2004 YAMAHA TDM 900 coolant
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TABLE OF CONTENTS
SAFETY INFORMATION ............. 1-1
DESCRIPTION ............................. 2-1
Left view ..................................... 2-1
Right view................................... 2-2
Controls and instruments ........... 2-3
INSTRUMENT AND CONTROL
FUNCTIONS ................................ 3-1
Immobilizer system ................... 3-1
Main switch/steering lock .......... 3-2
Indicator and warning lights ...... 3-3
Speedometer unit ...................... 3-5
Tachometer unit ........................ 3-6
Coolant temperature gauge ...... 3-7
Anti-theft alarm (optional) .......... 3-8
Handlebar switches ................... 3-8
Clutch lever ............................... 3-9
Shift pedal ............................... 3-10
Brake lever .............................. 3-10
Brake pedal ............................. 3-11
Fuel tank cap ........................... 3-11
Fuel ......................................... 3-12
Fuel tank breather hose .......... 3-13
Catalytic converter .................. 3-13
Seat ......................................... 3-13
Storage compartment .............. 3-14
Adjusting the front fork ............ 3-15Adjusting the shock absorber
assembly ............................... 3-16
Luggage strap holders ............ 3-18
Sidestand ................................ 3-18
Ignition circuit cut-off system ... 3-19
PRE-OPERATION CHECKS ....... 4-1
Pre-operation check list ............ 4-2
OPERATION AND IMPORTANT
RIDING POINTS ........................... 5-1
Starting the engine .................... 5-1
Shifting ...................................... 5-2
Tips for reducing fuel
consumption ............................ 5-3
Engine break-in ......................... 5-3
Parking ...................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR ............................ 6-1
Owner’s tool kit ......................... 6-1
Periodic maintenance and
lubrication chart ....................... 6-2
Removing and installing
cowlings and panels ................ 6-5
Checking the spark plugs .......... 6-6
Engine oil and oil filter
element ................................... 6-7Coolant .................................... 6-10
Replacing the air filter
element ................................. 6-14
Adjusting the engine idling
speed .................................... 6-15
Adjusting the throttle cable free
play ....................................... 6-16
Adjusting the valve
clearance .............................. 6-16
Tires ........................................ 6-16
Cast wheels ............................ 6-19
Adjusting the clutch lever free
play ....................................... 6-20
Adjusting the brake pedal
position .................................. 6-21
Adjusting the rear brake light
switch .................................... 6-21
Checking the front and rear
brake pads ............................ 6-22
Checking the brake fluid
level ....................................... 6-22
Changing the brake fluid ......... 6-23
Drive chain slack ..................... 6-24
Lubricating the drive chain ...... 6-25
Checking and lubricating the
cables .................................... 6-26
Checking and lubricating the
throttle grip and cable ........... 6-26
Page 13 of 92
DESCRIPTION
2-2
2
3
4
5
6
7
8
9
EAU10420
Right view
1234
5
6 7 8 9 10
1. Owner’s tool kit (page 6-1)
2. Coolant reservoir (page 6-10)
3. Throttle stop screw (page 6-15)
4. Front brake fluid reservoir (page 6-22)
5. Radiator cap (page 6-10)
6. Engine oil filler cap (page 6-7)
7. Engine oil filter element (page 6-7)
8. Engine oil drain bolt B (page 6-7)9. Brake pedal (page 3-11)
10. Rear brake fluid reservoir (page 6-22)
Page 14 of 92
DESCRIPTION
2-3
1
2
3
4
5
6
7
8
9
EAU10430
Controls and instruments
1 2 345 6 7 8 9
1. Clutch lever (page 3-9)
2. Left handlebar switches (page 3-8)
3. Speedometer unit (page 3-5)
4. Main switch/steering lock (page 3-2)
5. Tachometer unit (page 3-6)
6. Coolant temperature gauge (page 3-7)
7. Right handlebar switches (page 3-8)
8. Brake lever (page 3-10)9. Throttle grip (page 6-16)
Page 21 of 92
INSTRUMENT AND CONTROL FUNCTIONS
3-7
2
34
5
6
7
8
9
clock.
