits start flash-

    ing, push the RESET button toset the minutes.

    5. Push the SELECT button to start

    the clock.

    NOTE:_

    After setting the clock, be sure topush the SELECT button beforeturning the key to OFF , other-

    CoolanWith thcoolantthe temcoolantes in ththe neezone, s

    1. Tachometer2. Tachometer red zone3. Clock

    1. Coola2. Coola

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    INSTRUMENT AND CONTEAU00109

    Anti-theft alarm (optional)

    This motorcycle can be equipped withan optional anti-theft alarm by aYamaha dealer. Contact a Yamahadealer for more information.

    EAU00118

    Handlebar switches

    EAU00119

    Pass switch Press this switch to flash the headlight.

    Turn s

    To sigswitchturn, preleaster polights,

    turned

    Horn sPress

    HazarWith ttion, uard ligturn siThe h

    1. Pass switch 2. Hazard switch 3. Dimmer switch / 4. Turn signal switch / 5. Horn switch

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    INSTRUMENT AND CONTROL FUNCTIONS

    3

    EAU02935

    Fuel tank cap

    To open the fuel tank capOpen the fuel tank cap lock cover, in-sert the key into the lock, and then turnit 1/4 turn clockwise. The lock will be re-leased and the fuel tank cap can beopened.

    2. Turn the key counterclockwise tothe original position, remove it,and then close the lock cover.

    NOTE:@

    The fuel tank cap cannot be closed un-less the key is in the lock. In addition,the key cannot be removed if the cap is

    not properly closed and locked.@

    EWA00025

    WARNING@

    Make sure that the fuel tank cap isproperly closed before riding.@

    FuelMake sthe tankof the fi

    W_

    Doerw

    1. Fuel tank cap lock cover2. Unlock.

    1. Fuel ta2. Fuel le

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    INSTRUMENT AND CONTEAU00186

    CAUTION:_

    Immediately wipe off spilled fuelwith a clean, dry, soft cloth,since fuel may deteriorate paint-ed surfaces or plastic parts.For Germany only: Wheneverreplacement is necessary, use afuel tank cap of the same spe-cial design as the original.

    _

    EAU04284

    ECA00104

    CAUTION:_

    Use only unleaded gasoline. Theuse of leaded gasoline will cause se-vere damage to internal engineparts, such as the valves and pistonrings, as well as to the exhaust sys-tem._

    Your Yamaha engine has been de-signed to use regular unleaded gaso-line with a research octane number of91 or higher. If knocking (or pinging)occurs, use a gasoline of a differentbrand or premium unleaded fuel. Useof unleaded fuel will extend spark pluglife and reduce maintenance costs.

    Fuel (for GBefore

    CcCfi

    Recommended fuel:

    REGULAR UNLEADEDGASOLINE ONLYFuel tank capacity:

    Total amount:20 L

    Reserve amount:

    1. Fuel

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    INSTRUMENT AND CONTROL FUNCTIONS

    3

    EAU02925

    Seat

    To remove the seatInsert the key into the seat lock, turn itcounterclockwise, and then pull theseat off.

    To install the seatInsert the projections on the front of theseat into the seat holder, push the rearof the seat down to lock it in place, andthen remove the key.

    NOTE:_

    Make sure that the seat is properly se-cured before riding.

    StoragThis stoto hold LOCK.placingpartmenstraps. Wstorage

    1. Seat lock2. Unlock.

    1. Projection ( 2)2. Seat holder ( 2)

    1. U-LO2. Strap

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    INSTRUMENT AND CONTROL FUNCTIONS

    3

    EAU04477

    Adjusting the front fork

    This front fork is equipped with springpreload adjusting bolts and dampingforce adjusting screws.

    EW000035

    WARNING_

    Always adjust both fork legs equal-

    ly, otherwise poor handling and lossof stability may result._

    Spring preload

    To increase the spring preload andthereby harden the suspension, turnthe adjusting bolt on each fork leg in di-rection a . To decrease the spring pre-load and thereby soften thesuspension, turn the adjusting bolt on

    CI-01E

    1. Spring preload adjusting bolt2. Current setting3. Standard setting4. Front fork cap bolt

    Setting

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    INSTRUMENT AND CONT

    Damping force1. Turn the adjusting screw on each

    fork leg in direction a until the

    screw moves almost a 1/2 turnwithout clicking.2. Continue turning the adjusting

    screw in direction a until it clicks.This is the minimum setting.

    3. To increase the damping force,continue turning the adjustingscrew in direction a . The thirdclick after the minimum setting isthe maximum setting. If the adjust-ing screw is turned further in direc-tion a , it will move half a turnbefore returning to the minimumsetting.

    NOTE:_

    Make sure that the adjusting screw isturned to one of the four settings._

    CI-01E

    1. Damping force adjusting screw

    Minimum (soft) StandardMaximum

    (hard)

    Setting 1 2 3 4

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    INSTRUMENT AND CONTROL FUNCTIONS

    3

    EAU00324

    Luggage strap holdersThere are four luggage strap holdersbelow the passenger seat, two of whichcan be turned out for easier access.

    EAU00330

    Sidestand

    The sidestand is located on the left sideof the frame. Raise the sidestand orlower it with your foot while holding themotorcycle upright.

    NOTE:@

    The built-in sidestand switch is part ofthe ignition circuit cut-off system, whichcuts the ignition in certain situations.(See further down for an explanation ofthe ignition circuit cut-off system.)@

    W@

    The mowith thsidestanmoved erwise the grotor, resucontrol.cut-off sassist threspons

    stand becheck tscribed dealer rproperly@

    1. Luggage strap holder ( 4)

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    INSTRUMENT AND CONTEAU03720

    Ignition circuit cut-off system

    The ignition circuit cut-off system (com-prising the sidestand switch, clutchswitch and neutral switch) has the fol-lowing functions.

