2005 YAMAHA TDM 900 steering

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

SAFETY INFORMATION
1-3
1
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 slow
steering 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.

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

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 3-10)
2. Left handlebar switches (page 3-8)
3. Multi-function display (page 3-7)
4. Main switch/steering lock (page 3-2)
5. Tachometer unit (page 3-5)
6. Coolant temperature gauge (page 3-6)
7. Right handlebar switches (page 3-8)
8. Brake lever (page 3-10)9. Throttle grip (page 6-14)

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

EAU10471
Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering.
NOTE:

Be sure to use the standard key (black
bow) for regular use of the vehicle. To
minimize the risk of losing the code
re-registering key (red bow), keep it in a
safe place and only use it for code
re-registering.
EAU10570
ON
All electrical circuits are supplied with
power; the meter lighting, taillight and
auxiliary light come on, and the enginecan be started. The key cannot be re-
moved.
NOTE:

The headlight comes on automatically
when the engine is started and stays on
until the key is turned to “OFF”.
EAU10660
OFF
All electrical systems are off. The key
can be removed.
EAU10690
LOCK
The steering is locked, and all electrical
systems are off. The key can be re-
moved.To lock the steering
Turn the handlebars all the way to the
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.
OFF ON
LOCK
P

1. Push.
2. Turn.

INSTRUMENT AND CONTROL FUNCTIONS
3-3
2
34
5
6
7
8
9
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 in
loss of control or an accident. Make
sure that the vehicle is stopped be-
fore turning the key to “OFF” or
“LOCK”.
EAU33000
(Parking)
The steering is locked, and the taillight
and auxiliary light are on. The hazard
light and turn signal lights 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.
EAU11002
Indicator and warning lights
EAU11020
Turn signal indicator light “”
This indicator light flashes when the
turn signal switch is pushed to the left or
right.
1. Push.
2. Turn.
1. Fuel level warning indicator “ ”
2. Turn signal indicator light “ ”
3. High beam indicator light “ ”
4. Neutral indicator light “ ”
5. Engine trouble warning light “ ”
6. Anti-lock Brake System (ABS) warning
light “ ” (for ABS models)
7. Oil level warning light “ ”
8. Immobilizer system indicator light “ ”
12345678
ABS

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, alignment and condition.

Adjust and lubricate chain with a special O-ring chain
lubricant thoroughly.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

*
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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
2
3
4
5
67
8
9
CAUTION:

ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.

9-1
2
3
4
5
6
7
8
9

CONSUMER INFORMATION
EAU26351
Identification numbers
Record the key identification number,
vehicle identification number and mod-
el label information in the spaces pro-
vided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehi-
cle is stolen.
KEY IDENTIFICATION NUMBER:
VEHICLE IDENTIFICATION NUM-
BER:
MODEL LABEL INFORMATION:
EAU26381
Key identification number
The key identification number is
stamped into the key tag. Record this
number in the space provided and use
it for reference when ordering a new
key.
EAU26400
Vehicle identification number
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro-
vided.
NOTE:

The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcy-
cle with the licensing authority in your
area.
1. Key identification number
2. Code re-registering key (red bow)
3. Standard keys (black bow)
1. Vehicle identification number
1