2010 YAMAHA TDM 900 Owners Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
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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
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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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PERIODIC MAINTENANCE AND ADJUSTMENT
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23
Engine oil filter ele-
ment

Replace.
√√√
24 *
Cooling system

Check coolant level and vehicle
for coolant leakage.
√√√√√

Change. Every 3 years
25 *
Front and rear
brake switches

Check operation.
√√√√√√
26
Moving parts and
cables

Lubricate.
√√√√√
27 *
Throttle grip hous-
ing and cable

Check operation and free play.

Adjust the throttle cable free
play if necessary.

Lubricate the throttle grip
housing and cable.
√√√√√
28 *
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)
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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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU18712
Removing and installing
cowlings and panels
The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
a cowling or panel needs to be re-
moved and installed.
EAU18991
Cowlings A and B
To remove one of the cowlings
Remove the cowling screws and the
quick fastener, and then pull the cowl-
ing off as shown.
TIP

The quick fastener is removed by push-
ing the center pin in with a screwdriver,
and then pulling the fastener out.
1. Cowling A
2. Panel A
2
1

1. Cowling B
2. Panel B2
1

1. Screw
2. Quick fastener
1. Quick fastener (after removal)
2. Quick fastener (before installation)
1
1
1
2
12
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PERIODIC MAINTENANCE AND ADJUSTMENT
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To install the cowling
Place the cowling in the original posi-
tion, and then install the screws and the
quick fastener.TIP

To install the quick fastener, push the
center pin out so that it will protrude
from the fastener head, insert the fas-
tener into the cowling, and then push
the protruding pin in until it is flush with
the fastener head.
EAU19171
Panels A and B
To remove one of the panels
1. Remove the corresponding cowl-
ing A or B. (See page 6-7.)
2. Remove the seat. (See
page 3-16.)
3. Remove the screw, and then take
the panel off.To install the panel
1. Place the panel in the original po-
sition, and then install the screw.
2. Install the seat and the cowling.

EAU19642
Checking the spark plugs
The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal color
when the vehicle is ridden normally),
and all spark plugs installed in the en-
gine should have the same color. If any
spark plug shows a distinctly different
color, the engine could be operating im-
properly. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the vehicle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.
1. Screw
1. Panel A
1
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
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Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
TIP

If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
EAU19836
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart. A slight tilt to the side can
result in a false reading.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. Start the engine, warm it up for 15
minutes, and then turn it off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in and with the arrow
mark pointing upward as shown),
and then remove it again to check
the oil level.
WARNING! Never re-
move the engine oil tank cap af-
ter high-speed operation,
otherwise hot engine oil could

Specified spark plug:
NGK/DPR8EA-9
DENSO/X24EPR-U9
1. Spark plug gap
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
1

Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.7 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
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9spout out and cause damage or
injury. Always let the engine oil
cool down sufficiently before re-
moving the oil tank cap.

[EWA10361]
NOTICE:
Do not operate the ve-
hicle until you know that the en-
gine oil level is sufficient.
[ECA10011]

TIP

The engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Install the oil filler cap.
TIP


The engine oil tank is located be-
hind the cylinders.

The engine oil should be between
the minimum and maximum level
marks.
To change the engine oil (with or
without oil filter element replace-
ment)
1. Place the vehicle on a level sur-
face.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Place an oil pan under the engine
to collect the used oil.
4. Remove the engine oil filler cap,
the engine oil drain bolts and their
gasket to drain the oil from the
crankcase.
1. Engine oil filler cap
1

1. Engine oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
1
2
3
4

1. Engine oil drain bolt A
2. Gasket
2
1
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