    It prevents starting when the trans-mission is in gear and the side-

    stand is up, but the clutch lever isnot pulled.It prevents starting when the trans-mission is in gear and the clutchlever is pulled, but the sidestand isstill down.It cuts the running engine whenthe transmission is in gear and thesidestand is moved down.

    Periodically check the operation of theignition circuit cut-off system according

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    INSTRUMENT AND CONTROL FUNCTIONS

    3

    CD-01E

    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 mThe motorcycle shouchecked by a Yamah

    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.

    The sidestand switcThe motorcycle shouchecked by a Yamah

    NO

    NOTE:This check is most ra warmed-up engine

    YES

    YES NO

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    PRE OPERATION CHECKS

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    4

    4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner s responsibility. Vital components can start to deteriorate qeven if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fl

    of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thortion, to check the following points before each ride.

    Pre-operation check listCO-01E

    ITEM CHECKS

    Fuel Check fuel level in fuel tank. Refuel if necessary. Check fuel line for leakage.

    Engine oil Check oil level in engine. If necessary, add recommended oil to specified level. Check vehicle for oil leakage.

    Coolant Check coolant level in reservoir. If necessary, add recommended coolant to specified level. Check cooling system for leakage.

    Front brake

    Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check fluid level in reservoir. If necessary, add recommended brake fluid to specified level. Check hydraulic system for leakage. Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system.

    PRE OPE

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    PRE-OPE

    Control cables Make sure that operation is smooth.

    Lubricate if necessary.

    Drive chain

    Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary.

    Wheels and tires

    Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary.

    Brake and shift pedals Make sure that operation is smooth. Lubricate pedal pivoting points if necessary.

    Brake and clutch levers Make sure that operation is smooth. Lubricate lever pivoting points if necessary.

    Sidestand Make sure that operation is smooth. Lubricate pivot if necessary.

    Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary.Instruments, lights, signalsand switches

    Check operation. Correct if necessary.

    Sidestand switch Check operation of ignition circuit cut-off system. If system is defective, have Yamaha dealer check vehicle.

    ITEM CHECKS

    PRE OPERATION CHECKS

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    PRE-OPERATION CHECKS

    4

    NOTE:_

    Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accom

    short time; and the added safety it assures is more than worth the time involved._

    WARNING_

    If any item in the Pre-operation check list is not working properly, have it inspected and repaired before othe motorcycle._

    OPERATION AND IMPORTANT

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    OPERATION AND IMPORTANT

    Starting the engine ..............................................Shifting ...............................................................Recommended shift points (for Switzerland onlyTips for reducing fuel consumption ...................Engine break-in ..................................................Parking ................................................................

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    OPERATION AND IMPORTANT

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    OPERATION AND IMPORTANTNOTE:_

    If the engine fails to start, release the

    start switch, wait a few seconds, andthen try again. Each starting attemptshould be as short as possible to pre-serve the battery. Do not crank the en-gine more than 10 seconds on any oneattempt._

    ECA00045

    CAUTION:_

    For maximum engine life, never ac-celerate hard when the engine iscold!_

    NOTE:_

    The engine is warm when it quickly re-sponds to the throttle._

    OPERATION AND IMPORTANT RIDING POINTS

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    OPERATION AND IMPORTANT RIDING POINTS

    5EAU00423

    ShiftingShifting gears lets you control the

    amount of engine power available forstarting off, accelerating, climbing hills,etc.The gear positions are shown in the il-lustration.

    EC000048

    CAUTION:@

    Even with the transmission inthe neutral position, do notcoast for long periods of timewith the engine off, and do nottow the motorcycle for long dis-tances. The transmission isproperly lubricated only whenthe engine is running. Inade-quate lubrication may damagethe transmission.Always use the clutch whilechanging gears to avoid dam-aging the engine, transmission,and drive train, which are notdesigned to withstand theshock of forced shifting.

    @

    Recom

    (for SwThe recacceleralow.CF-02E

    NOTE:_

    When time, r(e.g., dfrom 5t_

    1. Shift pedalN. Neutral position

    1st2nd3rd4th5th

    OPERATION AND IMPORTANT

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    OPERATION AND IMPORTANTEAU03952

    Tips for reducing fuel

    consumptionFuel consumption depends largely onyour riding style. Consider the followingtips to reduce fuel consumption:

    Thoroughly warm up the engine.Shift up swiftly, and avoid high en-

    gine speeds during acceleration.Do not rev the engine while shift-ing down, and avoid high enginespeeds with no load on the engine.Turn the engine off instead of let-ting it idle for an extended lengthof time (e.g., in traffic jams, at traf-fic lights or at railroad crossings).

    EAU01128

    Engine break-in

    There is never a more important periodin the life of your engine than the periodbetween 0 and 1,600 km. For this rea-son, you should read the following ma-terial carefully.Since the engine is brand new, do not

    put an excessive load on it for the first1,600 km. The various parts in the en-gine wear and polish themselves to thecorrect operating clearances. Duringthis period, prolonged full-throttle oper-ation or any condition that might resultin engine overheating must be avoided.

    01,0Avoid4,000

    1,000Avoid6,000

    CAU_

    After gine ooil filt_

    1,600 The vmally.

    CAU_

    OPERATION AND IMPORTANT RIDING POINTS

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    OPERATION AND IMPORTANT RIDING POINTS

    5

    EAU00460

    Parking

    When parking, stop the engine, andthen remove the key from the mainswitch.

    EW000058

    WARNING@

    Since the engine and exhaust

    system can become very hot,park in a place where pedestri-ans or children are not likely totouch them.Do not park on a slope or onsoft ground, otherwise themotorcycle may overturn.

