2009 YAMAHA TDM 900 service

INSTRUMENT AND CONTROL FUNCTIONS
3-20
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force and thereby harden the compres-
sion damping, turn the adjusting knob
in direction (a). To decrease the com-
pression damping force and thereby
soften the compression damping, turn
the adjusting knob in direction (b).
TIP

To obtain a precise adjustment, it is ad-
visable to check the actual total number
of clicks or turns of each damping force
adjusting mechanism. This adjustment
range may not exactly match the spec-
ifications listed due to small differences
in production.
WARNING

EWA10221
This shock absorber assembly con-
tains highly pressurized nitrogen
gas. Read and understand the fol-lowing information before handling
the shock absorber assembly.
●
Do not tamper with or attempt to
open the cylinder assembly.
●
Do not subject the shock ab-
sorber assembly to an open
flame or other high heat source.
This may cause the unit to ex-
plode due to excessive gas
pressure.
●
Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.
●
Do not dispose of a damaged or
worn-out shock absorber as-
sembly yourself. Take the shock
absorber assembly to a Yamaha
dealer for any service.
EAU15140
Luggage strap holders
There are four luggage strap holders
below the passenger seat, two of which
can be turned out for easier access.
Compression damping setting:
Minimum (soft):
12 clicks in direction (b)*
Standard:
11 clicks in direction (b)*
Maximum (hard):
1 clicks in direction (b)*
*With the adjusting knob fully turned in
direction (a)
1. Luggage strap holder
1

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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
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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.
√√√√√
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*

Air induction system
●
Check the air cut-off valve, reed
valve, and hose for damage.
●
Replace the entire air induction
system if necessary.
√√√√√
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*

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
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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)

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU36451
Replacing an auxiliary light
bulb
1. Remove the auxiliary light lens by
removing the screws.
2. Remove the burnt out bulb by pull-
ing it out.3. Insert a new bulb into the socket.
4. Install the lens by installing the
screws.
NOTICE:
Do not over-
tighten the screws, otherwise
the lens may break.
[ECA10681]

EAU24350
Supporting the motorcycle
Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
a jack either under each side of the

1. Auxiliary light lens
2. Screw
21

1. Auxiliary light bulb
1

PERIODIC MAINTENANCE AND ADJUSTMENT
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frame in front of the rear wheel or under
each side of the swingarm.

EAU25871
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
WARNING

EWA15141
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from waterheaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-
plode, causing severe injury or
property damage.

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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