2009 YAMAHA TDM 900 air condition

SAFETY INFORMATION
1-2
1
ed by road and traffic conditions.
●
Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
●
The posture of the operator and
passenger is important for proper
control.
●
The operator should keep both
hands on the handlebar and
both feet on the operator foot-
rests during operation to main-
tain control of the motorcycle.
●
The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.
●
Never ride under the influence of
alcohol or other drugs.
●
This motorcycle is designed for
on-road use only. It is not suitable
for off-road use.
Protective apparel
The majority of fatalities from motorcy-cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the preven-
tion or reduction of head injuries.
●
Always wear an approved helmet.
●
Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
●
The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.
●
Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
●
Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys-
tem become very hot during or af-
ter operation and can cause burns.
●
A passenger should also observe
the above precautions.
Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbonmonoxide, a deadly gas. Breathing car-
bon monoxide can cause headaches,
dizziness, drowsiness, nausea, confu-
sion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be
present even if you do not see or smell
any engine exhaust. Deadly levels of
carbon monoxide can collect rapidly
and you can quickly be overcome and
unable to save yourself. Also, deadly
levels of carbon monoxide can linger
for hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poison-
ing, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
●
Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
●
Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
●
Do not run engine outdoors where

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
1
2
3
4
5
6
7
8
9

Rear 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
Clutch
●
Check operation.
●
Lubricate cable if necessary.
●
Check lever free play.
●
Adjust if necessary.6-18
Throttle grip
●
Make sure that operation is smooth.
●
Check cable free play.
●
If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-15, 6-24
Control cables
●
Make sure that operation is smooth.
●
Lubricate if necessary.6-24
Drive chain
●
Check chain slack.
●
Adjust if necessary.
●
Check chain condition.
●
Lubricate if necessary.6-22, 6-23
Wheels and tires
●
Check for damage.
●
Check tire condition and tread depth.
●
Check air pressure.
●
Correct if necessary.6-15, 6-18
Brake and shift pedals
●
Make sure that operation is smooth.
●
Lubricate pedal pivoting points if necessary.6-24
Brake and clutch levers
●
Make sure that operation is smooth.
●
Lubricate lever pivoting points if necessary.6-25
Sidestand
●
Make sure that operation is smooth.
●
Lubricate pivot if necessary.6-25
ITEM CHECKS PAGE

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
6-17
1
2
3
4
5
6
7
8
9Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
WARNING

EWA10901
●
The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motorcy-
cle may be different, which
could lead to an accident.
●
Always make sure that the valve
caps are securely installed to
prevent air pressure leakage.
●
Use only the tire valves andvalve cores listed below to
avoid tire deflation during a ride.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
WARNING

EWA10600
This motorcycle is fitted with su-per-high-speed tires. Note the fol-
lowing points in order to make the
most efficient use of these tires.
●
Use only the specified replace-
ment tires. Other tires may run
the danger of bursting at super
high speeds.
●
Brand-new tires can have a rela-
tively poor grip on certain road
surfaces until they have been
“broken in”. Therefore, it is ad-
visable before doing any
high-speed riding to ride con-
servatively for approximately
100 km (60 mi) after installing a
new tire.
●
The tires must be warmed up
before a high-speed run.
●
Always adjust the tire air pres-
sure according to the operating
conditions.
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
123

Front tire:
Size:
120/70 ZR18M/C (59W)
Manufacturer/model:
TDM900 METZELER/MEZ4
FRONT
TDM900A DUNLOP/D220FSTJ
TDM900 DUNLOP/D220FSTJ
Tire air valve:
TR412
Valve core:
#9100 (original)
Rear tire:
Size:
160/60 ZR17M/C (69W)
Manufacturer/model:
TDM900 METZELER/MEZ4
TDM900A DUNLOP/D220STJ
TDM900 DUNLOP/D220STJ
Tire air valve:
TR412
Valve core:
#9100 (original)

PERIODIC MAINTENANCE AND ADJUSTMENT
6-26
2
3
4
5
67
8
9

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.

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

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:
TDM900 METZELER/MEZ4 FRONT
TDM900A DUNLOP/D220FSTJ
Manufacturer/model:
TDM900 DUNLOP/D220FSTJ
Rear tire:
Type:
Tubeless
Size:
160/60 ZR17M/C (69W)
Manufacturer/model:
TDM900 METZELER/MEZ4
TDM900A DUNLOP/D220STJ
Manufacturer/model:
TDM900 DUNLOP/D220STJ
Loading:
Maximum load:
TDM900 201 kg (443 lb)
TDM900A 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 (2.25 kgf/cm2, 33 psi)
Rear:
250 kPa (2.50 kgf/cm2, 36 psi)
Loading condition:
TDM900 90–201 kg (198–443 lb)
TDM900A 90–198 kg (198–437 lb)
Front:
225 kPa (2.25 kgf/cm
2

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

, 42 psi)
High-speed riding:
Front:
225 kPa (2.25 kgf/cm 2
, 33 psi)Rear:
250 kPa (2.50 kgf/cm
2

, 36 psi)
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