wheel YAMAHA TDM 900 2004 Owners Manual

EAU26941
DECLARATION of CONFORMITY
We
Hereby declare that the product:
is in compliance with following norm(s) or documents: Type-designation:
5SL-00, 5VS-00, 5VX-00, 3HT-00, 5UX-00, 5UX-10, 5KS-00 and 5KS-10
R&TTE Directive(1999/5/EC)
EN300 330-2 v1.1.1(2001-6), EN60950(2000)
Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC)
Place of issue: Shizuoka, Japan
Date of issue: Aug. 1
st 2002 Kind of equipment: IMMOBILIZER Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan Company: MORIC CO., LTD.
Kazuji Kawai
representative name and signature
5PS-9-E2_hyoushi2&3 7/8/03 3:47 PM Page 1

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

SAFETY INFORMATION
1-2
1
dercornering (insufficient lean an-
gle for the speed).

Always obey the speed limit and
never travel faster than warrant-
ed by road and traffic conditions.

Always signal before turning or
changing lanes. Make sure that
other motorists can see you.

The posture of the operator and
passenger is important for proper
control.

The operator should keep both
hands on the handlebar and
both feet on the operator foot-
rests during operation to main-
tain control of the motorcycle.

The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.

Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.

Never ride under the influence of
alcohol or other drugs.

This motorcycle is designed for
on-road use only. It is not suitable
for off-road use.
Protective apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the preven-
tion or reduction of head injuries.

Always wear an approved helmet.

Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.

The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.

Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.

Never touch the engine or exhaust
system during or after operation.
They become very hot and cancause burns. Always wear protec-
tive clothing that covers your legs,
ankles, and feet.

A passenger should also observe
the above precautions.
Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the re-
moval of original equipment, may ren-
der the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your mo-
torcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your
motorcycle can adversely affect stabili-
ty and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use ex-
treme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here are some general guidelines to
follow if loading cargo or adding acces-
sories to your motorcycle:

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

10

*
Tires

Check tread depth and for damage.

Replace if necessary.

Check air pressure.

Correct if necessary.
√

√

√

√

√


11

*
Wheel bearings

Check bearing for looseness or damage.
√

√

√

√


12

*
Swingarm

Check operation and for excessive play.
√

√

√

√



Lubricate with lithium-soap-based grease. Every 50000 km
13

Drive chain

Check chain slack.

Make sure that the rear wheel is properly aligned.

Clean and lubricate.Every 1000 km and after washing the motorcycle or
riding in the rain
14

*
Steering bearings

Check bearing play and steering for roughness.
√

√

√

√

√



Lubricate with lithium-soap-based grease. Every 20000 km
15

*
Chassis fasteners

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

√

√

√

√


16

Sidestand

Check operation.

Lubricate.
√

√

√

√

√


17

*
Sidestand switch

Check operation.
√

√

√

√

√

√


18

*
Front fork

Check operation and for oil leakage.
√

√

√

√


19

*
Shock absorber assem-
bly

Check operation and shock absorber for oil leakage.
√

√

√

√


20

*
Rear suspension relay
arm and connecting arm
pivoting points

Check operation.
√

√

√

√



Lubricate with lithium-soap-based grease.
√

√


21

*
Electronic fuel injection

Adjust engine idling speed and synchronization.
√

√

√

√

√

√


22

Engine oil

Change.

Check oil level and vehicle for oil leakage.
√

√

√

√

√

√


23

Engine oil filter element

Replace.
√

√
√
24
*Cooling system
Check coolant level and vehicle for coolant leakage.√ √ √ √ √ Change. Every 3 years NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040

PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
2
3
4
5
67
8
9

with the local regulations.
WARNING

EWA10470

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.

The replacement of all wheel
and brake related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
WARNING

EWA10900

The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motorcy-
cle cannot be guaranteed.

After extensive tests, only the
tires listed below have been ap-
proved for this model by Yama-
ha Motor Co., Ltd.

Always make sure that the valvecaps are securely installed to
prevent air pressure leakage.

Use only the tire valves and
valve cores listed below to
avoid tire deflation during a ride.
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
123

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
1
2
3
4
5
6
7
8
9
WARNING

EWA10600
This motorcycle is fitted with su-
per-high-speed tires. Note the fol-
lowing points in order to make the
most efficient use of these tires.

Use only the specified replace-ment tires. Other tires may run
the danger of bursting at super
high speeds.

Brand-new tires can have a rela-
tively poor grip on certain road
surfaces until they have been
“broken in”. Therefore, it is ad-
visable before doing any
high-speed riding to ride con-
servatively for approximately
100 km (60 mi) after installing a
new tire.

The tires must be warmed up
before a high-speed run.

Always adjust the tire air pres-
sure according to the operating
conditions.
EAU21960
Cast wheels
To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.

The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.

The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.

Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
Front tire:
Size:
120/70 ZR18M/C (59W)
Manufacturer/model:
METZELER/MEZ4 FRONT
DUNLOP/D220FSTJ
Tire air valve:
TR412
Valve core:
#9000A (original)
Rear tire:
Size:
160/60 ZR17M/C (69W)
Manufacturer/model:
METZELER/MEZ4
DUNLOP/D220STJ
Tire air valve:
TR412
Valve core:
#9000A (original)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
2
3
4
5
67
8
9

EAU22760
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22770
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright po-
sition.
NOTE:

When checking and adjusting the drive
chain slack, the motorcycle should be
positioned straight up and there should
be no weight on it.
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.4. If the drive chain slack is incorrect,
adjust it as follows.
EAU22950
To adjust the drive chain slack
1. Loosen the axle nut, the brake cal-
iper bracket bolt and the locknut on
each side of the swingarm.
2. To tighten the drive chain, turn the
adjusting bolt on each side of the
swingarm in direction (a). To loos-
en the drive chain, turn the adjust-
ing bolt on each side of the
swingarm in direction (b), and then
push the rear wheel forward.
NOTE:

Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same posi- Drive chain slack:
50.0–60.0 mm (1.97–2.36 in)
1. Drive chain slack
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
1
3
4 1
2 (b)
(a)

1. Brake caliper bracket bolt
2. Brake caliper bracket
1
2