2004 YAMAHA TDM 900 lights

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

SAFETY INFORMATION
1-3
1
Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit of
203 kg (448 lb). When loading within
this weight limit, keep the following in
mind:


Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Make
sure to distribute the weight as
evenly as possible on both sides of
the motorcycle to minimize imbal-
ance or instability.

Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.

Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a slowsteering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re-
sponsible for the proper selection, in-
stallation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any ac-
cessories.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.


Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.

Accessories fitted to the handle-bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.

Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds. These ac-
cessories may also cause
instability when passing or being
passed by large vehicles.

Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.

SAFETY INFORMATION
1-4
1

Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas

GASOLINE IS HIGHLY FLAMMA-
BLE:

Always turn the engine off when
refueling.

Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.

Never refuel while smoking or in
the vicinity of an open flame.

Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has ad-
equate ventilation.

Always turn the engine off beforeleaving the motorcycle unattended
and remove the key from the main
switch. When parking the motorcy-
cle, note the following:

The engine and exhaust system
may be hot, therefore, park the
motorcycle in a place where pe-
destrians or children are not like-
ly to touch these hot areas.

Do not park the motorcycle on a
slope or soft ground, otherwise it
may fall over.

Do not park the motorcycle near
a flammable source, (e.g., a ker-
osene heater, or near an open
flame), otherwise it could catch
fire.

When transporting the motorcycle
in another vehicle, make sure that
it is kept upright. If the motorcycle
should lean over, gasoline may
leak out of the fuel tank.

If you should swallow any gaso-
line, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediate-ly. If any gasoline spills on your
skin or clothing, immediately wash
the affected area with soap and
water and change your clothes.

INSTRUMENT AND CONTROL FUNCTIONS
3-3
2
34
5
6
7
8
9
left or right.
1. Push the key in from the “OFF” po-
sition, and then turn it to “LOCK”
while still pushing it.
2. Remove the key.
To unlock the steering
Push the key into the main switch, and
then turn it to “OFF” while still pushing
it.
WARNING

EWA10060
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving,
otherwise the electrical systems will
be switched off, which may result inloss of control or an accident. Make
sure that the vehicle is stopped be-
fore turning the key to “OFF” or
“LOCK”.
EAU10910
(Parking)
The steering is locked, the taillights and
auxiliary lights are on, and the hazard
light can be turned on, but all other
electrical systems are off. The key can
be removed.
The steering must be locked before the
key can be turned to “ ”.
CAUTION:

ECA11020
Do not use the parking position for
an extended length of time, other-
wise the battery may discharge.
EAU11001
Indicator and warning lights
EAU11030
Turn signal indicator lights “” and
“”
The corresponding indicator light flash-
es when the turn signal switch is
pushed to the left or right.
1. Push.
2. Turn.
1. Fuel level warning light “ ”
2. Left turn signal indicator light “ ”
3. High beam indicator light “ ”
4. Neutral indicator light “ ”
5. Engine trouble warning light “ ”
6. Right turn signal indicator light “ ”
7. Oil level warning light “ ”
8. Immobilizer system indicator light “ ”
12345678

INSTRUMENT AND CONTROL FUNCTIONS
3-8
1
2
3
4
5
6
7
8
9

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 “ ”
1
2
3
4
5

1. Engine stop switch “ / ”
2. Start switch “ ”
1
2

INSTRUMENT AND CONTROL FUNCTIONS
3-9
2
34
5
6
7
8
9
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
2
3
45
6
7
8
9

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

OPERATION AND IMPORTANT RIDING POINTS
5-3
1
2
3
4
5
6
7
8
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)