2010 YAMAHA TDM 900 brake fluid

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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PERIODIC MAINTENANCE AND ADJUSTMENT
6-6
1
2
3
4
5
6
7
8
9

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
6-14
1
2
3
4
5
6
7
8
9

EAU27055
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 6-7.)
3. Remove the fuel tank bolts.
TIP

For TDM900, skip steps 4 and 12.
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.
WARNING! Make
sure that the fuel tank is well
supported. Do not tilt or pull the
fuel tank too much, otherwise
the fuel hoses may come loose,
which could cause fuel leakage
and a fire hazard.

[EWA10411]

6. Remove the air filter case cover by
removing the screws.
1. Bolt
1

1. Bolt1
1. Rear brake fluid reservoir
2. Rear brake fluid reservoir holder
3. Bolt
12
3
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
2
3
4
5
67
8
9
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 breather
hose and the overflow hose in their
original position.
WARNING! Be-
fore installing the fuel tank,
make sure that the fuel hoses
are not damaged. If any fuel
hose is damaged, do not start
the engine but have a Yamaha
dealer replace the hose, other-
wise fuel may leak, creating a
fire hazard.
[EWA11331]

11. Install the fuel tank bolts.
12. Install the rear brake fluid reservoir
holder by installing the bolt.
13. Install the panels and cowlings.
14. Install the seat.
1. Air filter case cover
2. Screw
1. Air filter element
1 2
2 21

1. Fuel tank breather/overflow hose
2. Fuel hose
1. Original position (paint mark)
12
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
1
2
3
4
5
6
7
8
9

EAU38640
Checking the brake fluid level
Front brake
Rear brake (for TDM900)Rear brake (for TDM900A)
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
TIP

For TDM900A, the rear brake fluid res-
ervoir is located under the seat. (See
page 3-16.)Observe these precautions:

When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.

Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.

Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.

Be careful that water or dust does
not enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of the
fluid and may result in vapor lock,
and dirt may clog the ABS hydrau-
lic unit valves.

Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.

As the brake pads wear, it is nor-
1. Minimum level mark
1. Minimum level mark
1
1

1. Minimum level mark
1

Recommended brake fluid:
DOT 4
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
2
3
4
5
67
8
9
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.

EAU22731
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenance
and lubrication chart. In addition, have
the oil seals of the master cylinders and
calipers as well as the brake hoses re-
placed at the intervals listed below or
whenever they are damaged or leak-
ing.

Oil seals: Replace every two
years.

Brake hoses: Replace every four
years.
EAU22760
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22773
To check the drive chain slack
1. Place the motorcycle on the side-
stand.
TIP

When checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.
Drive chain slack:
50.0–60.0 mm (1.97–2.36 in)
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SPECIFICATIONS
8-2
2
3
4
5
6
7
89

Transmission type:
Constant mesh 6-speed
Operation:
Left foot operation
Gear ratio:
1st:
33/12 (2.750)
2nd:
37/19 (1.947)
3rd:
34/22 (1.545)
4th:
31/25 (1.240)
5th:
26/25 (1.040)
6th:
24/26 (0.923)
Chassis:
Frame type:
Diamond
Caster angle:
25.50 °
Trail:
114.0 mm (4.49 in)
Front tire:
Type:
Tubeless
Size:
120/70 ZR18M/C (59W)
Manufacturer/model:
TDM900 METZELER/MEZ4 FRONT
TDM900A DUNLOP/D220FSTJ
Manufacturer/model:
TDM900 DUNLOP/D220FSTJ
Rear tire:
Type:
Tubeless
Size:
160/60 ZR17M/C (69W)
Manufacturer/model:
TDM900 METZELER/MEZ4
TDM900A DUNLOP/D220STJ
Manufacturer/model:
TDM900 DUNLOP/D220STJ
Loading:
Maximum load:
TDM900 201 kg (443 lb)
TDM900A 198 kg (437 lb)
* (Total weight of rider, passenger, cargo
and accessories)
Tire air pressure (measured on cold
tires):
Loading condition:
0–90 kg (0–198 lb)
Front:
225 kPa (2.25 kgf/cm
2

