warning YAMAHA TDM 900 2004 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
1
2
3
4
5
6
7
8
9
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 besufficiently 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.
15. Install the radiator cap, start the
engine, let it idle for several min-
utes, and then turn it off.
16. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radia-
tor, and then install the radiator
cap and the cap retaining bolt.
17. Check the coolant level in the res-
ervoir. If necessary, remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the cap.
18. Install the fuel tank.
WARNING

EWA11290

Before installing the fuel tank,
make sure that the fuel hoses
are not damaged. If any fuel
hose is damaged, do not start
the engine but have a Yamaha
dealer replace the hose, other-
wise fuel may leak.

Make sure that the fuel hoses
are properly connected and
routed, and not pinched.

Be sure to place the fuel tank
breather hose in the original po-
sition.
19. Install the panel, the cowling, and
the seat.
20. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system. Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol
antifreeze containing corro-
sion inhibitors for aluminum
engines
Coolant quantity:
Radiator capacity (including all
routes):
1.70 L (1.80 US qt)
(1.50 Imp.qt)
Coolant reservoir capacity:
0.25 L (0.26 US qt)
(0.22 Imp.qt)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
2
3
4
5
67
8
9

EAU27050
Replacing the air filter element
The air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the seat. (See
page 3-13.)
2. Remove cowlings A and B as well
as panels A and B. (See
page 6-5.)
3. Remove the fuel tank bolts, and
then lift the fuel tank away from the
air filter case.4. Remove the air filter case cover by
removing the screws.
5. Pull the air filter element out.
6. Insert a new air filter element into
the air filter case.
CAUTION:

ECA10480

Make sure that the air filter ele-
ment is properly seated in the
air filter case.

The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
7. Install the air filter case cover by in-
stalling the screws.
8. Place the fuel tank in the original
position and install the bolts.
WARNING

EWA11330

Before installing the fuel tank,
make sure that the fuel hoses
are not damaged. If any fuel
hose is damaged, do not start
the engine but have a Yamaha
dealer replace the hose, other-
wise fuel may leak.

Make sure that the fuel hoses
are properly connected and
1. Bolt
1(×2)

1. Air filter case cover
2. Screw
1. Air filter element
1 2
2 2
(×8)
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
2
3
4
5
67
8
9

EAU21380
Adjusting the throttle cable
free play
The throttle cable free play should mea-
sure 3.0–5.0 mm (0.12–0.20 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, have a Yamaha dealer adjust it.
EAU21400
Adjusting the valve clearance
The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU33040
Tires
To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING

EWA10500

The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).

The tire air pressure must be ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
1. Throttle cable free play
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
1
2
3
4
5
6
7
8
9
WARNING

EWA11020
Because loading has an enormous
impact on the handling, braking,
performance and safety characteris-
tics of your motorcycle, you shouldkeep the following precautions in
mind.

NEVER OVERLOAD THE MO-
TORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider,
passenger, cargo, and accesso-
ries does not exceed the speci-
fied maximum load for the
vehicle.

Do not carry along loosely
packed items, which can shift
during a ride.

Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.

Adjust the suspension and tire
air pressure with regard to the
load.

Check the tire condition and air
pressure before each ride.Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
NOTE:

The tire tread depth limits may differ
from country to country. Always comply
Tire air pressure (measured on
cold tires):
0–90 kg (0–198 lb) :
Front:
225 kPa (33 psi) (2.25 kgf/cm
2
)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2
)
90–203 kg (198–448 lb) :
Front:
225 kPa (33 psi) (2.25 kgf/cm
2
)
Rear:
290 kPa (42 psi) (2.90 kgf/cm
2
)
High-speed riding:
Front:
225 kPa (33 psi) (2.25 kgf/cm
2
)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2
)
Maximum load*:
203 kg (448 lb)
* Total weight of rider, passenger,
cargo and accessories
1. Tire tread depth
2. Tire sidewall
Minimum tire tread depth (front
and rear):
1.6 mm (0.06 in)
21

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
6-21
1
2
3
4
5
6
7
8
9

EAU22240
Adjusting the brake pedal
position
The top of the brake pedal should be
positioned approximately 32.0 mm
(1.26 in) below the top of the footrest as
shown. Periodically check the brake
pedal position and, if necessary, have a
Yamaha dealer adjust it.
WARNING

EWA10690
A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there is
air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air inthe hydraulic system will diminish
the braking performance, which may
result in loss of control and an acci-
dent.
EAU22270
Adjusting the rear brake light
switch
The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction (a). To
make the brake light come on later, turn
the adjusting nut in direction (b).
1. Distance between brake pedal and footrest
1

1. Rear brake light switch
2. Rear brake light switch adjusting nut
1
2 (a)(b)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
2
3
4
5
67
8
9

EAU23100
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING

EWA10720
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.
EAU23110
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.
EAU23131
Checking and lubricating the
brake and shift pedals
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary. Recommended lubricant:
Engine oil
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
1
2
3
4
5
6
7
8
9

EAU23140
Checking and lubricating the
brake and clutch levers
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
EAU23200
Checking and lubricating the
sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
WARNING

EWA10730
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
EAU23250
Lubricating the rear
suspension
The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
2
3
4
5
67
8
9

EAU23271
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:

ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.