2009 YAMAHA TDM 900 fuel filter

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

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
6-12
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
6-13
1
2
3
4
5
6
7
8
9
4. Remove the rear brake fluid reser-
voir holder by removing the bolt.
For TDM900A
5. Lift the fuel tank away from the air
filter case, but do not disconnect
the fuel hoses.
6. Remove the air filter case cover by
removing the screws.7. Pull the air filter element out.
8. Insert a new air filter element into
the air filter case.
NOTICE:
Make
sure that the air filter element is
properly seated in the air filtercase. The engine should never
be operated without the air filter
element installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.

[ECA10481]

9. Install the air filter case cover by in-
stalling the screws.
10. Place the fuel tank in its original
position. Make sure that the fuel
hoses are properly connected and
routed, and are not pinched. Be
sure to place the fuel tank breath-
er/overflow hose in its original po-
sition.
WARNING! Before
installing the fuel tank, make
sure that the fuel hoses are not
damaged. If any fuel hose is
damaged, do not start the en-
gine but have a Yamaha dealer
replace the hose, otherwise fuel
may leak, creating a fire haz-
ard.
[EWA11331]

1. Rear brake fluid reservoir
2. Rear brake fluid reservoir holder
3. Bolt
12
3

1. Air filter case cover
2. Screw
1. Air filter element
1 2
2 21

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