Faulty Clutch; Clutch Slips; Clutch Drags; Overheating - Yamaha 2002 TDM900 Service Manual

EAS00852

FAULTY CLUTCH

CLUTCH SLIPS

Clutch
S Improperly assembled clutch
S Improperly assembled clutch master
cylinder
S Improperly assembled clutch release cylinder
S Incorrect clutch fluid level
S Damaged clutch hose
S Loose or fatigued clutch spring
S Loose union bolt
S Worn friction plate
S Worn clutch plate
S Damaged clutch release cylinder
Engine oil
S Incorrect oil level
S Incorrect oil viscosity (low)
S Deteriorated oil
EAS00855

OVERHEATING

ENGINE

Clogged coolant passages
S Cylinder head(s) and piston(s)
S Heavy carbon buildup
Engine oil
S Incorrect oil level
S Incorrect oil viscosity
S Inferior oil quality

COOLING SYSTEM

Coolant
S Low coolant level
Radiator
S Damaged or leaking radiator
S Faulty radiator cap
S Bent or damaged radiator fin
Water pump
S Damaged or faulty water pump
S Thermostat
S Thermostat stays closed
S Damaged hose
S Improperly connected hose
S Damaged pipe
S Improperly connected pipe
FAULTY CLUTCH/OVERHEATING

CLUTCH DRAGS

Clutch
S Air in hydraulic clutch system
S Unevenly tensioned clutch springs
S Warped pressure plate
S Bent clutch plate
S Swollen friction plate
S Bent clutch push rod
S Damaged clutch boss
S Burnt primary driven gear bushing
S Damaged clutch release cylinder
S Match marks not aligned
Engine oil
S Incorrect oil level
S Incorrect oil viscosity (high)
S Deteriorated oil

FUEL SYSTEM

Throttle body(-ies)
S Faulty throttle body(-ies)
S Damaged or loose throttle body joint
Air filter
S Clogged air filter element
CHASSIS
Brake(s)
S Dragging brake

ELECTRICAL SYSTEMS

Spark plug(s)
S Incorrect spark plug gap
S Incorrect spark plug heat range
Ignition system
S Faulty ECU
9-4
TRBL
SHTG