    @

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    PERIODIC MAINTENANCE AND

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    PERIODIC MAINTENANCE AND

    Periodic maintenance and lubrication chart

    NOTE:_The annual checks must be performed every year, except if a kilometer-based maintenance is performeFrom 50,000 km, repeat the maintenance intervals starting from 10,000 km.Items marked with an asterisk should be performed by a Yamaha dealer as they require special tocal skills.

    _

    CP-03E

    NO. ITEM CHECK OR MAINTENANCE JOBODOMETE1 10

    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.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.)

    PERIODIC MAINTENANCE AND MINOR REPAIR

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    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. E

    13 Drive chain Check chain slack. Make sure that the rear wheel is properly aligned. Clean and lubricate.

    Everthe m

    14 * Steering bearings Check bearing play and steering for roughness.

    Lubricate with lithium-soap-based grease. E

    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 absorberassembly Check operation and shock absorber for oil leakage.

    20Rear suspension relay

    d ti Check operation.

    NO. ITEM CHECK OR MAINTENANCE JOBODOMETER1 10

    PERIODIC MAINTENANCE AND

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    NOTE:_

    The air filter needs more frequent service if you are riding in unusually wet or dusty areas.Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinders and calipers, a

    fluid. Replace the brake hoses every four years and if cracked or damaged.

    25 * Front and rear brakeswitches Check operation.

    26 Moving parts and cables Lubricate.

    27 * Air induction system Check the air cut-off valve, read valve, and hose for

    damage. Replace the entire air induction system if necessary.

    28*

    Throttle grip housing

    and cable

    Check operation and free play. Adjust the throttle cable free play if necessary. Lubricate the throttle grip housing and cable.

    29 * Muffler and exhaust pipe Check the screw clamp for looseness.

    30 *Lights, signals andswitches

    Check operation. Adjust headlight beam.

    NO. ITEM CHECK OR MAINTENANCE JOBODOMETE1 10

    PERIODIC MAINTENANCE AND MINOR REPAIR

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    6

    EAU01139

    Removing and installingcowlings and panelsThe cowlings and panels shown aboveneed to be removed to perform someof the maintenance jobs described inthis chapter. Refer to this section eachtime a cowling or panel needs to be re-moved and installed

    CowlinTo remo

    Removtener, ashown.

    NOTE:_

    The quii th

    1. Cowling A2. Panel A

    1. Cowling B2. Panel B

    1. Screw2. Quick

    PERIODIC MAINTENANCE AND

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    NOTE:_

    Make sure that the projection fitsinto the grommet.To install the quick fastener, pushthe center pin out so that it will pro-trude from the fastener head, in-sert the fastener into the cowling,and then push the protruding pin in

    il i i fl h i h h f

    EAU03317

    Panels A and BTo remove one of the panels

    1. Remove the corresponding cowl-

    ing A or B. (See page 6-5 for cowl-ing removal and installationprocedures.)

    2. Remove the seat. (See page 3-11for seat removal and installationprocedures )

    To ins1. P

    s2. In

    1. Quick fastener2. Pin

    After removal Before installation

    1. Screw 1. Panel

    PERIODIC MAINTENANCE AND MINOR REPAIR

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    6

    EAU01880

    Checking the spark plugsThe spark plugs are important enginecomponents, which should be checkedperiodically, preferably by a Yamahadealer. Since heat and deposits willcause 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 shouldbe a medium-to-light tan (the ideal col-or when the motorcycle is ridden nor-mally), and all spark plugs installed inthe engine should have the same color.If any spark plug shows a distinctly dif-f t l th i ld b d f

    Before installing a spark plug, the sparkplug gap should be measured with awire thickness gauge and, if necessary,adjusted to specification.

    Clean tgasket awipe ofthreads

    Specified spark plug:DPR8EA-9 (NGK) orX24EPR-U9 (DENSO)

    a. Spark

    Spar0

    Tigh

    PERIODIC MAINTENANCE AND

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    NOTE:_

    If a torque wrench is not available when

    installing a spark plug, a good estimateof the correct torque is 1/4 1/2 turnpast finger tight. However, the sparkplug should be tightened to the speci-fied torque as soon as possible._

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    PERIODIC MAINTENANCE AND

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    4. If the engine oil is below the mini-mum level mark, add sufficient oil

    of the recommended type to raiseit 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 betweenthe minimum and maximum levelmarks.

    _

    To change the engine oil (with orwithout oil filter element replace-ment)

    1. Start the engine, warm it up forseveral minutes, and then turn itoff.

    2. Place an oil pan under the engineto collect the used oil.

    3. Remove the engine oil filler cap

    4. Rb

    1. Engine oil drain bolt A 1. Engine2. Oil f3. Bolt

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    6

    5. Remove and replace the oil filterelement and O-rings.

    6. Install the oil filter element cover

    by installing the bolts, then tighten-ing them to the specified torque.

    8. Add the specified amount of therecommended engine oil, andthen install and tighten the oil fillercap.

    CAUT_

    Inpalubmthgr

    noCOMria

    _

    9. St

    foit iman

    10. Tuch

    1. Oil filter element2. O-ring ( 2)

    Tightening torque:Oil filter element cover bolt:

    10 Nm (1 0 m kgf)

    Tightening torques:Engine oil drain bolt A:

    35 Nm (3.5 m kgf)Engine oil drain bolt B:

    30 Nm (3.0 m kgf)

    Recommended engine oil:See page 8-1.

    Oil quantity:Without oil filter elementreplacement:

    3.8 LWith oil filter elementreplacement:

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    EAU04298

    CoolantThe coolant level should be checkedbefore each ride. In addition, the cool-ant must be changed at the intervalsspecified in the periodic maintenanceand lubrication chart.

    To check the coolant level1. Place the motorcycle on a levelsurface and hold it in an uprightposition.

