2010 YAMAHA TDM 900 maintenance

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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INSTRUMENT AND CONTROL FUNCTIONS
3-15
2
34
5
6
7
8
9 your eyes, see your doctor immedi-
ately. If gasoline spills on your skin,
wash with soap and water. If gaso-
line spills on your clothing, change

your clothes.
EAU13320
NOTICE

ECA11400
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brandor premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.
EAU39451
Fuel tank breather/overflow
hose
Before operating the motorcycle:

Check the fuel tank breather/over-
flow hose connection.

Check the fuel tank breather/over-
flow hose for cracks or damage,
and replace it if damaged.

Make sure that the end of the fuel
tank breather/overflow hose is not
blocked, and clean it if necessary.
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)

1. Fuel tank breather/overflow hose
1
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INSTRUMENT AND CONTROL FUNCTIONS
3-16
1
2
3
4
5
6
7
8
9

EAU13445
Catalytic converters
This vehicle is equipped with catalytic
converters in the exhaust system.
WARNING

EWA10862
The exhaust system is hot after op-
eration. To prevent a fire hazard or
burns:

Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.

Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.

Make sure that the exhaust sys-
tem has cooled down before do-
ing any maintenance work.

Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
NOTICE

ECA10701
Use only unleaded gasoline. The use
of leaded gasoline will cause unre-pairable damage to the catalytic
converter.
EAU13861
Seat
To remove the seat
Insert the key into the seat lock, turn it
counterclockwise, and then pull the
seat off.
To install the seat
Insert the projections on the front of the
seat into the seat holders, push the rear
of the seat down to lock it in place, and
then remove the key.

1. Seat lock
2. Unlock.
1
2
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4-1
1
2
3
4
5
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.

Check the fuel tank breather/overflow hose for obstructions, cracks or damage,
and check the hose connection.3-14, 3-15
Engine oil

Check oil level in engine.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.6-9
Coolant

Check coolant level in reservoir.

If necessary, add recommended coolant to specified level.

Check cooling system for leakage.6-12
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.6-22
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6-1
2
3
4
5
67
8
9

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 ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
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
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
1
2
3
4
5
6
7
8
9

EAU46861
TIP


The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.

From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
EAU46910
Periodic maintenance chart for the emission control system
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)
1*
Fuel line

Check fuel hoses for cracks or
damage.
√√√√√
2*
Spark plugs

Check condition.

Clean and regap.
√√

Replace.
√√
3*
Valves

Check valve clearance.

Adjust.Every 40000 km (24000 mi)
4*
Fuel injection

Adjust engine idling speed and
synchronization.
√√√√√√
5*
Muffler and
exhaust pipe

Check the screw clamp(s) for
looseness.
√√√√√
6*
Air induction sys-
tem

Check the air cut-off valve, reed
valve, and hose for damage.

Replace the entire air induction
system if necessary.
√√√√√
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
2
3
4
5
67
8
9

EAU1770C
General maintenance and lubrication chart
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)
1
Air filter element

Replace.
√
2
Clutch

Check operation.

Adjust.
√√√√√
3*
Front brake

Check operation, fluid level and
vehicle for fluid leakage.
√√√√√√

Replace brake pads. Whenever worn to the limit
4*
Rear brake

Check operation, fluid level and
vehicle for fluid leakage.
√√√√√√

Replace brake pads. Whenever worn to the limit
5*
Brake hoses

Check for cracks or damage.
√√√√√

Replace. Every 4 years
6*
Wheels

Check runout and for damage.
√√√√
7*
Tires

Check tread depth and for
damage.

Replace if necessary.

Check air pressure.

Correct if necessary.
√√√√√
8*
Wheel bearings

Check bearing for looseness or
damage.
√√√√
9*
Swingarm

Check operation and for
excessive play.
√√√√

Lubricate with
lithium-soap-based grease.Every 50000 km (30000 mi)
10
Drive chain

Check chain slack, alignment
and condition.

Adjust and lubricate chain with a
special O-ring chain lubricant
thoroughly.Every 1000 km (600 mi) and after washing the motorcycle, riding in the rain or
riding in wet areas
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
1
2
3
4
5
6
7
8
9

11 *
Steering bearings

Check bearing play and steering
for roughness.
√√√√√

Lubricate with
lithium-soap-based grease.Every 20000 km (12000 mi)
12 *
Chassis fasteners

Make sure that all nuts, bolts
and screws are properly
tightened.
√√√√√
13
Brake lever pivot
shaft

Lubricate with silicone grease.
√√√√√
14
Brake pedal pivot
shaft

Lubricate with
lithium-soap-based grease.
√√√√√
15
Clutch lever pivot
shaft

Lubricate with
lithium-soap-based grease.
√√√√√
16
Shift pedal pivot
shaft

Lubricate with
lithium-soap-based grease.
√√√√√
17
Sidestand

Check operation.

Lubricate with
lithium-soap-based grease.
√√√√√
18 *
Sidestand switch

Check operation.
√√√√√√
19 *
Front fork

Check operation and for oil
leakage.
√√√√
20 *
Shock absorber
assembly

Check operation and shock
absorber for oil leakage.
√√√√
21 *
Rear suspension
relay arm and con-
necting arm pivot-
ing points

Check operation.
√√√√

Lubricate with
lithium-soap-based grease.
√√
22
Engine oil

Change.

Check oil level and vehicle for oil
leakage.
√√√√√√
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)
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