fuel YAMAHA TDM 900 2005 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
Tachometer unit ...............................3-5
Coolant temperature gauge .............3-6
Multi-function display .......................3-7
Anti-theft alarm (optional) ................3-8
Handlebar switches .........................3-8
Clutch lever ....................................3-10
Shift pedal ......................................3-10
Brake lever ....................................3-10
Brake pedal ...................................3-11
ABS (for ABS models) ...................3-11
Fuel tank cap .................................3-12
Fuel ................................................3-13
Fuel tank breather hose .................3-13
Catalytic converter .........................3-14
Seat ...............................................3-14
Storage compartment ....................3-15
Adjusting the front fork ...................3-15
Adjusting the shock absorber
assembly ....................................3-17Luggage strap holders .................. 3-18
Sidestand ...................................... 3-19
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 ....... 6-7
Coolant .......................................... 6-10
Replacing the air filter element ...... 6-12
Adjusting the engine idling
speed ......................................... 6-13
Checking the throttle cable free
play ............................................ 6-14Valve clearance ............................ 6-14
Tires .............................................. 6-15
Cast wheels .................................. 6-17
Adjusting the clutch lever free
play ............................................ 6-18
Adjusting the rear brake light
switch ......................................... 6-19
Checking the front and rear brake
pads ........................................... 6-19
Checking the brake fluid level ....... 6-20
Changing the brake fluid ............... 6-21
Drive chain slack ........................... 6-21
Cleaning and lubricating the drive
chain .......................................... 6-23
Checking and lubricating the
cables ........................................ 6-23
Checking and lubricating the throttle
grip and cable ............................ 6-24
Checking and lubricating the brake
and shift pedals ......................... 6-24
Checking and lubricating the brake
and clutch levers ........................ 6-24
Checking and lubricating the
sidestand ................................... 6-25
Lubricating the rear suspension .... 6-25
Checking the front fork .................. 6-25
Checking the steering ................... 6-26
Checking the wheel bearings ........ 6-27
Battery ........................................... 6-27
Replacing the fuses ...................... 6-28
Replacing a headlight bulb ........... 6-29

SAFETY INFORMATION
1-3
1
sure to distribute the weight as
evenly as possible on both sides of
the motorcycle to minimize imbal-
ance or instability.

Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.

Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a slow
steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re-
sponsible for the proper selection, in-
stallation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any ac-
cessories.Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.


Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.

Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.

Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-stable in cross winds. These ac-
cessories may also cause
instability when passing or being
passed by large vehicles.

Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.

Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas

GASOLINE IS HIGHLY FLAMMA-
BLE:

Always turn the engine off when
refueling.

Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.

Never refuel while smoking or in

SAFETY INFORMATION
1-4
1
the vicinity of an open flame.

Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has ad-
equate ventilation.

Always turn the engine off before
leaving the motorcycle unattended
and remove the key from the main
switch. When parking the motorcy-
cle, note the following:

The engine and exhaust system
may be hot, therefore, park the
motorcycle in a place where pe-
destrians or children are not like-
ly to touch these hot areas.

Do not park the motorcycle on a
slope or soft ground, otherwise it
may fall over.

Do not park the motorcycle near
a flammable source, (e.g., a ker-
osene heater, or near an open
flame), otherwise it could catch
fire.

When transporting the motorcyclein another vehicle, make sure that
it is kept upright. If the motorcycle
should lean over, gasoline may
leak out of the fuel tank.

If you should swallow any gaso-
line, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediate-
ly. If any gasoline spills on your
skin or clothing, immediately wash
the affected area with soap and
water and change your clothes.

INSTRUMENT AND CONTROL FUNCTIONS
3-3
2
34
5
6
7
8
9
To unlock the steering
Push the key into the main switch, and
then turn it to “OFF” while still pushing
it.
WARNING

EWA10060
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving,
otherwise the electrical systems will
be switched off, which may result in
loss of control or an accident. Make
sure that the vehicle is stopped be-
fore turning the key to “OFF” or
“LOCK”.
EAU33000
(Parking)
The steering is locked, and the taillight
and auxiliary light are on. The hazard
light and turn signal lights can be turned
on, but all other electrical systems are
off. The key can be removed.
The steering must be locked before the
key can be turned to “ ”.
CAUTION:

ECA11020
Do not use the parking position for
an extended length of time, other-
wise the battery may discharge.
EAU11002
Indicator and warning lights
EAU11020
Turn signal indicator light “”
This indicator light flashes when the
turn signal switch is pushed to the left or
right.
1. Push.
2. Turn.
1. Fuel level warning indicator “ ”
2. Turn signal indicator light “ ”
3. High beam indicator light “ ”
4. Neutral indicator light “ ”
5. Engine trouble warning light “ ”
6. Anti-lock Brake System (ABS) warning
light “ ” (for ABS models)
7. Oil level warning light “ ”
8. Immobilizer system indicator light “ ”
12345678
ABS

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

EAU11060
Neutral indicator light “”
This indicator light comes on when the
transmission is in the neutral position.
EAU11080
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU11120
Oil level warning light “”
This warning light comes on when the
engine oil level is low.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
NOTE:

