warning YAMAHA TDM 900 2004 User Guide

INSTRUMENT AND CONTROL FUNCTIONS
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(a). To decrease the rebound damping
force and thereby soften the rebound
damping, turn the adjusting knob in di-
rection (b).
Compression damping force
To increase the compression dampingforce and thereby harden the compres-
sion damping, turn the adjusting knob
in direction (a). To decrease the com-
pression damping force and thereby
soften the compression damping, turn
the adjusting knob in direction (b).
NOTE:

Although the total number of clicks of a
damping force adjusting mechanism
may not exactly match the above spec-
ifications due to small differences in
production, the actual number of clicks
always represents the entire adjusting
range. To obtain a precise adjustment,
it would be advisable to check the num-
ber of clicks of each damping force ad-
justing mechanism and to modify the
specifications as necessary.
WARNING

EWA10220
This shock absorber contains highly
pressurized nitrogen gas. For prop-
er handling, read and understand
the following information before
handling the shock absorber. The
manufacturer cannot be held re-
sponsible for property damage or
personal injury that may result from
improper handling.

Do not tamper with or attempt to
open the gas cylinder.

Do not subject the shock ab-
sorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.

Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping per-
formance.

Always have a Yamaha dealer
service the shock absorber. Rebound damping setting:
Minimum (soft):
20 clicks in direction (b)*
Standard:
12 clicks in direction (b)*
Maximum (hard):
3 clicks in direction (b)*
* With the adjusting knob fully
turned in direction (a)
1. Compression damping force adjusting
knob
1(a) (b)

Compression damping setting:
Minimum (soft):
12 clicks in direction (b)*
Standard:
11 clicks in direction (b)*
Maximum (hard):
1 click in direction (b)*
* With the adjusting knob fully
turned in direction (a)

INSTRUMENT AND CONTROL FUNCTIONS
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EAU15140
Luggage strap holders
There are four luggage strap holders
below the passenger seat, two of which
can be turned out for easier access.
EAU15300
Sidestand
The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.
NOTE:

The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.)
WARNING

EWA10240
The vehicle must not be ridden with
the sidestand down, or if the side-
stand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control. Yama-
ha’s ignition circuit cut-off system
has been designed to assist the op-
erator in fulfilling the responsibility
of raising the sidestand before start-
ing off. Therefore, check this systemregularly as described below and
have a Yamaha dealer repair it if it
does not function properly.
1. Luggage strap holder
1(×4)

INSTRUMENT AND CONTROL FUNCTIONS
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EAU15311
Ignition circuit cut-off system
The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.

It prevents starting when the trans-
mission is in gear and the side-
stand is up, but the clutch lever is
not pulled.

It prevents starting when the trans-
mission is in gear and the clutch le-
ver is pulled, but the sidestand is
still down.

It cuts the running engine when the
transmission is in gear and the sid-
estand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
WARNING

EWA10250
If a malfunction is noted, have a
Yamaha dealer check the system be-
fore riding.

PRE-OPERATION CHECKS
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EAU15591
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
NOTE:

Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short
time; and the added safety it assures is more than worth the time involved.
WARNING

EWA11150
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.

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OPERATION AND IMPORTANT RIDING POINTS
EAU15950
WARNING

EWA10270

Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.

Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.

Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU16380
Starting the engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.

The transmission is in gear with
the clutch lever pulled and the sid-
estand up.
WARNING

EWA10290

Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-19.

Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
CAUTION:

ECA11310
The oil level warning light and en-
gine trouble warning light should
come on for a few seconds, then gooff. If a warning light does not go off,
see page 3-3 for the corresponding
warning light circuit check.
2. Shift the transmission into the neu-
tral position.
NOTE:

When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a Yama-
ha dealer check the electrical circuit.
3. Start the engine by pushing the
start switch.
NOTE:

If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt.
CAUTION:

ECA11040
For maximum engine life, never ac-
celerate hard when the engine is

OPERATION AND IMPORTANT RIDING POINTS
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the oil filter element replaced.
1,600 km (1,000 mi) and beyond
The vehicle can now be operated nor-
mally.
CAUTION:

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.
EAU17211
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
WARNING

EWA10310

Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.

Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
CAUTION:

ECA10380
Never park in an area where there
are fire hazards such as grass or
other flammable materials.

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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17240
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, 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, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
WARNING

EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealer
do it for you.
EAU17520
Owner’s tool kit
The owner’s tool kit is located inside the
storage compartment under the seat.
(See page 3-13.)
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.
NOTE:

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
WARNING

EWA10350
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es.
1. Owner’s tool kit
1

PERIODIC MAINTENANCE AND MINOR REPAIR
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and then remove it again to check
the oil level.
NOTE:

The engine oil should be between the
minimum and maximum level marks.
CAUTION:

ECA10010
Do not operate the vehicle until you
know that the engine oil level is suf-
ficient.
WARNING

EWA10360
Never remove the engine oil tank
cap after high-speed operation, oth-
erwise hot engine oil could spout
out and cause damage or injury. Al-
ways let the engine oil cool down
sufficiently before removing the oil
tank cap.
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.
NOTE:


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. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolts 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
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PERIODIC MAINTENANCE AND MINOR REPAIR
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3. If the coolant is at or below the
minimum level mark, remove pan-
el B (See page 6-5.), remove the
reservoir cap, add coolant to the
maximum level mark, and then in-
stall the reservoir cap and the pan-
el.
CAUTION:

ECA10470

If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.

If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-ing system will not be protected
against frost and corrosion.

If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
WARNING

EWA10380
Never attempt to remove the radiator
cap when the engine is hot.
NOTE:


The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.

If the engine overheats, see page
6-39 for further instructions.
EAU20450
To change the coolant
1. Place the vehicle on a level sur-
face and let the engine cool if nec-
essary.
2. Remove the seat. (See
page 3-13.)
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
1 2
3

1. Coolant reservoir cap
Coolant reservoir capacity (up to
the maximum level mark):
0.25 L (0.26 US qt)
(0.22 Imp.qt)
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PERIODIC MAINTENANCE AND MINOR REPAIR
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3. Remove cowling B and panel B.
(See page 6-5.)
4. Remove the fuel tank bolts, and
then lift the fuel tank to position it
away from the coolant reservoir.
(Do not disconnect the fuel hoses!)
5. Place a container under the engine
to collect the used coolant.
6. Remove the radiator cap retaining
bolt and the radiator cap.
WARNING

EWA10380
Never attempt to remove the radiator
cap when the engine is hot.
7. Remove the coolant drain bolts todrain the cooling system.
8. Remove the coolant reservoir bolt.
9. Pull the coolant reservoir upward
and away from the vehicle.
10. Drain the remaining coolant fromthe coolant reservoir by opening
the cap, then turning the reservoir
upside down.
11. Install the coolant reservoir by
placing it in the original position,
then installing the bolt.
12. After the coolant is completely
drained, thoroughly flush the cool-
ing system with clean tap water.
13. Install the coolant drain bolts, and
then tighten them to the specified
torque.
NOTE:

Check the washers for damage and re-
place them if necessary.
14. Pour the recommended coolant
into the radiator until it is full.
1. Radiator cap retaining bolt
2. Radiator cap
1
2

1. Coolant drain bolt
1. Bolt
2. Coolant reservoir
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2

Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)