2010 YAMAHA TDM 900 engine
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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 ...................... 3-8
Anti-theft alarm (optional) ............... 3-9
Handlebar switches ........................ 3-9
Clutch lever ................................... 3-11
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/overflow
hose .......................................... 3-15
Catalytic converters ...................... 3-16
Seat .............................................. 3-16
Storage compartment ................... 3-17
Adjusting the front fork .................. 3-18Adjusting the shock absorber
assembly ................................... 3-19
Luggage strap holders ................. 3-21
Sidestand ..................................... 3-21
Ignition circuit cut-off system ........ 3-22
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 chart for
the emission control system ....... 6-2
General maintenance and
lubrication chart .......................... 6-3
Removing and installing
cowlings and panels ................... 6-7
Checking the spark plugs ............... 6-8
Engine oil and oil filter element ...... 6-9
Coolant ......................................... 6-12
Replacing the air filter element ..... 6-14Adjusting the engine idling
speed ........................................ 6-16
Checking the throttle cable free
play ........................................... 6-16
Valve clearance ........................... 6-17
Tires ............................................. 6-17
Cast wheels ................................. 6-19
Adjusting the clutch lever free
play ........................................... 6-20
Brake light switches ..................... 6-21
Checking the front and rear
brake pads ................................ 6-21
Checking the brake fluid level ...... 6-22
Changing the brake fluid .............. 6-23
Drive chain slack .......................... 6-23
Cleaning and lubricating the
drive chain ................................ 6-25
Checking and lubricating the
cables ....................................... 6-25
Checking and lubricating the
throttle grip and cable ............... 6-26
Checking and lubricating the
brake and shift pedals .............. 6-26
Checking and lubricating the
brake and clutch levers ............. 6-26
Checking and lubricating the
sidestand .................................. 6-27
Lubricating the rear suspension ... 6-27
Checking the front fork ................. 6-27
Checking the steering .................. 6-28
Checking the wheel bearings ....... 6-29
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Page 9 of 96
1-2
1
SAFETY INFORMATION
Always obey the speed limit and
never travel faster than warrant-
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 carbon
monoxide, 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-
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Page 10 of 96
1-3
1
SAFETY INFORMATION
ports.
Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loading
Adding accessories or cargo to your
motorcycle can adversely affect stabili-
ty and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use ex-
treme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here, along with the information about
accessories below, are some general
guidelines to follow if loading cargo to
your motorcycle:
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
Operation of an overloaded vehicle
could cause an accident.
When loading within this weight limit,
keep the following in mind:
Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Se-
curely pack your heaviest items as
close to the center of the vehicle as
possible and make sure to distrib-
ute the weight as evenly as possi-
ble on both sides of the motorcycle
to minimize imbalance or instabili-
ty.
Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.
Properly adjust the suspension
for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure of your tires.
Never attach any large or heavy
items to the handlebar, front
fork, or front fender. These
items, including such cargo as
sleeping bags, duffel bags, ortents, can create unstable han-
dling or a slow steering re-
sponse.
This vehicle is not designed to
pull a trailer or to be attached to
a sidecar.
Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail-
able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection to
Yamaha manufacture parts and acces-
sories or offer other modifications for
Yamaha vehicles. Yamaha is not in a
position to test the products that these
aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.
Maximum load:
TDM900 201 kg (443 lb)
TDM900A 198 kg (437 lb)
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Page 11 of 96
1-4
1
SAFETY INFORMATION
Aftermarket Parts, Accessories,
and Modifications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accessories
or modifications are not suitable be-
cause of potential safety hazards to you
or others. Installing aftermarket prod-
ucts or having other modifications per-
formed to your vehicle that change any
of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or death.
You are responsible for injuries related
to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-scure lights or reflectors.
Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds. These ac-
cessories may also cause
instability when passing or being
passed by large vehicles.
Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.
Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match the
performance capabilities and to provide
the best combination of handling, brak-
ing, and comfort. Other tires, rims, siz-
es, and combinations may not be
appropriate. Refer to page 6-17 for tire
specifications and more information on
replacing your tires.
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Page 12 of 96
2-1
1
2
DESCRIPTION
EAU32220
Left view
TDM900
12
345678
9 10 11 12 13 1412
345678
9 10 11 12 13 14
1. Front fork spring preload adjusting bolt (page 3-18)
2. Front fork damping adjusting screw (page 3-18)
3. Air filter element (page 6-14)
4. Shock absorber assembly compression damping force adjusting
knob (page 3-19)
5. Battery (page 6-29)
6. Fuses (page 6-30)
7. Storage compartment (page 3-17)8. Grab bar
9. Luggage strap holder (page 3-21)
10.Seat lock (page 3-16)
11.Shock absorber assembly rebound damping force adjusting knob
(page 3-19)
12.Shock absorber assembly spring preload adjusting ring (page 3-19)
13.Shift pedal (page 3-11)
14.Engine oil drain bolt A (page 6-9)
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Page 13 of 96
DESCRIPTION
2-2
2
3
4
5
6
7
8
9 TDM900A
12
3456
7 8 9 10 11 1212
3456
1. Front fork spring preload adjusting bolt (page 3-18)
2. Front fork damping adjusting screw (page 3-18)
3. Air filter element (page 6-14)
4. Coolant reservoir (page 6-12)
5. Battery (page 6-29)
6. Fuses (page 6-30)
7. Luggage strap holder (page 3-21)
8. Seat lock (page 3-16)9. Shock absorber assembly rebound damping force adjusting knob
(page 3-19)
10.Shock absorber assembly spring preload adjusting ring (page 3-19)
11.Shift pedal (page 3-11)
12.Engine oil drain bolt A (page 6-9)
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Page 14 of 96
DESCRIPTION
2-3
1
2
3
4
5
6
7
8
9
EAU32230
Right view
TDM900
1234
5
6 7 8 9 10
1. Owner’s tool kit (page 6-1)
2. Coolant reservoir (page 6-12)
3. Idle adjusting screw (page 6-16)
4. Front brake fluid reservoir (page 6-22)
5. Radiator cap (page 6-12)
6. Engine oil filler cap (page 6-9)7. Engine oil filter element (page 6-9)
8. Engine oil drain bolt B (page 6-9)
9. Brake pedal (page 3-12)
10.Rear brake fluid reservoir (page 6-22)
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Page 15 of 96
DESCRIPTION
2-4
2
3
4
5
6
7
8
9 TDM900A
1
56
7
8 9 10 11 12
23 4
1. Grab bar
2. Owner’s tool kit (page 6-1)
3. Storage compartment (page 3-17)
4. Shock absorber assembly compression damping force adjusting
knob (page 3-19)
5. Idle adjusting screw (page 6-16)
6. Front brake fluid reservoir (page 6-22)
7. Radiator cap (page 6-12)
8. Engine oil filler cap (page 6-9)9. Engine oil filter element (page 6-9)
10.Engine oil drain bolt B (page 6-9)
11.Brake pedal (page 3-12)
12.Rear brake fluid reservoir (page 6-22)
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