    NOTE:_

    The coolant level must be checkedon a cold engine since the levelvaries with engine temperature.Make sure that the motorcycle ispositioned straight up whenchecking the coolant level. A slight

    2. Check the coolant level in thecoolant reservoir.

    NOTE:_

    The coolant should be between theminimum and maximum level marks._

    3. Imprdamc

    1. Coolant reservoir2. Maximum level mark3. Minimum level mark

    1. Cool

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    6

    EC000080

    CAUTION:_

    If coolant is not available, usedistilled water or soft tap waterinstead. Do not use hard wateror salt water since it is harmfulto 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 besufficiently cooled and the cool-ing system will not be protectedagainst frost and corrosion.If water has been added to thecoolant, have a Yamaha dealercheck the antifreeze content ofthe coolant as soon as possible,otherwise the effectiveness of

    NOTE:_

    The radiator fan is automatically

    switched on or off according to thecoolant temperature in the radia-tor.If the engine overheats, see page6-44 for further instructions.

    _

    To chan1. Pl

    sune

    2. Refopr

    3. Re(Sinlat

    4. Reth

    aw(Des

    5. Plgi

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    6. Remove the radiator cap retainingbolt and the radiator cap.

    EW000067

    WARNING_Never attempt to remove the radia-tor cap when the engine is hot._

    7. Remove the coolant drain bolts todrain the cooling system. 8. R

    9. Pa

    10. Dttu

    11. Inp

    1. Radiator cap retaining bolt2. Radiator cap

    1. Coolant drain bolt ( 2) 1. Bolt2. Cool

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    13. Install the coolant drain bolts, andthen tighten them to the specified

    torque.NOTE:_

    Check the washers for damage and re-place them if necessary._

    14. Pour the recommended coolantinto the radiator until it is full.

    EC000080

    CAUTION:_

    If coolant is not available, usedistilled water or soft tap waterinstead. Do not use hard wateror salt water since it is harmfulto the engine.

    If co

    chthotth

    _

    15. Insenut

    16. Rethneun

    toca17. Ch

    ercoto

    Tightening torque:Coolant drain bolt:7 Nm (0.7 m kgf)

    Antifreeze/water mixture ratio:1:1

    Recommended antifreeze:High-quality ethylene glycolantifreeze containing corrosioninhibitors for aluminum engines

    Coolant quantity:Total amount:

    1.7 LCoolant reservoir capacity:

    0.3 L

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    6

    6. Insert a new air filter element intothe air filter case.

    EC000082*

    CAUTION:_

    Make sure that the air filter ele-ment is properly seated in theair filter case.The engine should never be op-erated without the air filter ele-

    7. Install the air filter case cover byinstalling the screws.

    8. Place the fuel tank in the originalposition and install the bolts.EWA00013

    WARNING_

    Make sure that the fuel hose andbreather hose are properly connect-

    ed and routed, and not pinched. Re-place any damaged hoses._

    9. Install the panels and cowlings.10. Install the seat.

    AdjustspeedThe encheckedfollowsperiodicchart.

    1. Stse2,vi

    NOTE:@

    The engsponds @

    1. Air filter element

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    2. Check the engine idling speedand, if necessary, adjust it to spec-ification by turning the throttle stopscrew. To increase the engineidling speed, turn the screw in di-rection a . To decrease the engineidling speed, turn the screw in di-rection b .

    EAU00635

    Adjusting the throttle cablefree playThe throttle cable free play should

    measure 3 5 mm at the throttle grip.Periodically check the throttle cablefree play and, if necessary, have aYamaha dealer adjust it.

    AdjuThe varesultiand/orfrom must bat the

    mainte1. Throttle stop screw a. Throttle cable free play

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    6

    EAU00658

    TiresTo maximize the performance, durabil-ity, and safe operation of your motor-cycle, note the following pointsregarding the specified tires.

    Tire air pressure

    The tire air pressure should bechecked and, if necessary, adjustedbefore each ride.

    EW000082

    WARNING_

    The tire air pressure must be

    checked and adjusted on coldtires (i.e., when the temperatureof the tires equals the ambienttemperature).The tire air pressure must beadjusted in accordance with the

    CE-01E

    CE-07E

    W_

    Becauseimpact oformancof your the follo

    NEMovsutrothsedomDopaduSeite

    Tire air pressure(measured on cold tires)

    Load* Front Rear

    Up to 90 kg250 kPa(2.50 kgf/cm 2,2.50 bar)

    250 kPa(2.50 kgf/cm 2,2.50 bar)

    90 kg maximum250 kPa(2.50 kgf/cm 2,2.50 bar)

    290 kPa(2.90 kgf/cm 2,2.90 bar)

    High-speed riding250 kPa(2.50 kgf/cm 2,2.50 bar)

    250 kPa(2.50 kgf/cm 2,2.50 bar)

    Maximum load* 203 kg

    * Total weight of rider, passenger, cargo andaccessories

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    EAU00692

    Adjusting the clutch lever freeplayThe clutch lever free play should mea-sure 10 15 mm as shown. Periodicallycheck the clutch lever free play and, ifnecessary, adjust it as follows.

    1. Loosen the locknut at the clutch le-

    NOTE:@

    If the specified free play cannot be ob-tained as described above or if theclutch does not operate correctly, havea Yamaha dealer check the internalclutch mechanism.@

    1. Locknut2. Clutch lever free play adjusting boltc. Clutch lever free play

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    6

    EAU00712

    Adjusting the brake pedalpositionThe top of the brake pedal should be

    positioned approximately 32 mm belowthe top of the footrest as shown. Peri-odically check the brake pedal positionand, if necessary, have a Yamahadealer adjust it.

