Professional Documents
Culture Documents
TDM900
5PS-28199-E1
EAU04575
INTRODUCTION
As the owner of the TDM900, you are benefiting from Yamaha’s vast experience and newest technol-
ogy regarding the design and manufacture of high-quality products, which have earned Yamaha a
reputation for dependability.
Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TDM900.
The owner’s manual does not only instruct you in how to operate, inspect and maintain your motorcy-
cle, but also in how to safeguard yourself and others from trouble and injury.
In addition, the many tips given in this manual will help keep your motorcycle in the best possible
condition. If you have any further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
EAU00005
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
Q IS INVOLVED!
NOTE:
8 This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
8 Yamaha continually seeks advancements in product design and quality. Therefore, while this
manual contains the most current product information available at the time of printing, there
may be minor discrepancies between your motorcycle and this manual. If you have any ques-
tions concerning this manual, please consult your Yamaha dealer.
w
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE.
EAU04229
TDM900
OWNER’S MANUAL
©2002 by Yamaha Motor Co., Ltd.
1st edition, August 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
EAU00009
TABLE OF CONTENTS
2 DESCRIPTION 2
4 PRE-OPERATION CHECKS 4
8 SPECIFICATIONS 8
9 CONSUMER INFORMATION 9
INDEX
EAU00021
Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and free-
dom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.
1
Regular care and maintenance are essential for preserving value and operating condition of your
motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders—more than car drivers—must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passen-
gers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic
materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum pro-
tective wear, however, should not encourage carelessness. Although full-coverage helmets and suits,
in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable.
Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is
even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensive-
ly—avoiding all dangers, including those caused by others.
1-1
DESCRIPTION
EAU00026
DESCRIPTION
Part locations
Left view 12 3 4 5 6 7 8
14 13 12 1110 9 9
1. Front fork spring preload adjusting bolt (page 3-15) 8. Grab bar
2. Front fork damping force adjusting 9. Luggage strap holders (page 3-18)
screw (page 3-15) 10. Seat lock (page 3-13)
3. Air filter element (page 6-16) 11. Shock absorber assembly rebound
4. Shock absorber assembly compression damping force adjusting knob (page 3-17)
damping force adjusting knob (page 3-17) 12. Shock absorber assembly spring
5. Battery (page 6-33) preload adjusting ring (page 3-16)
6. Fuses (page 6-34) 13. Shift pedal (page 3-9)
7. Storage compartment (page 3-14) 14. Engine oil drain bolt A (page 6-9)
2-1
DESCRIPTION
Right view 9 15 9 16 17 18 19
24 23 22 21 20
15. Tool kit (page 6-1) 20. Engine oil filler cap (page 6-8)
16. Coolant reservoir (page 6-11) 21. Engine oil filter element (page 6-10)
17. Throttle stop screw (page 6-17) 22. Engine oil drain bolt B (page 6-10)
18. Front brake master cylinder (page 6-25) 23. Brake pedal (page 3-10)
19. Radiator cap (page 6-13) 24. Rear brake fluid reservoir (page 6-26)
2-2
DESCRIPTION
Controls and instruments
1 2 345 6 7 8 9
2-3
EAU00027
NOTE:
The headlight comes on automatical-
ly when the engine is started and
stays on until the key is turned to
“OFF”.
EAU00038
3 OFF
All electrical systems are off. The key
can be removed.
EAU00029 EAU00040
a b . (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 “.”. 3
ECA00043
3-2
High beam indicator light “&” Oil level warning light “7”
High beam indicator light Oil level warning light
This indicator light comes on when This warning light comes on when
the high beam of the headlight is the engine oil level is low.
switched on. The electrical circuit of the warning
light can be checked by turning the
EAU00061
key to “ON”.
3 Neutral indicator light “N” If the warning light does not come on
Neutral indicator light
This indicator light comes on when for a few seconds, then go off, have a
1. Fuel level warning symbol “ ” the transmission is in the neutral Yamaha dealer check the electrical
2. Left turn signal indicator light “4”
position. circuit.
3. High beam indicator light “&”
4. Neutral indicator light “N”
5. Engine trouble indicator light “ ”
EAU04585 NOTE:
6. Right turn signal indicator light “6” Engine trouble warning light “ ” Even if the oil level is sufficient, the
Engine trouble warning light
7. Oil level warning light “7” This warning light comes on or flash- warning light may flicker when riding
EAU04121 es when an electrical circuit monitor- on a slope or during sudden acceler-
Turn signal indicator lights “4” ing the engine is defective. When this ation or deceleration, but this is not a
and “6” occurs, have a Yamaha dealer check malfunction.
