User manual YAMAHA XZ400 SUPPLEMENTARY SERVICE MANUAL

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Manual abstract: user guide YAMAHA XZ400SUPPLEMENTARY SERVICE MANUAL

Detailed instructions for use are in the User's Guide.

[. . . ] As the owner of the TDM900, you are benefiting from Yamaha's vast experience and newest technology 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 motorcycle, 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. [. . . ] 1 * Fuel line 2 * Spark plugs 3 * Valves 4 5 Air filter element Clutch ITEM G G G G G G G G G G 2 3 4 5 6 7 CHECK OR MAINTENANCE JOB 1 Check fuel hoses for cracks or damage. 10 Every 40000 km 20 30 40 ANNUAL CHECK 6 * Front brake G G Whenever worn to the limit 8 9 7 * Rear brake G 8 * Brake hoses 9 * Wheels G G G Whenever worn to the limit Every 4 years 6-2 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) NO. ITEM G CHECK OR MAINTENANCE JOB 1 G G G 10 20 30 40 ANNUAL CHECK 1 2 3 10 * Tires 11 * Wheel bearings 12 * Swingarm 13 G G G G Drive chain G 4 14 * Steering bearings G G 5 6 7 8 9 15 * Chassis fasteners 16 17 18 19 20 G Brake lever pivot shaft Brake pedal pivot shaft Clutch lever pivot shaft Shift pedal pivot shaft Sidestand G G G G G G G G 21 * Sidestand switch 22 * Front fork Shock absorber assem23 * bly Rear suspension relay 24 * arm and connecting arm pivoting points 25 * Fuel injection 26 Check tread depth and for damage. Adjust and lubricate chain with a special O-ring chain lubricant thoroughly. 6-3 Every 50000 km Every 1000 km and after washing the motorcycle or riding in the rain Every 20000 km G G G G G G Engine oil PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) NO. 27 ITEM Engine oil filter element G G G CHECK OR MAINTENANCE JOB 1 Replace. 10 20 30 40 Every 3 years ANNUAL CHECK 28 * Cooling system 29 * 30 31 * Front and rear brake switches Moving parts and cables Throttle grip housing and cable G 2 3 4 5 G G G G G 32 * Air induction system G 33 * Muffler and exhaust pipe Lights, signals and 34 * switches G G G 6 EAU18680 NOTE: G Air filter This model's air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas. G 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, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged. G G G G G 7 8 9 6-4 PERIODIC MAINTENANCE AND MINOR REPAIR EAU18712 Removing and installing cowlings and panels 1 2 3 4 The cowlings and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be removed and installed. 1 2 1 1 1 2 1. Minimum level mark ECA10010 CAUTION: Do not operate the vehicle until you know that the engine oil level is sufficient. EWA10360 WARNING 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. 6-8 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 2 2 installing the bolts, then tightening them to the specified torque. Tightening torque: Oil filter element cover bolt: 10 Nm (1. 0 m·kgf, 7. 2 ft·lbf) 2 1 3 1. Install the engine oil drain bolts, and then tighten them to the specified torques. Tightening torques: Engine oil drain bolt A: 35 Nm (3. 5 m·kgf, 25 ft·lbf) Engine oil drain bolt B: 30 Nm (3. 0 m·kgf, 21. 7 ft·lbf) 4 5 6 7 8 9 NOTE: Skip steps 4­6 if the oil filter element is not being replaced. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap. 1. Install the oil filter element cover by 6-9 PERIODIC MAINTENANCE AND MINOR REPAIR Recommended engine oil: See page 8-1. Oil quantity: Without oil filter element replacement: 3. 80 L (4. 02 US qt) (3. 34 Imp. qt) With oil filter element replacement: 3. 90 L (4. 12 US qt) (3. 43 Imp. qt) for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. Turn the engine off, and then check the oil level and correct it if necessary. EAU20070 Coolant The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. EAU20252 2 3 4 5 6 7 8 9 NOTE: Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down. ECA11620 To check the coolant level 1. Place the vehicle on a level surface and hold it in an upright position. NOTE: G The coolant level must be checked on a cold engine since the level varies with engine temperature. [. . . ] Follow all the instructions in the "Care" section of this chapter. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the CAUTION: G Apply spray oil and wax sparingly and make sure to wipe off any excess. G Never apply oil or wax to any rubber and plastic parts, but 7-3 MOTORCYCLE CARE AND STORAGE fuel from deteriorating. Perform the following steps to protect the cylinders, piston rings, etc. [. . . ]

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