To set the clock:
1. Push both the “SELECT” and “RE-
SET” buttons for at least two sec-
onds.
2. When the hour digits start flashing,
push the “RESET” button to set the
hours.
3. Push the “SELECT” button to
change the minutes.
4. When the minute digits start flash-
ing, push the “RESET” button to
set the minutes.
5. Push the “SELECT” button to start
the clock.
NOTE:
After setting the clock, be sure to
push the “SELECT” button before
turning the key to “OFF”, otherwise
the clock will not be set.
When the key is turned to “OFF”,
the clock display will remain on for
48 hours and then go off to prevent
the battery from discharging.
EAU12180
Coolant temperature gauge
With the key in the “ON” position, the
coolant temperature gauge indicates
the temperature of the coolant. When
the key is turned to “ON”, the coolant
temperature gauge needle will move to
“H” and back to “C” in order to test the
electrical circuit. The coolant tempera-
ture varies with changes in the weather
and engine load. If the needle reaches
or enters the red zone, stop the vehicle
and let the engine cool. (See
page 6-39.)
CAUTION:
ECA10020
Do not operate the engine if it is
overheated.
1. Coolant temperature gauge
2. Coolant temperature gauge red zone
12
Page 36 of 92
PRE-OPERATION CHECKS
4-2
1
2
3
4
5
6
7
8
9
EAU15601
Pre-operation check list
ITEM CHECKS PAGE
Fuel
Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-12
Engine oil
Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-7
Coolant
Check coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-10
Front brake
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-22
Rear brake
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-21, 6-22
Clutch
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-20
Page 44 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
1
2
3
4
5
6
7
8
9
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. Every 50000 km
13
Drive chain
Check chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate.Every 1000 km and after washing the motorcycle or
riding in the rain
14
*
Steering bearings
Check bearing play and steering for roughness.
√
√
√
√
√
Lubricate with lithium-soap-based grease. Every 20000 km
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 absorber assem-
bly
Check operation and shock absorber for oil leakage.
√
√
√
√
20
*
Rear suspension relay
arm and connecting arm
pivoting points
Check operation.
√
√
√
√
Lubricate with lithium-soap-based grease.
√
√
21
*
Electronic fuel injection
Adjust engine idling speed and synchronization.
√
√
√
√
√
√
22
Engine oil
Change.
Check oil level and vehicle for oil leakage.
√
√
√
√
√
√
23
Engine oil filter element
Replace.
√
√
√
24
*Cooling system
Check coolant level and vehicle for coolant leakage.√ √ √ √ √ Change. Every 3 years NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
Page 51 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
2
3
4
5
67
8
9
CAUTION:
ECA11620
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
Make sure that no foreign mate-
rial enters the crankcase.
9. Start the engine, and then let it idlefor several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
10. 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 cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU20101
To check the coolant level
1. Place the vehicle on the center-
stand.
NOTE:
The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.
NOTE:
The coolant should be between the
minimum and maximum level marks. Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
3.80 L (4.02 US qt)
(3.34 Imp.qt)
With oil filter element replace-
ment:
3.90 L (4.12 US qt)
(3.43 Imp.qt)
Page 52 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
1
2
3
4
5
6
7
8
9
3. If the coolant is at or below the
minimum level mark, remove pan-
el B (See page 6-5.), remove the
reservoir cap, add coolant to the
maximum level mark, and then in-
stall the reservoir cap and the pan-
el.
CAUTION:
ECA10470
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to 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 be
sufficiently cooled and the cool-ing system will not be protected
against frost and corrosion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
WARNING
EWA10380
Never attempt to remove the radiator
cap when the engine is hot.
NOTE:
The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.
If the engine overheats, see page
6-39 for further instructions.
EAU20450
To change the coolant
1. Place the vehicle on a level sur-
face and let the engine cool if nec-
essary.
2. Remove the seat. (See
page 3-13.)
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
1 2
3
1. Coolant reservoir cap
Coolant reservoir capacity (up to
the maximum level mark):
0.25 L (0.26 US qt)
(0.22 Imp.qt)
1