2004 YAMAHA TDM 900 light

INSTRUMENT AND CONTROL FUNCTIONS
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EAU12330
Anti-theft alarm (optional)
This model can be equipped with an
optional anti-theft alarm by a Yamaha
dealer. Contact a Yamaha dealer for
more information.
EAU12342
Handlebar switches
LeftRight
EAU12350
Pass switch “”
Press this switch to flash the headlight.
EAU12400
Dimmer switch “/”
Set this switch to “ ” for the high
beam and to “ ” for the low beam.
EAU12460
Turn signal switch “/”
To signal a right-hand turn, push this
switch to “ ”. To signal a left-hand
turn, push this switch to “ ”. When re-
leased, the switch returns to the center
position. To cancel the turn signal
lights, push the switch in after it has re-
1. Pass switch “ ”
2. Hazard switch “ ”
3. Dimmer switch “ / ”
4. Turn signal switch “ / ”
5. Horn switch “ ”
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1. Engine stop switch “ / ”
2. Start switch “ ”
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INSTRUMENT AND CONTROL FUNCTIONS
3-9
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turned to the center position.

EAU12500
Horn switch “”
Press this switch to sound the horn.
EAU12660
Engine stop switch “/”
Set this switch to “ ” before starting
the engine. Set this switch to “ ” to
stop the engine in case of an emergen-
cy, such as when the vehicle overturns
or when the throttle cable is stuck.
EAU12710
Start switch “”
Push this switch to crank the engine
with the starter.
CAUTION:

ECA10050
See page 5-1 for starting instruc-
tions prior to starting the engine.
EAU12730
Hazard switch “”
With the key in the “ON” or “ ” posi-
tion, use this switch to turn on the haz-
ard light (simultaneous flashing of all
turn signal lights).
The hazard light is used in case of an
emergency or to warn other drivers
when your vehicle is stopped where itmight be a traffic hazard.
CAUTION:

ECA10060
Do not use the hazard light for an ex-
tended length of time, otherwise the
battery may discharge.
EAU12820
Clutch lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See
page 3-19.)
1. Clutch lever
1

PRE-OPERATION CHECKS
4-3
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Throttle grip

Make sure that operation is smooth.

Check cable free play.

If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-16, 6-26
Control cables

Make sure that operation is smooth.

Lubricate if necessary.6-26
Drive chain

Check chain slack.

Adjust if necessary.

Check chain condition.

Lubricate if necessary.6-24, 6-25
Wheels and tires

Check for damage.

Check tire condition and tread depth.

Check air pressure.

Correct if necessary.6-16, 6-19
Brake and shift pedals

Make sure that operation is smooth.

Lubricate pedal pivoting points if necessary.6-26
Brake and clutch levers

Make sure that operation is smooth.

Lubricate lever pivoting points if necessary.6-27
Sidestand

Make sure that operation is smooth.

Lubricate pivot if necessary.6-27
Chassis fasteners

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

Tighten if necessary.—
Instruments, lights, signals
and 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.3-18
ITEM CHECKS PAGE

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OPERATION AND IMPORTANT RIDING POINTS
EAU15950
WARNING

EWA10270

Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.

Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.

Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU16380
Starting the engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.

The transmission is in gear with
the clutch lever pulled and the sid-
estand up.
WARNING

EWA10290

Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-19.

Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
CAUTION:

ECA11310
The oil level warning light and en-
gine trouble warning light should
come on for a few seconds, then gooff. If a warning light does not go off,
see page 3-3 for the corresponding
warning light circuit check.
2. Shift the transmission into the neu-
tral position.
NOTE:

When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a Yama-
ha dealer check the electrical circuit.
3. Start the engine by pushing the
start switch.
NOTE:

If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt.
CAUTION:

ECA11040
For maximum engine life, never ac-
celerate hard when the engine is

OPERATION AND IMPORTANT RIDING POINTS
5-2
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cold!
NOTE:

The engine is warm when it quickly re-
sponds to the throttle.
EAU16671
Shifting
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.
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.
CAUTION:

ECA10260

Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.

Always use the clutch while
changing gears to avoid damag-
ing the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU16751
Recommended shift points (for
Switzerland only)
The recommended shift points during
acceleration are shown in the table be-
low.
1. Shift pedal
2. Neutral position1
1 2 3
4 5 6
N2

OPERATION AND IMPORTANT RIDING POINTS
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9
NOTE:

When shifting down two gears at a
time, reduce the speed accordingly
(e.g., down to 35 km/h (22 mi/h) when
shifting from 5th to 3rd gear).
EAU16810
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Shift up swiftly, and avoid high en-
gine speeds during acceleration.

Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.

Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16841
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17100
0–1,000 km (0–600 mi)
Avoid prolonged operation above 4,000
r/min.
1,000–1,600 km (600–1,000 mi)
Avoid prolonged operation above 6,000
r/min.
CAUTION:

ECA11150
After 1,000 km (600 mi) of operation,
the engine oil must be changed, and Shift up points:
1st
→
2nd: 20 km/h (12 mi/h)
2nd
→
3rd: 30 km/h (19 mi/h)
3rd
→
4th: 40 km/h (25 mi/h)
4th
→
5th: 50 km/h (31 mi/h)
5th
→
6th: 60 km/h (37 mi/h)

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU18680
NOTE:


Air filter

This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed air to avoid damaging it.

The air filter element needs to be replaced more frequently when 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, and change the brake
fluid.

Replace the brake hoses every four years and if cracked or damaged.
25

*
Front and rear brake
switches

Check operation.
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Moving parts and cables

Lubricate.
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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.
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Air induction system

Check the air cut-off valve, reed valve, and hose for
damage.

Replace the entire air induction system if necessary.
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Muffler and exhaust pipe

Check the screw clamp for looseness.
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Lights, signals and
switches

Check operation.

Adjust headlight beam.
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NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040

PERIODIC MAINTENANCE AND MINOR REPAIR
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To install the cowling
Place the cowling in the original posi-
tion, and then install the screws and the
quick fastener.NOTE:

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

EAU19641
Checking the spark plugs
The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal color
when the vehicle is ridden normally),
and all spark plugs installed in the en-
gine should have the same color. If any
spark plug shows a distinctly different
color, the engine could be defective. Do
not attempt to diagnose such problems
yourself. Instead, have a Yamaha deal-
er check the vehicle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.
1. Screw
1. Panel B
1
1