2009 YAMAHA TDM 900 check oil

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

EAU47040
Indicator and warning lights
For TDM900For TDM900A
EAU38572
Turn signal indicator lights “ ” and
“” (For TDM900)/Turn signal indi-
cator light “ ” (For TDM900A)
●
For TDM900: The corresponding
indicator light flashes when the
turn signal switch is pushed to theleft or right.
●
For TDM900A: This indicator light
flashes when the turn signal switch
is pushed to the left or right.
EAU11060
Neutral indicator light “ ”
This indicator light comes on when the
transmission is in the neutral position.
EAU11080
High beam indicator light “ ”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU38601
Oil level warning light
This warning light comes on if the en-
gine oil level is low.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
TIP

Even if the oil level is sufficient, the
1. Fuel level warning indicator “ ”
2. Left turn signal indicator light “ ”
3. High beam indicator light “ ”
4. Neutral indicator light “ ”
5. Engine trouble warning light “ ”
6. Right turn signal indicator light “ ”
7. Oil level warning light
8. Immobilizer system indicator light
12345678

1. Fuel level warning indicator “ ”
2. Turn signal indicator light “ ”
3. High beam indicator light “ ”
4. Neutral indicator light “ ”
5. Engine trouble warning light “ ”
6. Anti-lock Brake System (ABS) warning
light “ ”
7. Oil level warning light
8. Immobilizer system indicator light
1234567
8
ABS

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

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

OPERATION AND IMPORTANT RIDING POINTS
EAU15951
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING

EWA10271
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
EAU45310
TIP

This model is equipped with a lean an-
gle sensor to stop the engine in case of
a turnover. To start the engine after a
turnover, be sure to turn the main
switch to “OFF” and then to “ON”. Fail-
ing to do so will prevent the engine from
starting even though the engine will
crank when pushing the start switch.
EAU39893
Starting the engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
●
The transmission is in the neutral
position.
●
The transmission is in gear with
the clutch lever pulled and the sid-
estand up.
See page 3-21 for more information.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
The following warning lights and
indicator light should come on for a
few seconds, then go off.
●
Oil level warning light
●
Engine trouble warning light
●
Immobilizer system indicator light
●
ABS warning light
NOTICE

ECA11831
If a warning or indicator light does
not go off, see page 3-4 for the corre-
sponding warning and indicator
light circuit check.
2. Shift the transmission into the neu-

OPERATION AND IMPORTANT RIDING POINTS
5-3
1
2
3
4
5
6
7
8
9

EAU16810
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
●
Shift up swiftly, and avoid high en-
gine speeds during acceleration.
●
Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.
●
Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16841
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17101
0–1000 km (0–600 mi)
Avoid prolonged operation above
4000 r/min.
NOTICE:
After 1000
km (600 mi) of operation, the en-
gine oil must be changed, and
the oil filter element re-
placed.

[ECA11151]

1000–1600 km (600–1000 mi)
Avoid prolonged operation above 6000
r/min.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
NOTICE

ECA10310
●
Keep the engine speed out of
the tachometer red zone.
●
If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-
cle.

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)

PERIODIC MAINTENANCE AND ADJUSTMENT
6-8
2
3
4
5
67
8
9
Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
TIP

If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
EAU19835
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart. A slight tilt to the side can
result in a false reading.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. Start the engine, warm it up for 15
minutes, and then turn it off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in and with the arrow
mark pointing upward as shown),
and then remove it again to check
the oil level.
WARNING! Never re-
move the engine oil tank cap af-
ter high-speed operation,
otherwise hot engine oil could

Specified spark plug:
NGK/DPR8EA-9
DENSO/X24EPR-U9
1. Spark plug gap
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
1

Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.7 ft·lbf)