2009 YAMAHA TDM 900 maintenance

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

INSTRUMENT AND CONTROL FUNCTIONS
3-15
2
34
5
6
7
8
9
or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.

EAU13412
Fuel tank breather hose
Before operating the motorcycle:
●
Check the fuel tank breather hose
connection.
●
Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.
●
Make sure that the fuel tank
breather hose is not blocked, and
clean it if necessary.
EAU13445
Catalytic converters
This vehicle is equipped with catalytic
converters in the exhaust system.
WARNING

EWA10862
The exhaust system is hot after op-
eration. To prevent a fire hazard or
burns:
●
Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
●
Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.
●
Make sure that the exhaust sys-
tem has cooled down before do-
ing any maintenance work.
●
Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
NOTICE

ECA10701
Use only unleaded gasoline. The use
of leaded gasoline will cause unre-
1. Fuel tank breather hose
1

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

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

PERIODIC MAINTENANCE AND ADJUSTMENT
EAU17241
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, depending on the
weather, terrain, geographical location,
and individual use, the maintenance in-
tervals may need to be shortened.
WARNING

EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance
activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle
service, have a Yamaha dealer per-
form service.
WARNING

EWA15121
Turn off the engine when performing
maintenance unless otherwise
specified.
●
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
●
Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more in-
formation about carbon monox-
ide.
EAU17521
Owner’s tool kit
The owner’s tool kit is located inside the
storage compartment under the seat.
(See page 3-16.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
TIP

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
1. Owner’s tool kit
1

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

EAU1770A
Periodic maintenance and lubrication chart
TIP

●
The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.
●
From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
●
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
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
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 (24000 mi)
4
Air filter element
●
Replace.
√
5
Clutch
●
Check operation.
●
Adjust.
√√√√√
6*
Front brake
●
Check operation, fluid level and
vehicle for fluid leakage.
√√√√√√
●
Replace brake pads. Whenever worn to the limit
7*
Rear brake
●
Check operation, fluid level and
vehicle for fluid leakage.
√√√√√√
●
Replace brake pads. Whenever worn to the limit
8*
Brake hoses
●
Check for cracks or damage.
√√√√√
●
Replace. Every 4 years

PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
1
2
3
4
5
6
7
8
9

9*
Wheels
●
Check runout and for damage.
√√√√
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 (30000 mi)

13

Drive chain
●
Check chain slack, alignment and
condition.
●
Adjust and lubricate chain with a
special O-ring chain lubricant
thoroughly.Every 1000 km (600 mi) 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 (12000 mi)

15

*
Chassis fasteners
●
Make sure that all nuts, bolts and
screws are properly tightened.
√√√√√
16

Brake lever pivot
shaft
●
Lubricate with silicone grease.
√√√√√
17

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

√√√√√
18

Clutch lever pivot
shaft
●
Lubricate with lithium-soap-based
grease.

√√√√√
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
6-4
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
6-5
1
2
3
4
5
6
7
8
9

EAU18680
TIP

●
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 housing
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 damage.
●
Replace the entire air induction
system if necessary.
√√√√√
33

*

Muffler and exhaust
pipe
●
Check the screw clamp(s) 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)