2008 YAMAHA TDM 900 brake fluid

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 .............3-4
Tachometer unit ...............................3-6
Coolant temperature gauge .............3-6
Multi-function display .......................3-7
Anti-theft alarm (optional) ................3-8
Handlebar switches .........................3-9
Clutch lever ....................................3-10
Shift pedal ......................................3-10
Brake lever ....................................3-11
Brake pedal ...................................3-11
ABS ...............................................3-12
Fuel tank cap .................................3-12
Fuel ................................................3-13
Fuel tank breather hose .................3-14
Catalytic converters .......................3-14
Seat ...............................................3-14
Storage compartment ....................3-15
Adjusting the front fork ...................3-16
Adjusting the shock absorber
assembly ....................................3-17Luggage strap holders .................. 3-19
Sidestand ...................................... 3-19
Ignition circuit cut-off system ......... 3-20
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 .......................................... 6-6
Checking the spark plugs ................ 6-7
Engine oil and oil filter element ....... 6-8
Coolant .......................................... 6-11
Replacing the air filter element ...... 6-13
Adjusting the engine idling
speed ......................................... 6-15
Checking the throttle cable free
play ............................................ 6-15Valve clearance ............................ 6-16
Tires .............................................. 6-16
Cast wheels .................................. 6-19
Adjusting the clutch lever free
play ............................................ 6-19
Adjusting the rear brake light
switch ......................................... 6-20
Checking the front and rear brake
pads ........................................... 6-20
Checking the brake fluid level ....... 6-21
Changing the brake fluid ............... 6-22
Drive chain slack ........................... 6-22
Cleaning and lubricating the drive
chain .......................................... 6-24
Checking and lubricating the
cables ........................................ 6-25
Checking and lubricating the throttle
grip and cable ............................ 6-25
Checking and lubricating the brake
and shift pedals ......................... 6-25
Checking and lubricating the brake
and clutch levers ........................ 6-26
Checking and lubricating the
sidestand ................................... 6-26
Lubricating the rear suspension .... 6-26
Checking the front fork .................. 6-27
Checking the steering ................... 6-27
Checking the wheel bearings ........ 6-28
Battery ........................................... 6-28
Replacing the fuses ...................... 6-30
Replacing a headlight bulb ........... 6-31

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

EAU18680
NOTE:


Air filter

This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed air to avoid damaging it.

The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.

Replace the brake hoses every four years and if cracked or damaged.
31

*
Throttle grip hous-
ing and cable

Check operation and free play.

Adjust the throttle cable free
play if necessary.

Lubricate the throttle grip
housing and cable.
√√√√√
32

*
Air induction system

Check the air cut-off valve,
reed valve, and hose for dam-
age.

Replace the entire air induction
system if necessary.
√√√√√
33

*
Muffler and exhaust
pipe

Check the screw clamp for
looseness.
√√√√√
34

*
Lights, signals and
switches

Check operation.

Adjust headlight beam.
√√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
2
3
4
5
67
8
9

EAU42350
Replacing the air filter element
The air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the seat. (See
page 3-14.)
2. Remove cowlings A and B as well
as panels A and B. (See
page 6-6.)
3. Remove the fuel tank bolts.
4. Remove the rear brake fluid reser-
voir holder by removing the bolt,
and then lift the fuel tank awayfrom the air filter case. (Do not dis-
connect the fuel hoses!)
WARNING

EWA10410

Make sure that the fuel tank is
well supported.

Do not tilt or pull the fuel tank
too much, otherwise the fuel
hoses may come loose, which
could cause fuel leakage.
5. Remove the air filter case cover by
removing the screws.6. Pull the air filter element out.
7. Insert a new air filter element into
the air filter case.
1. Bolt
1

1. Rear brake fluid reservoir holder
2. Rear brake fluid reservoir
3. Bolt
12
3

1. Air filter case cover
2. Screw
1. Air filter element
1 2
2 21

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
1
2
3
4
5
6
7
8
9
CAUTION:

ECA10480

Make sure that the air filter ele-
ment is properly seated in the
air filter case.

The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
8. Install the air filter case cover by in-
stalling the screws.
9. Place the fuel tank in the original
position and install the bolts.
WARNING

EWA11330

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 and the fuel tankoverflow hose in the original po-
sition.
10. Install the rear brake fluid reservoir
holder by installing the bolt.11. Install the panels and cowlings.
12. Install the seat.
1. Fuel tank breather/overflow hose
2. Fuel hose
1. Original position (paint mark)
12
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
2
3
4
5
67
8
9
indicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.

EAU22500
Rear brake pads
Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 0.8 mm (0.03 in),
have a Yamaha dealer replace the
brake pads as a set.
EAU36680
Checking the brake fluid level
Front brake
Rear brake
Insufficient brake fluid may allow air toenter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
NOTE:

The rear brake fluid reservoir is located
under the seat. (See page 3-14.)
Observe these precautions:

When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.

Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.

Refill with the same type of brake
fluid. Mixing fluids may result in a
1. Lining thickness
1

1. Minimum level mark
1. Minimum level mark
1
1

Recommended brake fluid:
DOT 4

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
1
2
3
4
5
6
7
8
9
harmful chemical reaction and
lead to poor braking performance.


