brake YAMAHA TDM 900 2004 Owners Manual

TABLE OF CONTENTS
SAFETY INFORMATION ............. 1-1
DESCRIPTION ............................. 2-1
Left view ..................................... 2-1
Right view................................... 2-2
Controls and instruments ........... 2-3
INSTRUMENT AND CONTROL
FUNCTIONS ................................ 3-1
Immobilizer system ................... 3-1
Main switch/steering lock .......... 3-2
Indicator and warning lights ...... 3-3
Speedometer unit ...................... 3-5
Tachometer unit ........................ 3-6
Coolant temperature gauge ...... 3-7
Anti-theft alarm (optional) .......... 3-8
Handlebar switches ................... 3-8
Clutch lever ............................... 3-9
Shift pedal ............................... 3-10
Brake lever .............................. 3-10
Brake pedal ............................. 3-11
Fuel tank cap ........................... 3-11
Fuel ......................................... 3-12
Fuel tank breather hose .......... 3-13
Catalytic converter .................. 3-13
Seat ......................................... 3-13
Storage compartment .............. 3-14
Adjusting the front fork ............ 3-15Adjusting the shock absorber
assembly ............................... 3-16
Luggage strap holders ............ 3-18
Sidestand ................................ 3-18
Ignition circuit cut-off system ... 3-19
PRE-OPERATION CHECKS ....... 4-1
Pre-operation check list ............ 4-2
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
MINOR REPAIR ............................ 6-1
Owner’s tool kit ......................... 6-1
Periodic maintenance and
lubrication chart ....................... 6-2
Removing and installing
cowlings and panels ................ 6-5
Checking the spark plugs .......... 6-6
Engine oil and oil filter
element ................................... 6-7Coolant .................................... 6-10
Replacing the air filter
element ................................. 6-14
Adjusting the engine idling
speed .................................... 6-15
Adjusting the throttle cable free
play ....................................... 6-16
Adjusting the valve
clearance .............................. 6-16
Tires ........................................ 6-16
Cast wheels ............................ 6-19
Adjusting the clutch lever free
play ....................................... 6-20
Adjusting the brake pedal
position .................................. 6-21
Adjusting the rear brake light
switch .................................... 6-21
Checking the front and rear
brake pads ............................ 6-22
Checking the brake fluid
level ....................................... 6-22
Changing the brake fluid ......... 6-23
Drive chain slack ..................... 6-24
Lubricating the drive chain ...... 6-25
Checking and lubricating the
cables .................................... 6-26
Checking and lubricating the
throttle grip and cable ........... 6-26

TABLE OF CONTENTS
Checking and lubricating the
brake and shift pedals ........... 6-26
Checking and lubricating the
brake and clutch levers ......... 6-27
Checking and lubricating the
sidestand ............................... 6-27
Lubricating the rear
suspension ............................ 6-27
Checking the front fork ............ 6-28
Checking the steering ............. 6-28
Checking the wheel
bearings ................................ 6-29
Battery ..................................... 6-29
Replacing the fuses ................. 6-30
Replacing a headlight bulb ...... 6-31
Replacing the tail/brake light
bulb ....................................... 6-33
Replacing a turn signal light
bulb ....................................... 6-33
Supporting the motorcycle ...... 6-34
Front wheel ............................. 6-35
Rear wheel .............................. 6-36
Troubleshooting ...................... 6-38
Troubleshooting charts ............ 6-39
MOTORCYCLE CARE AND
STORAGE..................................... 7-1
Care .......................................... 7-1Storage ..................................... 7-3
SPECIFICATIONS ....................... 8-1
CONSUMER INFORMATION ...... 9-1
Identification numbers ............... 9-1

DESCRIPTION
2-2
2
3
4
5
6
7
8
9

EAU10420
Right view
1234
5
6 7 8 9 10

1. Owner’s tool kit (page 6-1)
2. Coolant reservoir (page 6-10)
3. Throttle stop screw (page 6-15)
4. Front brake fluid reservoir (page 6-22)
5. Radiator cap (page 6-10)
6. Engine oil filler cap (page 6-7)
7. Engine oil filter element (page 6-7)
8. Engine oil drain bolt B (page 6-7)9. Brake pedal (page 3-11)
10. Rear brake fluid reservoir (page 6-22)

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

EAU10430
Controls and instruments
1 2 345 6 7 8 9

1. Clutch lever (page 3-9)
2. Left handlebar switches (page 3-8)
3. Speedometer unit (page 3-5)
4. Main switch/steering lock (page 3-2)
5. Tachometer unit (page 3-6)
6. Coolant temperature gauge (page 3-7)
7. Right handlebar switches (page 3-8)
8. Brake lever (page 3-10)9. Throttle grip (page 6-16)

