2009 YAMAHA TDM 900 coolant level

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

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

PERIODIC MAINTENANCE AND ADJUSTMENT
6-35
1
2
3
4
5
6
7
8
9Engine overheating
WARNING

EWA10400
●
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
●
After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing
sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
TIP

If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible.
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See TIP.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.

8-1
2
3
4
5
6
7
89

SPECIFICATIONS
EAU2633P
Dimensions:
Overall length:
2180 mm (85.8 in)
Overall width:
800 mm (31.5 in)
Overall height:
1290 mm (50.8 in)
Seat height:
825 mm (32.5 in)
Wheelbase:
1485 mm (58.5 in)
Ground clearance:
160 mm (6.30 in)
Minimum turning radius:
2900 mm (114.2 in)
Weight:
With oil and fuel:
TDM900 223.0 kg (492 lb)
TDM900A 226.0 kg (498 lb)
Engine:
Engine type:
Liquid cooled 4-stroke, DOHC
Cylinder arrangement:
Forward-inclined parallel 2-cylinder
Displacement:
897.0 cm
3

Bore
×
stroke:
92.0
×
67.5 mm (3.62
×
2.66 in)
Compression ratio:
10.40 :1Starting system:
Electric starter
Lubrication system:
Dry sump

Engine oil:
Type:
SAE 10W-30, SAE 10W-40, SAE 15W-40,
SAE 20W-40 or SAE 20W-50
Recommended engine oil grade:
API service SG type or higher, JASO stan-
dard MA
Engine oil quantity:
Without oil filter element replacement:
3.80 L (4.02 US qt, 3.34 Imp.qt)
With oil filter element replacement:
3.90 L (4.12 US qt, 3.43 Imp.qt)
Cooling system:
Coolant reservoir capacity (up to the maxi-
mum level mark):
0.25 L (0.26 US qt, 0.22 Imp.qt)
Radiator capacity (including all routes):
1.75 L (1.85 US qt, 1.54 Imp.qt)
Air filter:
Air filter element:
Oil-coated paper element
Fuel:
Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
20.0 L (5.28 US gal, 4.40 Imp.gal)
Fuel reserve amount:
3.5 L (0.92 US gal, 0.77 Imp.gal)
Fuel injection:
Throttle body:
Type/quantity:
38EIS/2
Spark plug (s):
Manufacturer/model:
NGK/DPR8EA-9
Manufacturer/model:
DENSO/X24EPR-U9
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
Clutch:
Clutch type:
Wet, multiple-disc
Transmission:
Primary reduction system:
Spur gear
Primary reduction ratio:
67/39 (1.718)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
42/16 (2.625)
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40SAE 10W-50

INDEX
A
ABS (for ABS models) ............................ 3-12
ABS warning light (for ABS models) ......... 3-5
Air filter element, replacing ..................... 6-12
Anti-theft alarm (optional).......................... 3-9
Auxiliary light bulb, replacing .................. 6-32
B
Battery..................................................... 6-27
Brake and clutch levers, checking and
lubricating ............................................. 6-25
Brake and shift pedals, checking and
lubricating ............................................. 6-24
Brake fluid, changing .............................. 6-21
Brake fluid level, checking ...................... 6-20
Brake lever .............................................. 3-11
Brake pedal ............................................. 3-12
C
Cables, checking and lubricating ............ 6-24
Care .......................................................... 7-1
Catalytic converters ................................ 3-15
Clutch lever ............................................. 3-10
Clutch lever free play, adjusting .............. 6-18
Coolant.................................................... 6-11
Coolant temperature gauge ...................... 3-7
Cowlings and panels, removing and
installing.................................................. 6-6
D
Dimmer switch .......................................... 3-9
Drive chain, cleaning and lubricating ...... 6-23
Drive chain slack ..................................... 6-22
E
Engine break-in ......................................... 5-3
Engine idling speed................................. 6-14
Engine oil and oil filter element ................. 6-8
Engine stop switch .................................. 3-10Engine trouble warning light ...................... 3-5
F
Front and rear brake pads, checking ....... 6-19
Front fork, adjusting ................................. 3-17
Front fork, checking ................................. 6-26
Fuel.......................................................... 3-14
Fuel consumption, tips for reducing........... 5-3
Fuel level warning indicator ....................... 3-5
Fuel tank breather hose........................... 3-15
Fuel tank cap ........................................... 3-13
Fuses, replacing ...................................... 6-28
H
Handlebar switches ................................... 3-9
Hazard switch .......................................... 3-10
Headlight bulb, replacing ......................... 6-30
High beam indicator light ........................... 3-4
Horn switch .............................................. 3-10
I
Identification numbers ............................... 9-1
Ignition circuit cut-off system ................... 3-21
Immobilizer system .................................... 3-1
Immobilizer system indicator light.............. 3-5
Indicator and warning lights ....................... 3-4
K
Key identification number .......................... 9-1
L
Luggage strap holders ............................. 3-20
M
Main switch/steering lock........................... 3-2
Matte color, caution ................................... 7-1
Model label ................................................ 9-2
Multi-function display ................................. 3-7
N
Neutral indicator light ................................. 3-4
O
Oil level warning light ................................ 3-4
P
Parking ...................................................... 5-4
Part locations ............................................ 2-1
Pass switch ............................................... 3-9
Periodic maintenance and lubrication
chart ........................................................ 6-2
R
Rear brake light switch, adjusting ........... 6-19
Rear suspension, lubricating ................... 6-25
S
Safety information ..................................... 1-1
Seat ......................................................... 3-16
Shifting ...................................................... 5-2
Shift pedal ............................................... 3-11
Shock absorber assembly, adjusting ...... 3-19
Sidestand ................................................ 3-21
Sidestand, checking and lubricating........ 6-25
Spark plugs, checking ............................... 6-7
Specifications ............................................ 8-1
Starting the engine .................................... 5-1
Start switch .............................................. 3-10
Steering, checking................................... 6-26
Storage...................................................... 7-3
Storage compartment.............................. 3-17
Supporting the motorcycle ...................... 6-32
T
Tachometer unit ........................................ 3-6
Tail/brake light bulb, replacing ................ 6-31
Throttle cable free play, checking ........... 6-15
Throttle grip and cable, checking and
lubricating.............................................. 6-24
Tires ........................................................ 6-15
Tool kit....................................................... 6-1