2009 YAMAHA TDM 900 Owners Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
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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.
EAU38640
Checking the brake fluid level
Front brake
Rear brake (for TDM900)Rear brake (for TDM900A)
Insufficient brake fluid may allow air to
enter 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.
TIP

For TDM900A, the rear brake fluid res-
ervoir is located under the seat. (See
page 3-16.)
1. Lining thickness
1

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

1. Minimum level mark
1

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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
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.
EAU22731
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenance
and lubrication chart. In addition, have
the oil seals of the master cylinders and
calipers as well as the brake hoses re-
placed at the intervals listed below or
whenever they are damaged or leak-
ing.
●
Oil seals: Replace every two
years.
●
Brake hoses: Replace every four
years.
Recommended brake fluid:
DOT 4

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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.
TIP

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.4. If the drive chain slack is incorrect,
adjust it as follows.
EAU22952
To adjust the drive chain slack
1. Loosen the axle nut, the brake cal-
iper bracket bolt and the locknut on
each side of the swingarm.
2. To tighten the drive chain, turn the
drive chain slack adjusting bolt on
Drive chain slack:
50.0–60.0 mm (1.97–2.36 in)
1. Drive chain slack
1

1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
1. Brake caliper bracket bolt
2. Brake caliper bracket
3
4 1
2 (b)
(a)
1
2

PERIODIC MAINTENANCE AND ADJUSTMENT
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each side of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting bolt on each side
of the swingarm in direction (b),
and then push the rear wheel for-
ward.
NOTICE:
Improper drive
chain slack will overload the en-
gine as well as other vital parts
of the motorcycle and can lead
to chain slippage or breakage.
To prevent this from occurring,
keep the drive chain slack with-
in the specified limits.

[ECA10571]

TIP

Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same posi-
tion for proper wheel alignment.
3. Tighten the locknuts, and then
tighten the axle nut and the brake
caliper bracket bolt to the specified
torques.
EAU23023
Cleaning and lubricating the
drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
NOTICE

ECA10581
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.
1.Clean the drive chain with kero-
sene and a small soft brush.
NOTICE:
To prevent damaging
the O-rings, do not clean the
drive chain with steam cleaners,
high-pressure washers or inap-
propriate solvents.

[ECA11121]

2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
NOTICE:
Do not use
engine oil or any other lubri-
cants for the drive chain, as theymay contain substances that
could damage the O-rings.
[ECA11111]

Tightening torque:
Axle nut:
150 Nm (15.0 m·kgf, 108.5 ft·lbf)
Brake caliper bracket bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)

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EAU23101
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING! Damage to the outer
sheath may interfere with proper ca-
ble operation and will cause the in-
ner cable to rust. Replace a
damaged cable as soon as possible
to prevent unsafe conditions.
[EWA10721]

EAU23111
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
EAU44271
Checking and lubricating the
brake and shift pedals
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
Recommended lubricant:
Engine oil
Recommended lubricant:
Lithium-soap-based grease

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EAU23142
Checking and lubricating the
brake and clutch levers
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
EAU23202
Checking and lubricating the
sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
WARNING

EWA10731
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. Otherwise,
the sidestand could contact the
ground and distract the operator, re-
sulting in a possible loss of control.
EAU23250
Lubricating the rear
suspension
The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease

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EAU23272
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.

[EWA10751]

2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
NOTICE

ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23283
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. (See page 6-32 for more
information.)
WARNING! To
avoid injury, securely support
the vehicle so there is no danger
of it falling over.
[EWA10751]

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.

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EAU23290
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
EAU23374
Battery
This model is equipped with a VRLA
(Valve Regulated Lead Acid) battery.
There is no need to check the electro-
lyte or to add distilled water. However,
the battery lead connections need to be
checked and, if necessary, tightened.
NOTICE

ECA10620
Never attempt to remove the battery
cell seals, as this would permanent-
ly damage the battery.
WARNING

EWA10760
●
Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
●
EXTERNAL: Flush with plenty
of water.
●
INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
●
EYES: Flush with water for 15
minutes and seek prompt
medical attention.
●
Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.
●
KEEP THIS AND ALL BAT-
TERIES OUT OF THE REACH
OF CHILDREN.
1. Battery
2. Positive battery lead (red)
3. Negative battery lead
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