2009 YAMAHA TDM 900 engine coolant

TABLE OF CONTENTS
SAFETY INFORMATION
...................1-1
DESCRIPTION
...................................2-1
Left view ...........................................2-1
Right view .........................................2-3
Controls and instruments..................2-5
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 .............3-7
Multi-function display .......................3-7
Anti-theft alarm (optional) ................3-9
Handlebar switches .........................3-9
Clutch lever ....................................3-10
Shift pedal ......................................3-11
Brake lever ....................................3-11
Brake pedal ...................................3-12
ABS (for ABS models) ...................3-12
Fuel tank cap .................................3-13
Fuel ................................................3-14
Fuel tank breather hose .................3-15
Catalytic converters .......................3-15
Seat ...............................................3-16
Storage compartment ....................3-17
Adjusting the front fork ...................3-17
Adjusting the shock absorber
assembly ....................................3-19Luggage strap holders .................. 3-20
Sidestand ...................................... 3-21
Ignition circuit cut-off system ......... 3-21
FOR YOUR SAFETY –
PRE-OPERATION CHECKS
.............. 4-1
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
ADJUSTMENT
.................................... 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 ...... 6-12
Adjusting the engine idling
speed ......................................... 6-14
Checking the throttle cable free
play ............................................ 6-15
Valve clearance ............................. 6-15Tires .............................................. 6-15
Cast wheels .................................. 6-18
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 ........................... 6-22
Cleaning and lubricating the
drive chain ................................. 6-23
Checking and lubricating the
cables ........................................ 6-24
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 .............. 6-25
Checking and lubricating the
sidestand ................................... 6-25
Lubricating the rear suspension .... 6-25
Checking the front fork .................. 6-26
Checking the steering ................... 6-26
Checking the wheel bearings ........ 6-27
Battery ........................................... 6-27
Replacing the fuses ...................... 6-28
Replacing a headlight bulb ........... 6-30

DESCRIPTION
2-2
2
3
4
5
6
7
8
9 TDM900A
12
3456
7 8 9 10 11 1212
3456

1. Front fork spring preload adjusting bolt (page 3-17)
2. Front fork damping adjusting screw (page 3-17)
3. Air filter element (page 6-12)
4. Coolant reservoir (page 6-11)
5. Battery (page 6-27)
6. Fuses (page 6-28)
7. Luggage strap holder (page 3-20)
8. Seat lock (page 3-16)9. Shock absorber assembly rebound damping force adjusting knob
(page 3-19)
10. Shock absorber assembly spring preload adjusting ring (page 3-19)
11. Shift pedal (page 3-11)
12. Engine oil drain bolt A (page 6-8)

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

EAU32230
Right view
TDM900
1234
5
6 7 8 9 10

1. Owner’s tool kit (page 6-1)
2. Coolant reservoir (page 6-11)
3. Idle adjusting screw (page 6-14)
4. Front brake fluid reservoir (page 6-20)
5. Radiator cap (page 6-11)
6. Engine oil filler cap (page 6-8)
7. Engine oil filter element (page 6-8)8. Engine oil drain bolt B (page 6-8)
9. Brake pedal (page 3-12)
10. Rear brake fluid reservoir (page 6-20)

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

EAU12182
Coolant temperature gauge
With the key in the “ON” position, the
coolant temperature gauge indicates
the temperature of the coolant. When
the key is turned to “ON”, the coolant
temperature gauge needle will sweep
once across the temperature range and
then return to “C” in order to test the
electrical circuit. The coolant tempera-
ture varies with changes in the weather
and engine load. If the needle reaches
or enters the red zone, stop the vehicle
and let the engine cool. (See
page 6-34.)
NOTICE

ECA10021
Do not continue to operate the en-
gine if it is overheating.
EAU36612
Multi-function display
WARNING

EWA12312
Be sure to stop the vehicle before
making any setting changes to the
multi-function display. Changing
settings while riding can distract the
operator and increase the risk of an
accident.
The multi-function display is equipped
with the following:
●
a digital speedometer (which
1. Coolant temperature gauge
2. Coolant temperature gauge red zone
12