Be careful that water or dust does
not enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of the
fluid and may result in vapor lock,
and dirt may clog the ABS hydrau-
lic unit valves.

Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.

As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22730
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

Oil seals: Replace every two
years.

Brake hoses: Replace every four
years.
EAU22760
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22773
To check the drive chain slack
1. Place the motorcycle on the side-
stand.
NOTE:

When checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.
Drive chain slack:
50.0–60.0 mm (1.97–2.36 in)

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

Secondary reduction ratio:
42/16 (2.625)
Transmission type:
Constant mesh 6-speed
Operation:
Left foot operation
Gear ratio:
1st:
33/12 (2.750)
2nd:
37/19 (1.947)
3rd:
34/22 (1.545)
4th:
31/25 (1.240)
5th:
26/25 (1.040)
6th:
24/26 (0.923)
Chassis:
Frame type:
Diamond
Caster angle:
25.50 °
Trail:
114.0 mm (4.49 in)
Front tire:
Type:
Tubeless
Size:
120/70 ZR18M/C (59W)
Manufacturer/model:
DUNLOP/D220FSTJ
Rear tire:
Type:
Tubeless
Size:
160/60 ZR17M/C (69W)
Manufacturer/model:
DUNLOP/D220STJ
Loading:
Maximum load:
198 kg (437 lb)
* (Total weight of rider, passenger, cargo
and accessories)
Tire air pressure (measured on cold
tires):
Loading condition:
0–90 kg (0–198 lb)
Front:
225 kPa (33 psi) (2.25 kgf/cm
2

)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2

)
Loading condition:
90–198 kg (198–437 lb)
Front:
225 kPa (33 psi) (2.25 kgf/cm
2

)
Rear:
290 kPa (42 psi) (2.90 kgf/cm
2

)
High-speed riding:
Front:
225 kPa (33 psi) (2.25 kgf/cm
2

)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2

)
Front wheel:
Wheel type:
Cast wheel
Rim size:
18M/C x MT3.50
Rear wheel:
Wheel type:
Cast wheel
Rim size:
17M/C x MT5.00
Front brake:
Type:
Dual disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:
Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
150.0 mm (5.91 in)

INDEX
A
ABS ......................................................... 3-12
ABS warning light...................................... 3-4
Air filter element, replacing ..................... 6-13
Anti-theft alarm (optional).......................... 3-8
Auxiliary light bulb, replacing .................. 6-33
B
Battery..................................................... 6-28
Brake and clutch levers, checking and
lubricating ............................................. 6-26
Brake and shift pedals, checking and
lubricating ............................................. 6-25
Brake fluid, changing .............................. 6-22
Brake fluid level, checking ...................... 6-21
Brake lever .............................................. 3-11
Brake pedal ............................................. 3-11
C
Cables, checking and lubricating ............ 6-25
Care .......................................................... 7-1
Catalytic converters ................................ 3-14
Clutch lever ............................................. 3-10
Clutch lever free play, adjusting .............. 6-19
Coolant.................................................... 6-11
Coolant temperature gauge ...................... 3-6
Cowlings and panels, removing and
installing.................................................. 6-6
D
Dimmer switch .......................................... 3-9
Drive chain, cleaning and lubricating ...... 6-24
Drive chain slack ..................................... 6-22
E
Engine break-in ......................................... 5-3
Engine idling speed................................. 6-15
Engine oil and oil filter element ................. 6-8Engine stop switch .....................................3-9
Engine trouble warning light ......................3-4
F
Front and rear brake pads, checking .......6-20
Front fork, adjusting .................................3-16
Front fork, checking .................................6-27
Fuel ..........................................................3-13
Fuel consumption, tips for reducing ...........5-3
Fuel level warning indicator .......................3-4
Fuel tank breather hose ...........................3-14
Fuel tank cap ...........................................3-12
Fuses, replacing ......................................6-30
H
Handlebar switches ...................................3-9
Hazard switch ..........................................3-10
Headlight bulb, replacing .........................6-31
High beam indicator light ...........................3-4
Horn switch ................................................3-9
I
Identification numbers................................9-1
Ignition circuit cut-off system ...................3-20
Immobilizer system ....................................3-1
Immobilizer system indicator light ..............3-5
Indicator and warning lights .......................3-4
K
Key identification number ..........................9-1
L
Luggage strap holders .............................3-19
M
Main switch/steering lock ...........................3-2
Matte color, caution ...................................7-1
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............ 6-20
Rear suspension, lubricating ................... 6-26
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 ........ 6-26
Spark plugs, checking ............................... 6-7
Specifications ............................................ 8-1
Starting the engine .................................... 5-1
Start switch ................................................ 3-9
Steering, checking ................................... 6-27
Storage ...................................................... 7-3
Storage compartment .............................. 3-15
Supporting the motorcycle....................... 6-33
T
Tachometer unit ........................................ 3-6
Tail/brake light bulb, replacing................. 6-32
Throttle cable free play, checking............ 6-15