, 33 psi)
Rear:
250 kPa (2.50 kgf/cm
2

, 36 psi)
Loading condition:
TDM900 90–201 kg (198–443 lb)
TDM900A 90–198 kg (198–437 lb)
Front:
225 kPa (2.25 kgf/cm
2

, 33 psi)
Rear:
290 kPa (2.90 kgf/cm
2

, 42 psi)
High-speed riding:
Front:
225 kPa (2.25 kgf/cm
2

, 33 psi)Rear:
250 kPa (2.50 kgf/cm
2

, 36 psi)
Front wheel:
Wheel type:
Cast wheel
Rim size:
18M/C x MT3.50
Rear wheel:
Wheel type:
Cast wheel
Rim size:
17M/C x MT5.00
Front brake:
Type:
Dual disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:
Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
150.0 mm (5.91 in)
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INDEX
A
ABS (for ABS models) ............................ 3-12
ABS warning light (for ABS models) ......... 3-5
Air filter element, replacing ..................... 6-14
Anti-theft alarm (optional).......................... 3-9
Auxiliary light bulb, replacing .................. 6-34
B
Battery..................................................... 6-29
Brake and clutch levers, checking and
lubricating ............................................. 6-26
Brake and shift pedals, checking and
lubricating ............................................. 6-26
Brake fluid, changing .............................. 6-23
Brake fluid level, checking ...................... 6-22
Brake lever .............................................. 3-11
Brake light switches ................................ 6-21
Brake pedal ............................................. 3-12
C
Cables, checking and lubricating ............ 6-25
Care .......................................................... 7-1
Catalytic converters ................................ 3-16
Clutch lever ............................................. 3-11
Clutch lever free play, adjusting .............. 6-20
Coolant.................................................... 6-12
Coolant temperature gauge ...................... 3-7
Cowlings and panels, removing and
installing.................................................. 6-7
D
Dimmer switch ........................................ 3-10
Drive chain, cleaning and lubricating ...... 6-25
Drive chain slack ..................................... 6-23
E
Engine break-in ......................................... 5-3
Engine idling speed................................. 6-16Engine oil and oil filter element.................. 6-9
Engine stop switch................................... 3-10
Engine trouble warning light ...................... 3-5
F
Front and rear brake pads, checking ....... 6-21
Front fork, adjusting ................................. 3-18
Front fork, checking ................................. 6-27
Fuel.......................................................... 3-14
Fuel consumption, tips for reducing........... 5-3
Fuel level warning indicator ....................... 3-5
Fuel tank breather/overflow hose ............ 3-15
Fuel tank cap ........................................... 3-13
Fuses, replacing ...................................... 6-30
H
Handlebar switches ................................... 3-9
Hazard switch .......................................... 3-10
Headlight bulb, replacing ......................... 6-32
High beam indicator light ........................... 3-4
Horn switch .............................................. 3-10
I
Identification numbers ............................... 9-1
Ignition circuit cut-off system ................... 3-22
Immobilizer system .................................... 3-1
Immobilizer system indicator light.............. 3-5
Indicator and warning lights ....................... 3-4
L
Luggage strap holders ............................. 3-21
M
Main switch/steering lock........................... 3-2
Maintenance and lubrication, periodic ....... 6-3
Maintenance, emission control system...... 6-2
Matte color, caution ................................... 7-1
Model label ................................................ 9-1
Multi-function display ................................. 3-8
N
Neutral indicator light ................................ 3-4
O
Oil level warning light ................................ 3-4
P
Parking ...................................................... 5-4
Part locations ............................................ 2-1
Pass switch ............................................. 3-10
R
Rear suspension, lubricating ................... 6-27
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........ 6-27
Spark plugs, checking ............................... 6-8
Specifications ............................................ 8-1
Starting the engine .................................... 5-1
Start switch .............................................. 3-10
Steering, checking................................... 6-28
Storage...................................................... 7-3
Storage compartment.............................. 3-17
Supporting the motorcycle ...................... 6-34
T
Tachometer unit ........................................ 3-6
Tail/brake light bulb, replacing ................ 6-33
Throttle cable free play, checking ........... 6-16
Throttle grip and cable, checking and
lubricating.............................................. 6-26
Tires ........................................................ 6-17
Tool kit....................................................... 6-1
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