Turn signal indicator lights
3-3
3-4
3-5
cC NOTE:
8 After setting the clock, be sure to
Do not operate the engine in the
push the “SELECT” button
tachometer red zone.
before turning the key to “OFF”,
Red zone: 8,000 r/min and above
otherwise the clock will not be
set.
This tachometer unit is equipped with 8 When the key is turned to “OFF”,
a clock. the clock display will remain on 3
for 48 hours and then go off to 1. Coolant temperature gauge
To set the clock: prevent the battery from dis- 2. Coolant temperature red zone
1. Push both the “SELECT” and charging. EAU04939
3-6
Handlebar switches
Handlebar switches
EAU00119
3-7
To signal a right-hand turn, push this Do not use the hazard light for an
switch to “6”. To signal a left-hand extended length of time, otherwise
turn, push this switch to “4”. When the battery may discharge.
released, the switch returns to the
center position. To cancel the turn
signal lights, push the switch in after 3
it has returned to the center position.
1. Engine stop switch “#/$”
EAU00129
2. Start switch “,”
Horn switch “*” EAU03890
Horn switch
Press this switch to sound the horn. Engine stop switch “#/$”
Engine stop switch
With the key in the “ON” or “.” posi- stop the engine in case of an emer-
tion, use this switch to turn on the gency, such as when the motorcycle
hazard light (simultaneous flashing of overturns or when the throttle cable is
all turn signal lights). stuck.
EAU00143
The hazard light is used in case of an
emergency or to warn other drivers Start switch “,”
Start switch
when your motorcycle is stopped Push this switch to crank the engine
where it might be a traffic hazard. with the starter.
EC000005
cC
See page 5-1 for starting instruc-
tions prior to starting the engine.
3-8
3-9
3-10
w Fuel
Fuel
Fuel tank capacity:
Make sure that there is sufficient fuel Total amount:
Make sure that the fuel tank cap is 20 L
in the tank. Fill the fuel tank to the
properly closed before riding. Reserve amount:
bottom of the filler tube as shown.
EW000130 3.5 L
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8 Do not overfill the fuel tank,
otherwise it may overflow
when the fuel warms up and
expands.
8 Avoid spilling fuel on the hot
engine.
3-11
cC Catalytic converter
Catalytic converter
3-12
cC a
The following precautions must be
observed to prevent a fire hazard
or other damages.
8 Use only unleaded gasoline.
The use of leaded gasoline will
cause unrepairable damage to
1
3
the catalytic converter.
8 Never park the motorcycle 1. Seat lock 1. Projection (×2)
a. Unlock. 2. Seat holder (×2)
near possible fire hazards EAU02925
such as grass or other materi- To install the seat
Seat Insert the projections on the front of
als that easily burn.
8 Do not allow the engine to idle Seat the seat into the seat holder, push
To remove the seat the rear of the seat down to lock it in
too long.
Insert the key into the seat lock, turn place, and then remove the key.
it counterclockwise, and then pull the
seat off. NOTE:
Make sure that the seat is properly
secured before riding.
3-13
partment, be sure to wrap them in a This front fork is equipped with spring
plastic bag so that they will not get preload adjusting bolts and damping
wet. When washing the motorcycle, force adjusting screws.
be careful not to let any water enter
EW000035
the storage compartment.
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3
Always adjust both fork legs
1. U-LOCK (optional) equally, otherwise poor handling
2. Strap
and loss of stability may result.
EAU04292
Storage compartment
Storage compartment
3-14
b 1
2
1 4
3
a 6
5
1 7
2 8
3
1. Spring preload adjusting bolt 1. Standard setting 1. Damping force adjusting screw
2. Current setting
Spring preload 3. Front fork cap bolt Damping force
To increase the spring preload and 1. Turn the adjusting screw on each
NOTE:
thereby harden the suspension, turn fork leg in direction a until the
Align the appropriate groove on the
the adjusting bolt on each fork leg in screw moves almost a 1/2 turn
adjusting mechanism with the top of
direction a. To decrease the spring without clicking.
the front fork cap bolt.
preload and thereby soften the sus- 2. Continue turning the adjusting
pension, turn the adjusting bolt on screw in direction a until it
Setting
each fork leg in direction b. clicks. This is the minimum set-
Minimum (soft) 8
ting.