1. Speedometer
2. Odometer/tripmeter
3. “SELECT” button
4. “RESET” button
5. Fuel gauge
1
2
3
4
5

4-1
2
3
45
6
7
8
9

FOR YOUR SAFETY – PRE-OPERATION CHECKS
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING

EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel
●
Check fuel level in fuel tank.
●
Refuel if necessary.
●
Check fuel line for leakage.3-14
Engine oil
●
Check oil level in engine.
●
If necessary, add recommended oil to specified level.
●
Check vehicle for oil leakage.6-8
Coolant
●
Check coolant level in reservoir.
●
If necessary, add recommended coolant to specified level.
●
Check cooling system for leakage.6-11
Front brake
●
Check operation.
●
If soft or spongy, have Yamaha dealer bleed hydraulic system.
●
Check brake pads for wear.
●
Replace if necessary.
●
Check fluid level in reservoir.
●
If necessary, add recommended brake fluid to specified level.
●
Check hydraulic system for leakage.6-19, 6-20

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

19

Shift pedal pivot
shaft
●
Lubricate with lithium-soap-based
grease.

√√√√√
20

Sidestand
●
Check operation.
●
Lubricate.
√√√√√
21

*
Sidestand switch
●
Check operation.
√√√√√√
22

*
Front fork
●
Check operation and for oil
leakage.
√√√√
23

*
Shock absorber
assembly
●
Check operation and shock
absorber for oil leakage.
√√√√
24

*
Rear suspension
relay arm and
connecting arm
pivoting points
●
Check operation.
√√√√
●
Lubricate with lithium-soap-based
grease.

√√
25

*
Fuel injection
●
Adjust engine idling speed and
synchronization.
√√√√√√
26

Engine oil
●
Change.
●
Check oil level and vehicle for oil
leakage.
√√√√√√
27

Engine oil filter
element
●
Replace.
√√√
28

*
Cooling system
●
Check coolant level and vehicle
for coolant leakage.
√√√√√
●
Change. Every 3 years
29

*
Front and rear brake
switches
●
Check operation.
√√√√√√
30

Moving parts and
cables
●
Lubricate.
√√√√√
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 ADJUSTMENT
6-11
1
2
3
4
5
6
7
8
9
10. 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.
11. Turn the engine off, and then
check 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.
EAU38583
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
TIP

●
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.
TIP

The coolant should be between the
minimum and maximum level marks.
For TDM900
For TDM900A
3. If the coolant is at or below the
1. “CD” specification
2. “ENERGY CONSERVING II”
1
2

1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
1. Maximum level mark
2. Coolant reservoir
3. Minimum level mark
1 2
33 1
2

PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
2
3
4
5
67
8
9
minimum level mark, remove pan-
el B for TDM900 or panel A for
TDM900A (See page 6-6.), re-
move the reservoir cap, add cool-
ant to the maximum level mark,
and then install the reservoir cap
and the panel.
WARNING! Re-
move only the coolant reservoir
cap. Never attempt to remove
the radiator cap when the en-
gine is hot.

[EWA15161]

NOTICE:
If
coolant is not available, use dis-
tilled water or soft tap water in-
stead. Do not use hard water or
salt water since it is harmful to
the engine. If water has been
used instead of coolant, replace
it with coolant as soon as possi-
ble, otherwise the cooling sys-
tem will not be protected
against frost and corrosion. If
water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be re-
duced.
[ECA10472]

For TDM900
For TDM900A
EAU27054
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 3-16.)
2. Remove cowlings A and B as well
as panels A and B. (See
page 6-6.)
3. Remove the fuel tank bolts.
TIP

For TDM900, skip steps 4 and 12.
1. Coolant reservoir cap
1. Coolant reservoir cap
Coolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt, 0.22 Imp.qt)
1
1

1. Bolt
1