    EW000109

    WARNING@

    A soft or spongy feeling in the brakepedal can indicate the presence ofair in the hydraulic system. If thereis air in the hydraulic system, have aYamaha dealer bleed the system be-fore operating the motorcycle. Air in

    the hydraulic system will diminishthe braking performance, whichmay result in loss of control and anaccident.@

    Adjustswitch

    The reativated adjustedon just necessaas follo

    a. Distance between brake pedal and footrest 1. Brake light sw2. Brake

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    6

    EAU03294

    Checking the brake fluid levelInsufficient brake fluid may allow air toenter the brake system, possibly caus-

    ing it to become ineffective.Before riding, check that the brake fluidis above the minimum level mark andreplenish if necessary. A low brake flu-id level may indicate worn brake padsand/or brake system leakage If the

    Observe these precautions:When checking the fluid level,make sure that the top of the brakefluid reservoir is level.

    Use only the recommended quali-ty brake fluid, otherwise the rubberseals may deteriorate, causingleakage and poor braking perfor-mance.

    RefluhaleaBeterrelo

    anBredwaimAmgrbrdech

    1. Minimum level mark

    Front brake

    1. Minimum level mark

    Rear brake

    PERIODIC MAINTENANCE ANDEAU03985 EAU00744

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    EAU03985

    Changing the brake fluidHave a Yamaha dealer change thebrake fluid at the intervals specified inthe NOTE after the periodic mainte-nance and lubrication chart. In addition,have the oil seals of the brake mastercylinder and caliper as well as thebrake hose replaced at the intervalslisted below or whenever they are dam-aged or leaking.

    Oil seals: Replace every twoyears.Brake hose: Replace every four

    years.

    EAU00744

    Drive chain slackThe drive chain slack should bechecked before each ride and adjustedif necessary.

    To check the drive chain slack1. Place the motorcycle on a level

    surface and hold it in an uprightposition.

    NOTE:@

    When checking and adjusting the drivechain slack, the motorcycle should bepositioned straight up and there shouldbe no weight on it.@

    2. St

    3. Mt

    ets

    a. Driv

    Dri

    PERIODIC MAINTENANCE AND MINOR REPAIR3 Ti

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    6

    EAU04372

    To adjust the drive chain slack

    1. Loosen the axle nut, the brake cal-iper bracket bolt and the locknuton each side of the swingarm.

    2. To tighten the drive chain, turn theadjusting bolt on each side of the

    i i di ti a T l

    NOTE:_

    Using the alignment marks on eachside of the swingarm, make sure that

    both chain pullers are in the same posi-tion for proper wheel alignment._

    EC000096

    CAUTION:_

    Improper drive chain slack will over-

    3. Titigcato

    1. Axle nut2. Drive chain slack adjusting bolt3. Locknut4. Alignment marks

    1. Bolt2. Brake caliper bracket

    TighA

    B

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    EAU03165

    Checking and lubricating thesidestandThe operation of the sidestand should

    be checked before each ride, and thesidestand pivot and metal-to-metalcontact surfaces should be lubricated ifnecessary.

    EW000113

    WARNING

    LubrisuspeThe pi

    sion mspecifand lu

    Recommended lubricant:Lithium-soap-based grease

    (all-purpose grease)

    RecL

    PERIODIC MAINTENANCE AND MINOR REPAIREAU02939

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    6

    Checking the front forkThe condition and operation of the frontfork must be checked as follows at theintervals specified in the periodic main-tenance and lubrication chart.

    To check the conditionEW000115

    WARNING@

    Securely support the motorcycle sothat there is no danger of it fallingover.@

    Check the inner tubes for scratches,damage and excessive oil leakage.

    To check the operation1. Place the motorcycle on a level

    surface and hold it in an uprightposition.

    2. While applying the front brake,push down hard on the handle-bars several times to check if thefront fork compresses and re-bounds smoothly.

    CheckWorn ocause dof the slows at riodic chart.

    1. Plragr

    W@

    Securel

    that theover.@

    PERIODIC MAINTENANCE ANDEAU01144

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    2. Hold the lower ends of the frontfork legs and try to move them for-ward and backward. If any freeplay can be felt, have a Yamaha

    dealer check or repair the steer-ing.

    Checking the wheel bearingsThe front and rear wheel bearings mustbe checked at the intervals specified inthe periodic maintenance and lubrica-tion chart. If there is play in the wheelhub or if the wheel does not turnsmoothly, have a Yamaha dealercheck the wheel bearings.

    PERIODIC MAINTENANCE AND MINOR REPAIREAU00800 EW000116 KE

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    6

    BatteryThis motorcycle is equipped with asealed-type (MF) battery, which doesnot require any maintenance. There isno need to check the electrolyte or toadd distilled water.

    EC000101

    CAUTION:@

    Never attempt to remove the batterycell seals, as this would permanent-ly damage the battery.@

    WARNING@

    Electrolyte is poisonous anddangerous since it contains sul-furic acid, which causes severeburns. Avoid any contact withskin, eyes or clothing and al-ways shield your eyes when

    working near batteries. In caseof contact, administer the fol-lowing FIRST AID. EXTERNAL: Flush with plenty

    of water. INTERNAL: Drink large quan-

    tities of water or milk and im-mediately call a physician.

    EYES: Flush with water for15 minutes and seek promptmedical attention.