Standard 7
Maximum (hard) 1
3-15
3-16
NOTE:
Although the total number of clicks of
a damping force adjusting mecha-
nism may not exactly match the
above specifications due to small dif-
ferences in production, the actual
number of clicks always represents
3 the entire adjusting range. To obtain
1. Rebound damping force adjusting knob 1. Compression damping force adjusting
a precise adjustment, it would be
knob advisable to check the number of
Rebound damping force clicks of each damping force adjust-
Compression damping force
To increase the rebound damping ing mechanism and to modify the
To increase the compression damp-
force and thereby harden the specifications as necessary.
ing force and thereby harden the
rebound damping, turn the adjusting
compression damping, turn the
knob in direction a. To decrease the
adjusting knob in direction a. To
rebound damping force and thereby
decrease the compression damping
soften the rebound damping, turn the
force and thereby soften the com-
adjusting knob in direction b.
pression damping, turn the adjusting
Minimum (soft) 20 clicks in direction b* knob in direction b.
Standard 12 clicks in direction b*
Minimum (soft) 12 clicks in direction b*
Maximum (hard) 3 clicks in direction b*
Standard 11 clicks in direction b*
* With the adjusting knob fully turned in direction a
Maximum (hard) 1 clicks in direction b*
* With the adjusting knob fully turned in direction a
3-17
w Sidestand
Sidestand
3-18
3-19
3-20
PRE-OPERATION CHECKS
EAU01114
PRE-OPERATION CHECKS
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
EAU03439
4-1
PRE-OPERATION CHECKS
ITEM CHECKS PAGE
• Make sure that operation is smooth.
• Check cable free play.
Throttle grip 6-18, 6-29
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
• Make sure that operation is smooth.
Control cables 6-29
• Lubricate if necessary.
• Check chain slack.
• Adjust if necessary.
Drive chain 6-27–6-29
• Check chain condition.
• Lubricate if necessary.
• Check for damage.
Wheels and tires
• Check tire condition and tread depth.
6-18–6-22
4
• Check air pressure.
• Correct if necessary.
• Make sure that operation is smooth.
Brake and shift pedals 6-30
• Lubricate pedal pivoting points if necessary.
• Make sure that operation is smooth.
Brake and clutch levers 6-30
• Lubricate lever pivoting points if necessary.
• Make sure that operation is smooth.
Sidestand 6-30
• Lubricate pivot if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
Chassis fasteners —
• Tighten if necessary.
Instruments, lights, signals • Check operation.
3-2–3-3, 3-7–3-8, 6-35–6-38
and switches • Correct if necessary.
• Check operation of ignition circuit cut-off system.
Sidestand switch 3-18–3-20
• If system is defective, have Yamaha dealer check vehicle.
4-2
PRE-OPERATION CHECKS
NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a
very short time; and the added safety it assures is more than worth the time involved.
EWA00033
w
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operat-
ing the motorcycle.
4-3
EAU00372
8 Become thoroughly familiar In order for the ignition circuit cut-off The oil level warning light and
with all operating controls and system to enable starting, one of the engine trouble warning light
their functions before riding. following conditions must be met: should come on for a few seconds,
Consult a Yamaha dealer 8 The transmission is in the neutral then go off. If a warning light does
regarding any control or func- position. not go off, see pages 3-2 and 3-3
tion that you do not thorough- 8 The transmission is in gear with for the corresponding warning
ly understand. the clutch lever pulled and the light circuit check.
8 Never start the engine or oper- sidestand up.
ate it in a closed area for any EW000054
2. Shift the transmission into the
length of time. Exhaust fumes w
5 neutral position.
are poisonous, and inhaling 8 Before starting the engine,
them can cause loss of con- check the function of the igni- NOTE:
sciousness and death within a tion circuit cut-off system When the transmission is in the neu-
short time. Always make sure according to the procedure tral position, the neutral indicator light
that there is adequate ventila- described on page 3-20. should be on, otherwise have a
tion. 8 Never ride with the sidestand Yamaha dealer check the electrical
8 Before starting out, make sure down. circuit.
that the sidestand is up. If the
sidestand is not raised com- 1. Turn the key to “ON” and make 3. Start the engine by pushing the
pletely, it could contact the sure that the engine stop switch start switch.
ground and distract the opera- is set to “#”.
tor, resulting in a possible loss
of control.
5-1
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.
5-2
5-3
0–1,000 km Parking
Parking
Avoid prolonged operation above When parking, stop the engine, and
4,000 r/min. then remove the key from the main
switch.
