2010 YAMAHA TDM 900 oil change

OPERATION AND IMPORTANT RIDING POINTS
5-3
2
3
4
56
7
8
9

EAU16810
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Shift up swiftly, and avoid high en-
gine speeds during acceleration.

Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.

Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16841
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17101
0–1000 km (0–600 mi)
Avoid prolonged operation above 4000
r/min.
NOTICE:
After 1000 km (600
mi) of operation, the engine oil must
be changed, and the oil filter ele-
ment replaced.

[ECA11151]

1000–1600 km (600–1000 mi)
Avoid prolonged operation above 6000
r/min.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
NOTICE

ECA10310

Keep the engine speed out of
the tachometer red zone.

If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-
cle.
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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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PERIODIC MAINTENANCE AND ADJUSTMENT
6-5
2
3
4
5
67
8
9

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
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
6-9
2
3
4
5
67
8
9
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
6-10
1
2
3
4
5
6
7
8
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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PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
1
2
3
4
5
6
7
8
9
9. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the oil filler
cap.
TIP

Be sure to wipe off spilled oil on any
parts after the engine and exhaust sys-
tem have cooled down.
NOTICE

ECA11620

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Donot use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

Make sure that no foreign mate-
rial enters the crankcase.
10. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
11. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU38583
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
TIP


The coolant level must be checked
on a cold engine since the level
varies with engine temperature.

Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.
TIP

The coolant should be between the
minimum and maximum level marks.
Tightening torques:
Engine oil drain bolt A:
35 Nm (3.5 m·kgf, 25 ft·lbf)
Engine oil drain bolt B:
30 Nm (3.0 m·kgf, 21.7 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
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)
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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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