    KEIECH

    @

    To charHave a tery as have dibattery if the mtional e

    To store1. If

    fothth

    2. If m

    PERIODIC MAINTENANCE ANDEC000102 2. R

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    CAUTION:@

    Always keep the batterycharged. Storing a dischargedbattery can cause permanentbattery damage.To charge a sealed-type (MF)battery, a special (constant-

    voltage) battery charger is re-quired. Using a conventionalbattery charger will damage thebattery. If you do not have ac-cess to a sealed-type (MF) bat-tery charger, have a Yamaha

    dealer charge your battery.@

    EAU04482*

    Replacing the fusesThe main fuse and the fuse box which

    2. Ria

    CAU

    1. Backup fuse (odometer and clock)2. Radiator fan fuse3. Turn signal and hazard light fuse4. Ignition fuse5. Signaling system fuse6. Headlight fuse7. Spare fuse ( 4)

    8. Parking lighting fuse9. Electronic Fuel Injection System fuse10. Main fuse

    SpeMH

    RIBaTl

    PE

    PERIODIC MAINTENANCE AND MINOR REPAIR3. Turn the key to ON and turn on

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    6

    3. u t e ey to O a d tu othe electrical circuit in question tocheck if the device operates.

    4. If the fuse immediately blowsagain, have a Yamaha dealercheck the electrical system.

    EAU04136*

    Replacing a headlight bulbThis motorcycle is equipped withquartz bulb headlights. If a headlightbulb burns out, replace it as follows.

    1. Disconnect the headlight coupler,and then remove the bulb cover.

    2. Unanbu

    W_Headligfore, kefrom a ltouch td

    1. Headlight bulb holder2. headlight coupler

    1. Headl

    PERIODIC MAINTENANCE AND5. I

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    EC000105

    CAUTION:_

    Do not touch the glass part of theheadlight bulb to keep it free from

    oil, otherwise the transparency ofthe glass, the luminosity of the bulb,and the bulb life will be adversely af-fected. Thoroughly clean off any dirtand fingerprints on the headlight

    EAU04411

    Replacing a tail/brake lightbulb

    1. Remove the seat. (See page 3-11

    for seat removal and installationprocedures.)2. Remove the socket (together with

    the bulb) by turning it counter-clockwise.

    3 R th d f ti b lb b

    t6. I

    1. Do not touch this area. 1. Socket

    PERIODIC MAINTENANCE AND MINOR REPAIR

    S

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    6

    EAU03497

    Replacing a turn signal lightbulb

    1. Remove the turn signal light lensby removing the screw.

    2. Remove the defective bulb bypushing it in and turning it counter-clockwise.

    3. Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.

    4. Install the lens by installing the

    screw.ECA00065

    CAUTION:@

    Do not overtighten the screw, other-wise the lens may break.

    SuppoSince th

    centerstwhen wheel nance stand ucycle isbefore strong wder the

    To serv

    1. Stbyannode

    h

    1. Screw2. Turn signal light lens

    1. Turn signal light bulb

    PERIODIC MAINTENANCE ANDTo service the rear wheel

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    Raise the rear wheel off the ground byusing a motorcycle stand or, if a motor-cycle stand is not available, by placinga jack either under each side of theframe in front of the rear wheel or undereach side of the swingarm.

    EAU01617

    Front wheel

    To remove the front wheelEW000122

    WARNING_

    It is advisable to have a Yamahadealer service the wheel.Securely support the motor-

    3. Lap

    4. Rb5. R

    m6. P

    r

    1. Wheel axle2. Front wheel axle pinch bolt

    1. Bolt2. Brak

    PERIODIC MAINTENANCE AND MINOR REPAIREAU04376

    To install the front wheel Tightening torques:

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    6

    To install the front wheel1. 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 install-

    ing the bolts.

    NOTE:_

    Make sure that there is enough spacebetween the brake pads before install-ing the brake calipers onto the brakediscs._

    5. Install the brake hose holders byinstalling the bolts.

    6. Tighten the wheel axle, the frontwheel axle pinch bolt and thebrake caliper bolts to the specified

    7. Push down hard on the handlebarseveral times to check for properfork operation.

    Rear w

    To remo

    W_

    It deSe

    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)

    1. Bolt (2. Quick

    PERIODIC MAINTENANCE AND

    After removal Before installation

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    1. Remove the drive chain cover byremoving the quick fasteners andthe bolts. 2. Loosen the axle nut and the brake

    caliper bracket bolt.3. Lift the rear wheel off the ground

    according to the procedure onpage 6-39.

    4. R5. L

    t

    6. Ti7. P

    trr

    1. Quick fastener2. Pin

    1. Axle nut2. Drive chain slack adjusting bolt3. Locknut4. Alignment marks

    1. Bolt2. Brak

    PERIODIC MAINTENANCE AND MINOR REPAIREAU04456

    To install the rear wheel Tigh

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    6

    8. Pull the wheel axle out, and thenremove the wheel.

    ECA00119

    CAUTION:_

    Do not apply the brake after thewheel has been removed togetherwith the brake disc, otherwise thebrake caliper pistons will be forcedout.

    To install the rear wheel1. Install the wheel by inserting the

    wheel axle from the right handside.

    NOTE:_

    Make sure that there is enough spacebetween the brake pads before install-

    ing 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 ad- justment procedures.)

    5. Install the axle nut, and then lowerthe rear wheel so that it is on theground

    7. Insta

    er

    NOTE:_

    To instaback sofastener

    tener antil it is f_

    TighA

    B

    PERIODIC MAINTENANCE ANDEAU03087

    Troubleshooting

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    TroubleshootingAlthough Yamaha motorcycles receive

    a thorough inspection before shipmentfrom the factory, trouble may occur dur-ing operation. Any problem in the fuel,compression, or ignition systems, forexample, can cause poor starting andloss of power.The following troubleshooting chartsrepresent quick and easy proceduresfor checking these vital systems your-self. However, should your motorcyclerequire any repair, take it to a Yamaha

    dealer, whose skilled technicians havethe necessary tools, experience, andknow-how to service the motorcycleproperly.Use only genuine Yamaha replace-

    t t I it ti t l k

    PERIODIC MAINTENANCE AND MINOR REPAIREAU

    Troubleshooting charts

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    6

    Troubleshooting chartsStarting problems or poor engine performance

    EW0

    WARNING@

    Keep away open flames and do not smoke while checking or working on the fuel system.@

    CT-1AE

    Check the fuel level inthe fuel tank.