1,000–1,600 km
Avoid prolonged operation above EW000058
6,000 r/min. w
ECA00058
8 Since the engine and exhaust
cC
system can become very hot,
After 1,000 km of operation, the park in a place where pedestri-
engine oil must be changed, and ans or children are not likely
the oil filter element replaced. 5
to touch them.
8 Do not park on a slope or on
1,600 km and beyond soft ground, otherwise the
The vehicle can now be operated motorcycle may overturn.
normally.
EC000053
cC
8 Keep the engine speed out of
the tachometer red zone.
8 If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehi-
cle.
5-4
Owner’s tool kit .....................................................6-1 Checking and lubricating the brake and
Periodic maintenance and lubrication chart .........6-2 shift pedals ......................................................6-30
Removing and installing cowlings and panels ......6-5 Checking and lubricating the brake and
Checking the spark plugs .....................................6-7 clutch levers ....................................................6-30
Engine oil and oil filter element ............................6-8 Checking and lubricating the sidestand ..............6-30
Coolant ...............................................................6-11 Lubricating the rear suspension .........................6-31
Replacing the air filter element ...........................6-16 Checking the front fork .......................................6-31
Adjusting the engine idling speed .......................6-17 Checking the steering .........................................6-32
Adjusting the throttle cable free play ..................6-18 Checking the wheel bearings .............................6-32
Adjusting the valve clearance .............................6-18 Battery ................................................................6-33
Tires ...................................................................6-18 Replacing the fuses ............................................6-34
Cast wheels ........................................................6-22 Replacing a headlight bulb .................................6-35
Adjusting the clutch lever free play .....................6-22 Replacing a tail/brake light bulb .........................6-37 6
Adjusting the brake pedal position .....................6-23 Replacing a turn signal light bulb .......................6-37
Adjusting the rear brake light switch ...................6-24 Supporting the motorcycle ..................................6-38
Checking the front and rear brake pads .............6-24 Front wheel .........................................................6-39
Checking the brake fluid level ............................6-25 Rear wheel .........................................................6-40
Changing the brake fluid ....................................6-26 Troubleshooting ..................................................6-43
Drive chain slack ................................................6-27 Troubleshooting charts .......................................6-44
Lubricating the drive chain .................................6-28
Checking and lubricating the cables ...................6-29
Checking and lubricating the throttle grip
and cable .........................................................6-29
EAU00462
6-1
6-2
6-3
EAU03884
NOTE:
8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8 Hydraulic brake service
9 Regularly check and, if necessary, correct the brake fluid level.
9 Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
9 Replace the brake hoses every four years and if cracked or damaged.
6-4
6-5
6-6
6-7
To check the engine oil level 3. Wait a few minutes until the oil
1. Place the motorcycle on a level settles, remove the oil filler cap,
surface and hold it in an upright wipe the dipstick clean, insert it
position. back into the oil filler hole (with-
6
out screwing it in and with the
NOTE: arrow mark pointing upward as
Make sure that the motorcycle is shown), and then remove it
positioned straight up when checking again to check the oil level.
the oil level. A slight tilt to the side
can result in a false reading. NOTE:
The engine oil should be between the
2. Start the engine, warm it up for minimum and maximum level marks.
15 minutes, and then turn it off.
6-8
w
Never remove the engine oil tank
cap after high-speed operation,
otherwise hot engine oil could
spout out and cause damage or
injury. Always let the engine oil
cool down sufficiently before
removing the oil tank cap.
1. Oil filler cap 1. Engine oil drain bolt A
2. Dipstick
3. Maximum level mark 4. If the engine oil is below the min- To change the engine oil (with or
4. Minimum level mark
imum level mark, add sufficient without oil filter element replace-
EC000000
oil of the recommended type to ment)
cC
raise it to the correct level. 1. Start the engine, warm it up for
6 Do not operate the motorcycle 5. Install the oil filler cap. several minutes, and then turn it
until you know that the engine oil off.
level is sufficient. NOTE: 2. Place an oil pan under the
8 The engine oil tank is located engine to collect the used oil.
behind the cylinders. 3. Remove the engine oil filler cap
8 The engine oil should be and drain bolts to drain the oil
between the minimum and maxi- from the crankcase.
mum level marks.
NOTE:
Skip steps 4–6 if the oil filter element
is not being replaced.