INSTRUMENT AND CONTROL FUNCTIONS
3-10
1
2
3
4
5
6
7
8
9

EAU12870
Shift pedal
The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 6-speed con-
stant-mesh transmission equipped on
this motorcycle.
EAU26821
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
The brake lever is equipped with a po-
sition adjusting dial. To adjust the dis-
tance between the brake lever and the
handlebar grip, turn the adjusting dial
while holding the lever pushed away
from the handlebar grip. Make sure that
the appropriate setting on the adjustingdial is aligned with the “ ” mark on the
brake lever.
1. Shift pedal
1

1. Brake lever
2. Brake lever position adjusting dial
3. “ ” mark
4. Distance between brake lever and handle-
bar grip
1 2
4
3

INSTRUMENT AND CONTROL FUNCTIONS
3-11
2
34
5
6
7
8
9

EAU12941
Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
EAU13090
Fuel tank cap
To open the fuel tank cap
Open the fuel tank cap lock cover, in-
sert the key into the lock, and then turn
it 1/8 turn clockwise. The lock will be re-
leased and the fuel tank cap can be
opened.
To close the fuel tank cap
1. Push the fuel tank cap into position
with the key inserted in the lock.
2. Turn the key counterclockwise to
the original position, remove it, and
then close the lock cover.
NOTE:

The fuel tank cap cannot be closed un-less the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly closed and locked.
WARNING

EWA11090
Make sure that the fuel tank cap is
properly closed before riding.
1. Brake pedal
1

1. Fuel tank cap lock cover
2. Unlock.
1
2

PRE-OPERATION CHECKS
4-2
1
2
3
4
5
6
7
8
9

EAU15601
Pre-operation check list
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.3-12
Engine oil

Check oil level in engine.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.6-7
Coolant

Check coolant level in reservoir.

If necessary, add recommended coolant to specified level.

Check cooling system for leakage.6-10
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
Rear 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.6-21, 6-22
Clutch

Check operation.

Lubricate cable if necessary.

Check lever free play.

Adjust if necessary.6-20

PRE-OPERATION CHECKS
4-3
2
3
45
6
7
8
9

Throttle grip

Make sure that operation is smooth.

Check cable free play.

If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-16, 6-26
Control cables

Make sure that operation is smooth.

Lubricate if necessary.6-26
Drive chain

Check chain slack.

Adjust if necessary.

Check chain condition.

Lubricate if necessary.6-24, 6-25
Wheels and tires

Check for damage.

Check tire condition and tread depth.

Check air pressure.

Correct if necessary.6-16, 6-19
Brake and shift pedals

Make sure that operation is smooth.

Lubricate pedal pivoting points if necessary.6-26
Brake and clutch levers

Make sure that operation is smooth.

Lubricate lever pivoting points if necessary.6-27
Sidestand

Make sure that operation is smooth.

Lubricate pivot if necessary.6-27
Chassis fasteners

Make sure that all nuts, bolts and screws are properly tightened.

Tighten if necessary.—
Instruments, lights, signals
and switches

Check operation.

Correct if necessary.—
Sidestand switch

Check operation of ignition circuit cut-off system.

If system is defective, have Yamaha dealer check vehicle.3-18
ITEM CHECKS PAGE

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
2
3
4
5
67
8
9

EAU17701
Periodic maintenance and lubrication chart
NOTE:


The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.

From 50000 km, repeat the maintenance intervals starting from 10000 km.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040
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
4
Air filter element

Replace.
√

5
Clutch

Check operation.

Adjust.
√

√

√

√

√

6*
Front brake


Check operation, fluid level and vehicle for fluid leak-
age.
√

√

√

√

√

√



Replace brake pads. Whenever worn to the limit
7*
Rear brake

Check operation, fluid level and vehicle for fluid leak-
age.
√

√

√

√

√

√



Replace brake pads. Whenever worn to the limit
8*
Brake hoses

Check for cracks or damage.
√

√

√

√

√



Replace. Every 4 years
9*
Wheels

Check runout and for damage.
√

√

√

√

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
2
3
4
5
67
8
9

EAU18680
NOTE:


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.
25

*
Front and rear brake
switches

Check operation.
√

√

√

√

√

√


26

Moving parts and cables

Lubricate.
√

√

√

√

√


27

*
Throttle grip housing
and cable

Check operation and free play.

Adjust the throttle cable free play if necessary.

Lubricate the throttle grip housing and cable.
√

√

√

√

√


28

*
Air induction system

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

Replace the entire air induction system if necessary.
√

√

√

√

√


29

*
Muffler and exhaust pipe

Check the screw clamp for looseness.
√

√

√

√

√


30

*
Lights, signals and
switches

Check operation.

Adjust headlight beam.
√

√

√

√

√

√

NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040