    1. FuelThere is enough fuel.

    There is no fuel.

    Check the compression.

    Supply fuel. The engine does not starCheck the compression.

    Operate the electric starter.

    2. CompressionThere is compression.

    There is no compression.

    Check the ignition.

    Have a Yamaha dealercheck the vehicle.

    Remove the spark plugsd h k h l d

    3. Ignition Wipe off with a dry cloth and correct thespark plug gaps, or replace the spark plugs.Wet

    Open the tthe electri

    PERIODIC MAINTENANCE ANDEngine overheating

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    WARNING@

    Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steblown out under pressure, which could cause serious injury. Be sure to wait until the engine has coAfter removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cslowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. Wheing sound has stopped, press down on the cap while turning it counterclockwise, and then remove

    _

    CT-2AE

    Wait until theengine has cooled.

    Check the coolant level in thereservoir and radiator.

    The coolant levelis OK.

    The coolant level is low.Check the cooling systemfor leakage.

    Start the engine. If the eYamaha dealer check

    There isleakage.

    There isno leakage

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    MOTORCYCLE CAR

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    Care ....................................................................Storage ................................................................

    7-MOTORCYCLE CARE AND STORAGE

    CareWhil h d i f l

    Before cleaning1 Cover the muffler outlets with plas

    Cleanin

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    7

    While the open design of a motorcyclereveals the attractiveness of the tech-nology, it also makes it more vulnera-ble. Rust and corrosion can developeven if high-quality components areused. A rusty exhaust pipe may go un-noticed on a car, however, it detracts

    from the overall appearance of amotorcycle. Frequent and proper caredoes not only comply with the terms ofthe warranty, but it will also keep yourmotorcycle looking good, extend its lifeand optimize its performance.

    1. Cover the muffler outlets with plas-tic bags after the engine hascooled down.

    2. Make sure that all caps and coversas well as all electrical couplersand connectors, including thespark plug caps, are tightly in-stalled.

    3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply such prod-ucts onto seals, gaskets, sprock-

    ets, the drive chain and wheelaxles. Always rinse the dirt anddegreaser off with water.

    CAUT_

    AvclewhusnofestrthatecoIm

    wianonspwa

    MOTORCYCLE CARDo not use any harsh chemicalproducts on plastic parts Be

    For motorcycles equipped witha windshield: Do not use strong

    After Remo

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    products on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abrasivecleaning products, solvent orthinner, fuel (gasoline), rust re-movers or inhibitors, brake flu-id, antifreeze or electrolyte.Do not use high-pressure wash-ers or steam-jet cleaners sincethey cause water seepage anddeterioration in the following ar-eas: seals (of wheel and swing-

    arm bearings, fork and brakes),electric components (couplers,connectors, instruments,switches and lights), breatherhoses and vents.

    a windshield: Do not use strongcleaners or hard sponges asthey will cause dulling orscratching. Some cleaningcompounds for plastic mayleave scratches on the wind-shield. Test the product on asmall hidden part of the wind-shield to make sure that it doesnot leave any marks. If the wind-shield is scratched, use a quali-ty plastic polishing compoundafter washing.

    _

    Remodetergand thwater.for haand inthe area few

    After on saltSince during

    combifollowrain, nroads.

    NOTE

    MOTORCYCLE CARE AND STORAGE1. Clean the motorcycle with cold

    water and a mild detergent afterAfter cleaning

    1 Dry the motorcycle with a chamois W

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    7

    water and a mild detergent, afterthe engine has cooled down.

    ECA00012

    CAUTION:_

    Do not use warm water since it in-creases the corrosive action of thesalt._

    2. After drying the motorcycle, applya corrosion protection spray on allmetal, including chrome- and nick-el-plated, surfaces to prevent cor-rosion.

    1. Dry the motorcycle with a chamoisor an absorbing cloth.

    2. Immediately dry the drive chainand lubricate it to prevent it fromrusting.

    3. Use a chrome polish to shinechrome, aluminum and stainless-steel parts, including the exhaustsystem. (Even the thermally in-duced discoloring of stainless-steel exhaust systems can be re-moved through polishing.)

    4. To prevent corrosion, it is recom-

    mended to apply a corrosion pro-tection spray on all metal,including chrome- and nickel-plat-ed, surfaces.

    5. Use spray oil as a universal clean-

    W_

    M

    wanedireetowageBecym

    _

    MOTORCYCLE CARECA00013

    CAUTION:Storage Long-

    Before

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    _

    Apply spray oil and wax spar-ingly and make sure to wipe offany excess.Never apply oil or wax to anyrubber and plastic parts, buttreat them with a suitable careproduct.Avoid using abrasive polishingcompounds as they will wearaway the paint.

    _

    NOTE:_

    Consult a Yamaha dealer for advice onwhat products to use._

    Short-termAlways store your motorcycle in a cool,dry place and, if necessary, protect itagainst dust with a porous cover.

    ECA00014

    CAUTION:_

    Storing the motorcycle in apoorly ventilated room or cover-ing it with a tarp, while it is stillwet, will allow water and humid-ity to seep in and cause rust.To prevent corrosion, avoid

    damp cellars, stables (becauseof the presence of ammonia)and areas where strong chemi-cals are stored.

    _

    Beforesevera

    1. F

    2. Fstf

    3. Ptf

    MOTORCYCLE CARE AND STORAGEa. Remove the spark plug caps

    and spark plugs.4. Lubricate all control cables and

    the pivoting points of all levers andNOTE:_

    Make

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    7

    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 placethe spark plugs on the cylinderhead so that the electrodes aregrounded. (This will limit spark-ing during the next step.)

    d. Turn the engine over severaltimes with the starter. (This willcoat the cylinder walls with oil.)

    e. Remove the spark plug caps

    from the spark plugs, and theninstall the spark plugs and thespark plug caps.