6-9
6-10
cC Coolant
Coolant
6-11
cC w
8 If coolant is not available, use Never attempt to remove the radia-
distilled water or soft tap water tor cap when the engine is hot.
instead. Do not use hard water
or salt water since it is harmful NOTE:
to the engine. 8 The radiator fan is automatically
8 If water has been used instead switched on or off according to
of coolant, replace it with the coolant temperature in the
1. Coolant reservoir cap coolant as soon as possible, radiator.
3. If the coolant is at or below the otherwise the engine may not 8 If the engine overheats, see
minimum level mark, remove be sufficiently cooled and the page 6-45 for further instructions.
panel B (See page 6-6 for panel cooling system will not be pro-
removal and installation proce- tected against frost and corro-
sion. 6
dures.), remove the reservoir
cap, add coolant to the maximum 8 If water has been added to the
level mark, and then install the coolant, have a Yamaha dealer
reservoir cap and the panel. check the antifreeze content of
the coolant as soon as possi-
Coolant reservoir capacity ble, otherwise the effective-
(up to the maximum level mark): ness of the coolant will be
0.25 L reduced.
6-12
6-13
6-14
6-15
cC
Air filter element, replacing
position and install the bolts. The engine idling speed must be
EWA00067 checked and, if necessary, adjusted
w as follows at the intervals specified in
8 Before installing the fuel tank, the periodic maintenance and lubrica-
make sure that the fuel hoses tion chart.
are not damaged. If any fuel The engine should be warm before
making this adjustment. 1. Throttle stop screw
hose is damaged, do not start
the engine but have a Yamaha Check the engine idling speed and, if
dealer replace the hose, other- NOTE: necessary, adjust it to specification
wise fuel may leak. The engine is warm when it quickly by turning the throttle stop screw. To
8 Make sure that the fuel hoses responds to the throttle. increase the engine idling speed, turn
6
are properly connected and the screw in direction a. To
routed, and not pinched. decrease the engine idling speed,
8 Be sure to place the fuel tank turn the screw in direction b.
breather hose and the fuel
tank overflow hose in the orig- Engine idling speed:
inal position. 1,100–1,200 r/min
NOTE:
9. Install the panels and cowlings. If the specified idling speed cannot
10. Install the seat. be obtained as described above,
have a Yamaha dealer make the
adjustment.
6-17
clearance
Valve clearance, adjusting
To maximize the performance, dura-
The valve clearance changes with bility, and safe operation of your
use, resulting in improper air-fuel mix- motorcycle, note the following points
a ture and/or engine noise. To prevent regarding the specified tires.
this from occurring, the valve clear-
ance must be adjusted by a Yamaha Tire air pressure
dealer at the intervals specified in the The tire air pressure should be
a. Throttle cable free play periodic maintenance and lubrication checked and, if necessary, adjusted
EAU00635 chart. before each ride.
Adjusting the throttle cable EW000082
free play w
Throt le cable free play, adjusting
The throttle cable free play should 8 The tire air pressure must be
measure 3–5 mm at the throttle grip. checked and adjusted on cold 6
Periodically check the throttle cable tires (i.e., when the tempera-
free play and, if necessary, have a ture of the tires equals the
Yamaha dealer adjust it. ambient temperature).
8 The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passen-
ger, cargo, and accessories
approved for this model.
6-18
6-19
NOTE:
The tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.
EW000079
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8 Have a Yamaha dealer replace
1. Tire sidewall excessively worn tires. 1. Tire air valve
a. Tire tread depth Besides being illegal, operat- 2. Valve core
3. Valve cap with seal
Tire inspection ing the motorcycle with exces-
The tires must be checked before sively worn tires decreases Tire information
each ride. If the center tread depth riding stability and can lead to This motorcycle is equipped with cast
reaches the specified limit, if the tire loss of control. wheels and tubeless tires with valves. 6
has a nail or glass fragments in it, or 8 The replacement of all wheel
if the sidewall is cracked, have a and brake related parts,
Yamaha dealer replace the tire imme- including the tires, should be
diately. left to a Yamaha dealer, who
has the necessary profession-
Minimum tire tread depth
1.6 mm al knowledge and experience.
