2005 YAMAHA TDM 900 catalytic converter

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
Tachometer unit ...............................3-5
Coolant temperature gauge .............3-6
Multi-function display .......................3-7
Anti-theft alarm (optional) ................3-8
Handlebar switches .........................3-8
Clutch lever ....................................3-10
Shift pedal ......................................3-10
Brake lever ....................................3-10
Brake pedal ...................................3-11
ABS (for ABS models) ...................3-11
Fuel tank cap .................................3-12
Fuel ................................................3-13
Fuel tank breather hose .................3-13
Catalytic converter .........................3-14
Seat ...............................................3-14
Storage compartment ....................3-15
Adjusting the front fork ...................3-15
Adjusting the shock absorber
assembly ....................................3-17Luggage strap holders .................. 3-18
Sidestand ...................................... 3-19
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 ....... 6-7
Coolant .......................................... 6-10
Replacing the air filter element ...... 6-12
Adjusting the engine idling
speed ......................................... 6-13
Checking the throttle cable free
play ............................................ 6-14Valve clearance ............................ 6-14
Tires .............................................. 6-15
Cast wheels .................................. 6-17
Adjusting the clutch lever free
play ............................................ 6-18
Adjusting the rear brake light
switch ......................................... 6-19
Checking the front and rear brake
pads ........................................... 6-19
Checking the brake fluid level ....... 6-20
Changing the brake fluid ............... 6-21
Drive chain slack ........................... 6-21
Cleaning and lubricating the drive
chain .......................................... 6-23
Checking and lubricating the
cables ........................................ 6-23
Checking and lubricating the throttle
grip and cable ............................ 6-24
Checking and lubricating the brake
and shift pedals ......................... 6-24
Checking and lubricating the brake
and clutch levers ........................ 6-24
Checking and lubricating the
sidestand ................................... 6-25
Lubricating the rear suspension .... 6-25
Checking the front fork .................. 6-25
Checking the steering ................... 6-26
Checking the wheel bearings ........ 6-27
Battery ........................................... 6-27
Replacing the fuses ...................... 6-28
Replacing a headlight bulb ........... 6-29

INSTRUMENT AND CONTROL FUNCTIONS
3-14
1
2
3
4
5
6
7
8
9

EAU13441
Catalytic converter
This vehicle is equipped with catalytic
converters in the exhaust system.
WARNING

EWA10860
The exhaust system is hot after op-
eration. Make sure that the exhaust
system has cooled down before do-
ing any maintenance work.
CAUTION:

ECA10700
The following precautions must be
observed to prevent a fire hazard or
other damages.

Use only unleaded gasoline.
The use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.

Never park the vehicle near pos-
sible fire hazards such as grass
or other materials that easily
burn.

Do not allow the engine to idle
too long.
EAU13860
Seat
To remove the seat
Insert the key into the seat lock, turn it
counterclockwise, and then pull the
seat off.
To install the seat
Insert the projections on the front of the
seat into the seat holder, push the rear
of the seat down to lock it in place, and
then remove the key.
NOTE:

Make sure that the seat is properly se-
cured before riding.
1. Seat lock
2. Unlock.1
2

1. Projection
2. Seat holder
1
2

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