    EWA00003

    WARNING_

    the pivoting points of all levers andpedals as well as of the sidestand/ centerstand.

    5. Check and, if necessary, correctthe tire air pressure, and then liftthe motorcycle so that both of itswheels are off the ground. Alterna-tively, turn the wheels a little everymonth in order to prevent the tiresfrom becoming degraded in onespot.

    6. Cover the muffler outlets with plas-tic bags to prevent moisture from

    entering them.7. Remove the battery and fully

    charge it. Store it in a cool, dryplace and charge it once a month.Do not store the battery in an ex-

    a estoring _

    Specifications

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    Specifications .....................................................Conversion table .................................................

    8-SPECIFICATIONS

    SpecificationsCS-01E CS-01E

    M d l TDM900 E i il

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    8

    Model TDM900

    DimensionsOverall length 2,180 mm

    Overall width 800 mm

    Overall height 1,290 mm

    Seat height 825 mm

    Wheelbase 1,485 mm

    Ground clearance 160 mm

    Minimum turning radius 2,900 mm

    Basic weight (with oil and fullfuel tank) 221 kg

    Engine

    Engine type Liquid-cooled 4-stroke, DOHCCylinder arrangement Forward-inclined parallel

    2-cylinder

    Displacement 897 cm 3

    Bore stroke 92.0 67.5 mm

    Engine oil

    Type

    Recommended engine oilclassification

    CAUTION:Be sure to use motor oils thmodifiers. Passenger car ENERGY CONSERVINGwhich will cause clutch and/oing in reduced component life

    Cooling system capacity(total amount) 1.7 L

    Operation

    Gear ratio

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    Air filter Wet type element

    Fuel

    Type REGULAR UNLEADEDGASOLINE ONLY

    Fuel tank capacity 20 L

    Fuel reserve amount 3.5 L

    Spark plugManufacturer/model NGK / DPR8EA-9 or

    DENSO / X24EPR-U9

    Gap 0.8 0.9 mm

    Clutch type Wet, multiple-disc

    Transmission

    Primary reduction system Spur gear

    Primary reduction ratio 1.718

    Secondary reduction system Chain drive

    Secondary reduction ratio 2.625

    N b f d i h i

    Gear ratio

    1s

    2n

    3r

    4t

    5t

    6t

    Chassis

    Frame type

    Caster angle

    Trail

    Tires

    FrontType

    Size

    Manufacturer/model

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    Electrical system

    Ignition system T.C.I. (digital)

    Fuses

    Main fuse

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    Ignition system T.C.I. (digital)

    Charging system

    Type A.C. magneto

    Standard output 14 V, 31.5 A @ 5,000 r/min

    Battery

    Model GT12B-4

    Voltage, capacity 12 V, 10 Ah

    Headlight type Quartz bulb (halogen)

    Bulb voltage, wattage quantity

    Headlight 12 V, 55 W 2

    Auxiliary light 12 V, 5 W 1

    Tail/brake light 12 V, 5/21 W 2

    Turn signal light 12 V, 10 W 4Meter lighting 12 V, 2 W 2

    Neutral indicator light 14 V, 1.2 W 1

    High beam indicator light 14 V, 1.4 W 1

    Turn signal indicator light 14 V 1 2 W 2

    Main fuse

    Headlight fuse

    Signaling system fuse

    Ignition fuse

    Parking lighting fuse

    Turn signal and hazard lightfuse

    Backup fuse (odometer andclock)

    Radiator fan fuse

    Electronic Fuel InjectionSystem fuse

    SPECIFICATIONSEAU03941

    Conversion tableCS 03E

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    8

    CS-03E

    All specification data in this manual are listed in SI andMETRIC UNITS.

    Use this table to convert METRIC unit values to IMPERIALunit values.

    Example:

    METRIC VALUE CONVERSIONFACTOR

    IMPERIAL VALUE

    2 mm 0.03937 = 0.08 in

    ConverMETRIC SYSTEM T

    Metric unit

    Torque

    m kgfm kgfcm kgfcm kgf

    Weight kg

    gSpeed km/h

    Distance

    kmmmcmmm

    Volume,Capacity

    cc (cm 3)cc (cm 3)L (liter)L (liter)

    Miscellaneouskg/mmkgf/cm 2C

    CONSUM

    Identification numbers .........................................

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    Key identification number ...................................Vehicle identification number ..............................Model label ...........................................................

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    Sidestand, checking and lubricating....... 6-30Spark plugs, checking .............................6-7

    Wheel (rear).......................................... 6-39Installing .......................................... 6-41

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    Specifications ..........................................8-1

    Speedometer unit ....................................3-3Starting the engine ..................................5-1Start switch.............................................. 3-7Steering, checking .................................6-31Storage.................................................... 7-4Storage compartment ............................ 3-11Supporting the motorcycle..................... 6-37

    TTachometer unit ......................................3-5Tail/brake light bulb, replacing ............... 6-36Throttle cable free play, adjusting .......... 6-18Throttle grip and cable, checking and

    lubricating............................................ 6-29Tires ...................................................... 6-19

    Tool kit..................................................... 6-1Troubleshooting.....................................6-42Troubleshooting charts .......................... 6-43Turn signal indicator lights .......................3-2Turn signal light bulb, replacing ............. 6-37Turn signal switch....................................3-6

    Removing ........................................ 6-39

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    PRINTED IN JAPAN2001 . 11 - 1.0 3 CR

    (E)

    PRINTED ON RECYCLED PAPER

    YAMAHA MOTOR CO., LTD.