(front and rear)
6-20
6-21
6-22
1 2
2
1 b
a
1. Locknut (clutch lever) 1. Locknut (crankcase) a. Distance between brake pedal and footrest
2. Clutch lever free play adjusting bolt 2. Clutch lever free play adjusting nut
EAU00712
3. If the specified clutch lever free 5. Loosen the locknut at the Adjusting the brake pedal
play could be obtained as crankcase. position
Brake pedal position, adjusting
described above, tighten the 6. To increase the clutch lever free The top of the brake pedal should be
6 locknut and skip the rest of the play, turn the adjusting nut in positioned approximately 32 mm
procedure, otherwise proceed as direction a. To decrease the below the top of the footrest as
follows. clutch lever free play, turn the shown. Periodically check the brake
4. Fully turn the adjusting bolt at the adjusting nut in direction b. pedal position and, if necessary,
clutch lever in direction a to 7. Tighten the locknut at the clutch have a Yamaha dealer adjust it.
loosen the clutch cable. lever and the crankcase.
6-23
brake pedal can indicate the pres- The front and rear brake pads must
ence of air in the hydraulic system. be checked for wear at the intervals
If there is air in the hydraulic sys- specified in the periodic maintenance
tem, have a Yamaha dealer bleed and lubrication chart.
the system before operating the
motorcycle. Air in the hydraulic
system will diminish the braking 1. Brake light switch
2. Brake light switch adjusting nut
performance, which may result in
EAU00713
loss of control and an accident.
Adjusting the rear brake light
switch
Rear brake light switch, adjusting
1
1 1
1. Brake pad wear indicator groove 1. Lining thickness 1. Minimum level mark
EAU00725 EAU04510 EAU04856
Front brake pads Rear brake pads Checking the brake fluid
Each front brake pad is provided with Check each rear brake pad for dam- level
Brake fluid level, checking
a wear indicator groove, which allows age and measure the lining thick- Insufficient brake fluid may allow air
6 you to check the brake pad wear ness. If a brake pad is damaged or if to enter the brake system, possibly
without having to disassemble the the lining thickness is less than causing it to become ineffective.
brake. To check the brake pad wear, 0.8 mm, have a Yamaha dealer Before riding, check that the brake
check the wear indicator groove. If a replace the brake pads as a set. fluid is above the minimum level mark
brake pad has worn to the point that and replenish if necessary. A low
the wear indicator groove has almost brake fluid level may indicate worn
disappeared, have a Yamaha dealer brake pads and/or brake system
replace the brake pads as a set. leakage. If the brake fluid level is low,
be sure to check the brake pads for
wear and the brake system for leak-
age.
6-25
6-26
6 should be positioned straight up and 1. Loosen the axle nut, the brake
est portion of the drive chain,
there should be no weight on it. and then measure the drive caliper bracket bolt and the lock-
chain slack as shown. nut on each side of the
swingarm.
Drive chain slack: 2. To tighten the drive chain, turn
50–60 mm the adjusting bolt on each side of
4. If the drive chain slack is incor- the swingarm in direction a. To
rect, adjust it as follows. 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.
6-27
brake caliper bracket bolt to the The drive chain must be cleaned and
specified torques. lubricated at the intervals specified in
the periodic maintenance and lubrica-
Tightening torque: tion chart, otherwise it will quickly
Axle nut: wear out, especially when riding in
150 Nm (15.0 m·kgf) dusty or wet areas. Service the drive
Brake caliper bracket bolt: chain as follows.
1. Bolt 40 Nm (4.0 m·kgf) EC000097
2. Brake caliper bracket cC
NOTE: The drive chain must be lubricated
Using the alignment marks on each after washing the motorcycle or
side of the swingarm, make sure that riding in the rain.
both chain pullers are in the same 6
position for proper wheel alignment. 1. Clean the drive chain with
kerosene and a small soft brush.
EC000096 ECA00053
cC cC
Improper drive chain slack will To prevent damaging the O-rings,
overload the engine as well as do not clean the drive chain with
other vital parts of the motorcycle steam cleaners, high-pressure
and can lead to chain slippage or washers or inappropriate solvents.
breakage. To prevent this from
occurring, keep the drive chain
slack within the specified limits.
6-28
lubricant. The operation of all control cables The operation of the throttle grip
ECA00052 and the condition of the cables should be checked before each ride.
cC should be checked before each ride, In addition, the cable should be lubri-
Do not use engine oil or any other and the cables and cable ends cated or replaced at the intervals
lubricants for the drive chain, as should be lubricated if necessary. If a specified in the periodic maintenance
they may contain substances that cable is damaged or does not move chart.
could damage the O-rings. smoothly, have a Yamaha dealer
check or replace it.
