2005 YAMAHA TDM 900 clutch

OPERATION AND IMPORTANT RIDING POINTS
5-2
2
3
4
56
7
8
9

attempt.
CAUTION:

ECA11040
For maximum engine life, never ac-
celerate hard when the engine is
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 inthe 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.
1. Shift pedal
2. Neutral position
1
1 2 3
4 5 6
N2

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
2
3
4
5
67
8
9

EAU17705
Periodic maintenance and lubrication chart
NOTE:


The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.

From 50000 km, repeat the maintenance intervals starting from 10000 km.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040
1*
Fuel line


Check fuel hoses for cracks or damage.
√√√√ √
2*
Spark plugs

Check condition.

Clean and regap.
√√

Replace.
√√
3*
Valves

Check valve clearance.

Adjust.Every 40000 km
4
Air filter element

Replace.
√
5
Clutch

Check operation.

Adjust.
√√√√√
6*
Front brake

Check operation, fluid level and vehicle for fluid leak-
age.
√√√√√ √

Replace brake pads. Whenever worn to the limit
7*
Rear brake

Check operation, fluid level and vehicle for fluid leak-
age.
√√√√√ √

Replace brake pads. Whenever worn to the limit
8*
Brake hoses

Check for cracks or damage.
√√√√ √

Replace. Every 4 years
9*
Wheels

Check runout and for damage.
√√√√

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 idle
for 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 thencheck 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.
EAU20251
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
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 replacement:
3.90 L (4.12 US qt) (3.43 Imp.qt)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
2
3
4
5
67
8
9

EAU22041
Adjusting the clutch lever free
play
The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the clutch le-
ver.
2. To increase the clutch lever free
play, turn the adjusting bolt in di-
rection (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).
NOTE:

If the specified clutch lever free play
could be obtained as described above,
tighten the locknut and skip the rest of
the procedure, otherwise proceed as
follows.
3. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loos-
en the clutch cable.
4. Loosen the locknut at the crank-
case.
5. To increase the clutch lever free
play, turn the adjusting nut in direc-
tion (a). To decrease the clutch le-ver free play, turn the adjusting nut
in direction (b).
6. Tighten the locknut at the clutch le-
ver and the crankcase.
1. Locknut (clutch lever)
2. Clutch lever free play adjusting bolt
3. Clutch lever free play
12
3
(a)
(b)

1. Locknut (crankcase)
2. Clutch lever free play adjusting nut (crank-
case)12
(a)(b)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
2
3
4
5
67
8
9

EAU23111
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
EAU23131
Checking and lubricating the
brake and shift pedals
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
EAU23140
Checking and lubricating the
brake and clutch levers
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

8-1
1
2
3
4
5
6
7
8
9

SPECIFICATIONS
EAU26339
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:
224.0 kg (494 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 onlyFuel 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
Operation:
Left foot operation
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40

INDEX
A
ABS (for ABS models) .............................3-11
ABS warning light (for ABS models) ..........3-4
Air filter element, replacing ......................6-12
Anti-theft alarm (optional) ..........................3-8
Auxiliary light bulb, replacing ...................6-31
B
Battery .....................................................6-27
Brake and clutch levers, checking and
lubricating ..............................................6-24
Brake and shift pedals, checking and
lubricating ..............................................6-24
Brake fluid, changing ...............................6-21
Brake fluid level, checking .......................6-20
Brake lever ..............................................3-10
Brake pedal .............................................3-11
C
Cables, checking and lubricating .............6-23
Care ...........................................................7-1
Catalytic converter ...................................3-14
Clutch lever ..............................................3-10
Clutch lever free play, adjusting ..............6-18
Coolant ....................................................6-10
Coolant temperature gauge .......................3-6
Cowlings and panels, removing and
installing ..................................................6-5
D
Dimmer switch ...........................................3-9
Drive chain, cleaning and lubricating .......6-23
Drive chain slack .....................................6-21
E
Engine break-in .........................................5-3
Engine idling speed .................................6-13
Engine oil and oil filter element ..................6-7Engine stop switch .................................... 3-9
Engine trouble warning light ...................... 3-4
F
Front and rear brake pads, checking....... 6-19
Front fork, adjusting................................. 3-15
Front fork, checking ................................. 6-25
Fuel ......................................................... 3-13
Fuel consumption, tips for reducing .......... 5-3
Fuel level warning indicator ....................... 3-4
Fuel tank breather hose .......................... 3-13
Fuel tank cap ........................................... 3-12
Fuses, replacing ...................................... 6-28
H
Handlebar switches ................................... 3-8
Hazard switch ............................................ 3-9
Headlight bulb, replacing ......................... 6-29
High beam indicator light ........................... 3-4
Horn switch................................................ 3-9
I
Identification numbers ............................... 9-1
Ignition circuit cut-off system ................... 3-19
Immobilizer system.................................... 3-1
Immobilizer system indicator light ............. 3-4
Indicator and warning lights....................... 3-3
K
Key identification number .......................... 9-1
L
Luggage strap holders............................. 3-18
M
Main switch/steering lock .......................... 3-2
Model label ................................................ 9-2
Multi-function display ................................. 3-7
N
Neutral indicator light................................. 3-4
O
Oil level warning light ................................ 3-4
P
Parking ...................................................... 5-4
Part locations ............................................ 2-1
Pass switch ............................................... 3-9
Periodic maintenance and lubrication
chart ........................................................ 6-2
Pre-operation check list............................. 4-2
R
Rear brake light switch, adjusting ........... 6-19
Rear suspension, lubricating ................... 6-25
S
Safety information ..................................... 1-1
Seat ......................................................... 3-14
Shifting ...................................................... 5-2
Shift pedal ............................................... 3-10
Shock absorber assembly, adjusting ...... 3-17
Sidestand ................................................ 3-19
Sidestand, checking and lubricating........ 6-25
Spark plugs, checking ............................... 6-6
Specifications ............................................ 8-1
Starting the engine .................................... 5-1
Start switch................................................ 3-9
Steering, checking................................... 6-26
Storage...................................................... 7-3
Storage compartment.............................. 3-15
Supporting the motorcycle ...................... 6-32
T
Tachometer unit ........................................ 3-5
Tail/brake light bulb, replacing ................ 6-30
Throttle cable free play, checking ........... 6-14
Throttle grip and cable, checking and
lubricating ............................................. 6-24