Even if the oil level is sufficient, the
warning light may flicker when riding on
a slope or during sudden acceleration
or deceleration, but this is not a mal-
function.
EAU11371
Fuel level warning indicator “”
This fuel level warning indicator starts
flashing when the fuel level drops be-
low approximately 3.5 L (0.92 US gal)
(0.77 Imp.gal).
EAU11500
Engine trouble warning light “”
This warning light comes on or flashes
when an electrical circuit monitoring the
engine is defective. When this occurs,
have a Yamaha dealer check the
self-diagnosis system.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. If the warning light does not come
on for a few seconds, then go off, have
a Yamaha dealer check the electrical
circuit.
EAU11543
ABS warning light “” (for ABS
models)
If this warning light comes on or flashes
while riding, the ABS may be defective.
If this occurs, have a Yamaha dealer
check the system as soon as possible.
(See page 3-11.)
WARNING

EWA10081
If the ABS warning light comes on or
flashes while riding, the brake sys-
tem reverts to conventional braking.
Therefore, be careful not to cause
the wheels to lock during emergen-
cy braking. If the warning light
comes on or flashes while riding,
have a Yamaha dealer check the
brake system as soon as possible.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on or
remains on, have a Yamaha dealer
check the electrical circuit.
EAU32990
Immobilizer system indicator light
“”
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
ABS

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

EAU36610
Multi-function display
WARNING

EWA12311
Be sure to stop the vehicle before
making any setting changes to the
multi-function display.
The multi-function display is equipped
with the following:

a digital speedometer (which
shows riding speed)

an odometer (which shows the to-
tal distance traveled)

two tripmeters (which show the
distance traveled since they were
last set to zero)

a fuel reserve tripmeter (which
shows the distance traveled on the
fuel reserve)

a fuel gauge

a self-diagnosis device
NOTE:


Be sure to turn the key to “ON” be-
fore using the “SELECT” and “RE-
SET” buttons.

For the U.K. only: To switch the
speedometer and odometer/trip-
meter displays between kilometers
and miles, press the “SELECT”
button for at least one second.
Odometer and tripmeter modes
Pushing the “SELECT” button switches
the display between the odometer
mode “ODO” and the tripmeter modes
“TRIP 1” and “TRIP 2” in the following
order:
ODO
→
TRIP 1
→
TRIP 2
→
ODO
If the fuel level warning indicator flash-
es (see page 3-3), the odometer dis-
play will automatically change to the
fuel reserve tripmeter mode “TRIP F”and start counting the distance traveled
from that point. In that case, pushing
the “SELECT” button switches the dis-
play between the various tripmeter and
odometer modes in the following order:
TRIP F
→
TRIP 1
→
TRIP 2
→
ODO
→
TRIP F
To reset a tripmeter, select it by push-
ing the “SELECT” button, and then
push the “RESET” button for at least
one second. If you do not reset the fuel
reserve tripmeter manually, it will reset
itself automatically and the display will
return to the prior mode after refueling
and traveling 5 km (3 mi).
NOTE:

The display cannot be changed back to
“TRIP F” after pushing the “RESET”
button.
Fuel gauge
The fuel gauge indicates the amount of
fuel in the fuel tank. The display seg-
ments of the fuel gauge disappear to-
wards “E” (Empty) as the fuel level
decreases. When only one segment is
left near “E”, the fuel level warning indi-
cator and the last fuel gauge segment
will flash. Refuel as soon as possible.
1. Speedometer
2. Odometer/tripmeter
3. “SELECT” button
4. “RESET” button
5. Fuel gauge
1
2
3
4
5

INSTRUMENT AND CONTROL FUNCTIONS
3-12
1
2
3
4
5
6
7
8
9
allows the owner to experience the
pulsating at the brake lever or
brake pedal when the ABS is oper-
ating. However, special tools are
required, so please consult your
Yamaha dealer when performing

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

INSTRUMENT AND CONTROL FUNCTIONS
3-13
2
34
5
6
7
8
9

EAU13210
Fuel
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
WARNING

EWA10880

Do not overfill the fuel tank, oth-
erwise it may overflow when the
fuel warms up and expands.

Avoid spilling fuel on the hot en-
gine.
CAUTION:

ECA10070
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, sincefuel may deteriorate painted surfac-
es or plastic parts.
EAU13320
CAUTION:

ECA11400
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.
EAU13410
Fuel tank breather hose
Before operating the motorcycle:

Check the fuel tank breather hose
connection.

Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.

Make sure that the end of the fuel
tank breather hose is not blocked,
and clean it if necessary.
1. Fuel tank filler tube
2. Fuel level
1 2

Recommended fuel:
REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity:
20.0 L (5.28 US gal) (4.40 Imp.gal)
Fuel reserve amount:
3.5 L (0.92 US gal) (0.77 Imp.gal)
1. Fuel tank breather hose
1

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

EAU15603
Pre-operation check list
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.3-13
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.6-19, 6-20
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.6-19, 6-20
Clutch

Check operation.

Lubricate cable if necessary.

Check lever free play.

Adjust if necessary.6-18

OPERATION AND IMPORTANT RIDING POINTS
5-3
1
2
3
4
5
6
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.
EAU17100
0–1000 km (0–600 mi)
Avoid prolonged operation above
4000 r/min.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above
6000 r/min.
CAUTION:

ECA11150
After 1000 km (600 mi) of operation,
the engine oil must be changed, and
the oil filter element replaced.1600 km (1000 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.