Recommended lubricant:
Engine oil
6 EW000112
w
Damage to the outer sheath may
interfere with proper cable opera-
tion and will cause the inner cable
to rust. Replace a damaged cable
as soon as possible to prevent
unsafe conditions.
6-29
Checking and lubricating the Checking and lubricating the Checking and lubricating the
brake and shift pedals
Brake and shift pedals, checking and lubricating
brake and clutch levers
Brake and clutch levers, checking and lubricating
sidestand
Sidestand, checking and lubricating
The operation of the brake and shift The operation of the brake and clutch The operation of the sidestand
pedals should be checked before levers should be checked before should be checked before each ride, 6
each ride, and the pedal pivots each ride, and the lever pivots should and the sidestand pivot and metal-to-
should be lubricated if necessary. be lubricated if necessary. metal contact surfaces should be
lubricated if necessary.
Recommended lubricant: Recommended lubricant: EW000113
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
6-30
EAU04282
w
To check the operation
Lubricating the rear Securely support the motorcycle 1. Place the motorcycle on a level
suspension
Rear suspension, lubricating
so that there is no danger of it surface and hold it in an upright
The pivoting points of the rear sus- falling over. position.
6 pension must be lubricated at the 2. While applying the front brake,
intervals specified in the periodic Check the inner tubes for scratches, push down hard on the handle-
maintenance and lubrication chart. damage and excessive oil leakage. bars several times to check if the
front fork compresses and
Recommended lubricant:
rebounds smoothly.
Lithium-soap-based grease EC000098
cC
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
6-31
Worn or loose steering bearings may The front and rear wheel bearings
cause danger. Therefore, the opera- must be checked at the intervals
tion of the steering must be checked specified in the periodic maintenance
as follows at the intervals specified in and lubrication chart. If there is play
the periodic maintenance and lubrica- in the wheel hub or if the wheel does
tion chart. not turn smoothly, have a Yamaha
1. Place a stand under the engine dealer check the wheel bearings.
to raise the front wheel off the
ground. 2. Hold the lower ends of the front
EW000115
fork legs and try to move them
w
forward and backward. If any
Securely support the motorcycle free play can be felt, have a
so that there is no danger of it 6
Yamaha dealer check or repair
falling over. the steering.
6-32
6-33
6-35
6-36
1. Socket 1. Screw
2. Turn signal light lens
EAU04411
EAU03497
Replacing a tail/brake light
bulb Replacing a turn signal light
Tail/brake light bulb, replacing
bulb
1. Remove the seat. (See page Turn signal light bulb, replacing
6-37
6-38
cC
Do not apply the brake after the
1 2 brake calipers have been removed,
otherwise the brake pads will be
forced shut.
3
Front wheel
Wheel (front)
2. Loosen the wheel axle with a
19-mm hexagon wrench.
6 To remove the front wheel 3. Lift the front wheel off the ground
Removing
EW000122
6-40
NOTE:
The drive chain does not need to be
disassembled in order to remove and
install the rear wheel.
6-41
NOTE:
Make sure that there is enough
space between the brake pads
before installing the wheel. 1. Quick fastener
2. Pin
8. Pull the wheel axle out, and then
remove the wheel. 2. Install the drive chain onto the Tightening torques:
ECA00119 rear sprocket. Axle nut:
cC 3. Loosen the brake caliper bracket 150 Nm (15.0 m·kgf)
bolt. Brake caliper bracket bolt: 6
Do not apply the brake after the
wheel has been removed together 4. Adjust the drive chain slack. 40 Nm (4.0 m·kgf)
with the brake disc, otherwise the (See page 6-27 for drive chain
slack adjustment procedures.) 7. Install the drive chain cover by
brake caliper pistons will be forced
5. Install the axle nut, and then installing the bolts and quick fas-
out.
lower the rear wheel so that it is teners.
on the ground. NOTE:
6. Tighten the axle nut and the To install a quick fastener, push the
brake caliper bracket bolt to the pin back so that it will protrude from
specified torques. the fastener head, and then insert the
fastener and push the protruding pin
in until it is flush with the fastener
head.
6-42
Troubleshooting
Troubleshooting
6-43
Troubleshooting charts
Troubleshooting charts
w
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel
There is enough fuel. Check the compression.
Check the fuel level in
the fuel tank.
The engine does not start.
There is no fuel. Supply fuel.
Check the compression.
2. Compression
There is compression. Check the ignition.
Operate the electric starter. 6
Have a Yamaha dealer
There is no compression.
check the vehicle.
