2004 YAMAHA TDM 900 coolant level
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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 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.
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√
√
√
√
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.
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√
√
√
√
√
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.
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√
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√
√
22
Engine oil
Change.
Check oil level and vehicle for oil leakage.
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23
Engine oil filter element
Replace.
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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
Page 54 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
1
2
3
4
5
6
7
8
9
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 besufficiently 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.
15. Install the radiator cap, start the
engine, let it idle for several min-
utes, and then turn it off.
16. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radia-
tor, and then install the radiator
cap and the cap retaining bolt.
17. Check the coolant level in the res-
ervoir. If necessary, remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the cap.
18. Install the fuel tank.
WARNING
EWA11290
Before installing the fuel tank,
make sure that the fuel hoses
are not damaged. If any fuel
hose is damaged, do not start
the engine but have a Yamaha
dealer replace the hose, other-
wise fuel may leak.
Make sure that the fuel hoses
are properly connected and
routed, and not pinched.
Be sure to place the fuel tank
breather hose in the original po-
sition.
19. Install the panel, the cowling, and
the seat.
20. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system. Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol
antifreeze containing corro-
sion inhibitors for aluminum
engines
Coolant quantity:
Radiator capacity (including all
routes):
1.70 L (1.80 US qt)
(1.50 Imp.qt)
Coolant reservoir capacity:
0.25 L (0.26 US qt)
(0.22 Imp.qt)
Page 81 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-40
2
3
4
5
67
8
9 Engine overheating
WARNING
EWA10400
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.
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.
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.
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See NOTE.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.
Page 86 of 92
8-1
1
2
3
4
5
6
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8
9
SPECIFICATIONS
EAU26333
Dimensions:
Overall length:
2180 mm (85.8 in)
Overall width:
800 mm (31.5 in)
Overall height:
1290 mm (50.8 in)
Seat height:
825 mm (32.5 in)
Wheelbase:
1485 mm (58.5 in)
Ground clearance:
160 mm (6.30 in)
Minimum turning radius:
2900 mm (114.2 in)
Weight:
With oil and fuel:
221.0 kg (487 lb)
Engine:
Engine type:
Liquid cooled 4-stroke, DOHC
Cylinder arrangement:
Forward-inclined parallel 2-cylinder
Displacement:
897.0 cm
3
(54.73 cu.in)
Bore
×
stroke:
92.0
×
67.5 mm (3.62
×
2.66 in)
Compression ratio:
10.40 :1
Starting system:
Electric starter
Lubrication system:
Dry sump
Engine oil:
Type:
SAE10W30 or SAE10W40 or SAE15W40
or SAE20W40 or SAE20W50
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine 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)
Cooling system:
Coolant reservoir capacity (up to the maxi-
mum level mark):
0.25 L (0.26 US qt) (0.22 Imp.qt)
Radiator capacity (including all routes):
1.70 L (1.80 US qt) (1.50 Imp.qt)
Air filter:
Air filter element:
Oil-coated paper element
Fuel:
Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
20.0 L (5.28 US gal) (4.40 Imp.gal)
Fuel reserve amount:
3.5 L (0.92 US gal) (0.77 Imp.gal)
Electronic fuel injection:
Manufacturer:
DENSO
Model:
195500-3830/2
Spark plug(s):
Manufacturer/model:
NGK/DPR8EA-9
Manufacturer/model:
DENSO/X24EPR-U9
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
Clutch:
Clutch type:
Wet, multiple-disc
Transmission:
Primary reduction system:
Spur gear
Primary reduction ratio:
67/39 (1.718)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
42/16 (2.625)
Transmission type:
Constant mesh 6-speed
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40