3. Ignition Wipe off with a dry cloth and correct the Open the throttle halfway and operate
Wet
spark plug gaps, or replace the spark plugs. the electric starter.
Remove the spark plugs
and check the electrodes.
The engine does not start.
Dry Have a Yamaha dealer check the vehicle.
Check the battery.
6-44
Engine overheating
EW000070
w
8 Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
8 After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the
hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the
cap.
The coolant level Start the engine. If the engine overheats again, have a
is OK. Yamaha dealer check and repair the cooling system.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
6-45
Care ...................................................................................................7-1
Storage ..............................................................................................7-4
EAU04454
While the open design of a motorcy- plastic bags after the engine has cC
cle reveals the attractiveness of the cooled down. 8 Avoid using strong acidic
technology, it also makes it more vul- 2. Make sure that all caps and cov- wheel cleaners, especially on
nerable. Rust and corrosion can ers as well as all electrical cou- spoked wheels. If such prod-
develop even if high-quality compo- plers and connectors, including ucts are used on hard-to-
nents are used. A rusty exhaust pipe the spark plug caps, are tightly remove dirt, do not leave the
may go unnoticed on a car, however, installed. cleaner on the affected area
it detracts from the overall appear- 3. Remove extremely stubborn dirt, any longer than instructed.
ance of a motorcycle. Frequent and like oil burnt onto the crankcase, Also, thoroughly rinse the area
proper care does not only comply with a degreasing agent and a off with water, immediately dry
with the terms of the warranty, but it brush, but never apply such it, and then apply a corrosion
will also keep your motorcycle looking products onto seals, gaskets, protection spray.
good, extend its life and optimize its sprockets, the drive chain and 8 Improper cleaning can damage
performance. wheel axles. Always rinse the dirt windshields, cowlings, panels
7 and degreaser off with water. and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent
and water to clean plastic.
7-1
7-2
7-3
several months:
Short-term
ingly and make sure to wipe 1. Follow all the instructions in the
Always store your motorcycle in a
off any excess. “Care” section of this chapter.
cool, dry place and, if necessary, pro-
8 Never apply oil or wax to any 2. Fill up the fuel tank and add fuel
tect it against dust with a porous
rubber and plastic parts, but stabilizer (if available) to prevent
cover.
treat them with a suitable care ECA00014 the fuel tank from rusting and the
product. cC fuel from deteriorating.
8 Avoid using abrasive polish- 3. Perform the following steps to
8 Storing the motorcycle in a
ing compounds as they will protect the cylinders, piston
poorly ventilated room or cov-
wear away the paint. rings, etc. from corrosion.
ering it with a tarp, while it is
still wet, will allow water and a. Remove the spark plug caps
NOTE: and spark plugs.
humidity to seep in and cause
Consult a Yamaha dealer for advice b. Pour a teaspoonful of engine
rust.
on what products to use. oil into each spark plug bore.
8 To prevent corrosion, avoid
c. Install the spark plug caps 7
damp cellars, stables (because
of the presence of ammonia) onto the spark plugs, and then
and areas where strong chemi- place the spark plugs on the
cals are stored. cylinder head so that the elec-
trodes are grounded. (This will
limit sparking during the next
step.)
7-4
7-5
SPECIFICATIONS
Specifications ....................................................................................8-1
Conversion table ................................................................................8-5
EAU01038
SPECIFICATIONS
Specifications
Specifications
8-1
SPECIFICATIONS
Transmission type Constant mesh 6-speed Size 160/60 ZR17 M/C (69W)
Manufacturer/ Dunlop/D220STJ
model Metzeler/MEZ4
8-2
SPECIFICATIONS
8-3
SPECIFICATIONS
8-4
SPECIFICATIONS
EAU04513
8-5
CONSUMER INFORMATION
EAU01039
CONSUMER INFORMATION
EAU02944
Identification numbers
Identification numbers
9-1
CONSUMER INFORMATION
1. Model label
EAU01050
Model label
Model label
9-2
INDEX
INDEX
T
Tachometer unit .....................................3-5
Tail/brake light bulb, replacing ..............6-37
Throttle cable free play, adjusting ........6-18
Throttle grip and cable, checking
and lubricating ...................................6-29
Tires .....................................................6-18
Tool kit ....................................................6-1
Troubleshooting ....................................6-43
Troubleshooting charts .........................6-44
Turn signal light bulb, replacing ............6-37
V
Valve clearance, adjusting ...................6-18
Vehicle identification number .................9-1