ABS YAMAHA TDM 900 2004 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2004, Model line: TDM 900, Model: YAMAHA TDM 900 2004Pages: 92, PDF Size: 4.5 MB
Page 6 of 92
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
Page 12 of 92
2-1
1
2
3
4
5
6
7
8
9
DESCRIPTION
EAU10410
Left view
12
345678
9 9 10 11 12 13 1412
345678
9 9 10 11 12 13 14
1. Front fork spring preload adjusting bolt (page 3-15)
2. Front fork damping adjusting screw (page 3-15)
3. Air filter element (page 6-14)
4. Shock absorber assembly compression damping force adjusting
knob (page 3-16)
5. Battery (page 6-29)
6. Fuses (page 6-30)
7. Storage compartment (page 3-14)8. Grab bar
9. Luggage strap holder (page 3-18)
10. Seat lock (page 3-13)
11. Shock absorber assembly rebound damping force adjusting knob
(page 3-16)
12. Shock absorber assembly spring preload adjusting ring (page 3-16)
13. Shift pedal (page 3-10)
14. Engine oil drain bolt A (page 6-7)
Page 30 of 92
INSTRUMENT AND CONTROL FUNCTIONS
3-16
1
2
3
4
5
6
7
8
9
setting.
NOTE:
Make sure that the adjusting screw is
turned to one of the four settings.
EAU15030
Adjusting the shock absorber
assembly
This shock absorber assembly is
equipped with a spring preload adjust-
ing ring and rebound and compression
damping force adjusting knobs.
CAUTION:
ECA10100
Never attempt to turn an adjusting
mechanism beyond the maximum or
minimum settings.
Spring preload
To increase the spring preload and
thereby harden the suspension, turnthe adjusting ring in direction (a). To de-
crease the spring preload and thereby
soften the suspension, turn the adjust-
ing ring in direction (b).
Rebound damping force
To increase the rebound damping force
and thereby harden the rebound damp-
ing, turn the adjusting knob in direction
Damping setting:
Minimum (soft):
1
Standard:
2
Maximum (hard):
4
1. Spring preload adjusting ring
2. Special wrench
3. Position indicator
(a) (b)3
1
2
1 2 3 4 5 6 7 8 9
Spring preload setting:
Minimum (soft):
1
Standard:
5
Maximum (hard):
9
1. Rebound damping force adjusting knob
1
(a)
(b)
Page 31 of 92
INSTRUMENT AND CONTROL FUNCTIONS
3-17
2
34
5
6
7
8
9
(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)
Page 44 of 92
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
Page 83 of 92
MOTORCYCLE CARE AND STORAGE
7-2
2
3
4
5
6
78
9 any marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:
Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the motorcycle with cold wa-ter and a mild detergent, after the
engine has cooled down.
CAUTION:
ECA10790
Do not use warm water since it in-
creases the corrosive action of the
salt.
2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick-
el-plated, surfaces to prevent cor-
rosion.
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stain-
less-steel parts, including the ex-
haust system. (Even the thermally
induced discoloring of stain-
less-steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recom-mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
WARNING
EWA10930
Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent.
Before operating the motorcy-
cle test its braking performance
and cornering behavior.
Page 87 of 92
SPECIFICATIONS
8-2
2
3
4
5
6
7
89
Operation:
Left foot operation
Gear ratio:
1st:
33/12 (2.750)
2nd:
37/19 (1.947)
3rd:
34/22 (1.545)
4th:
31/25 (1.240)
5th:
26/25 (1.040)
6th:
24/26 (0.923)
Chassis:
Frame type:
Diamond
Caster angle:
25.5 °
Trail:
114.0 mm (4.49 in)
Front tire:
Type:
Tubeless
Size:
120/70 ZR18M/C (59W)
Manufacturer/model:
METZELER/MEZ4 FRONT
Manufacturer/model:
DUNLOP/D220FSTJ
Rear tire:
Type:
Tubeless
Size:
160/60 ZR17M/C (69W)
Manufacturer/model:
METZELER/MEZ4
Manufacturer/model:
DUNLOP/D220STJ
Loading:
Maximum load:
203 kg (448 lb)
(Total weight of rider, passenger, cargo
and accessories)
Tire air pressure (measured on cold
tires):
Loading condition:
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
)
Loading condition:
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
)
Front wheel:
Wheel type:
Cast wheel
Rim size:
18M/C x MT3.50
Rear wheel:
Wheel type:
Cast wheel
Rim size:
17M/C x MT5.00
Front brake:
Type:
Dual disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:
Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
150.0 mm (5.91 in)
Page 88 of 92
SPECIFICATIONS
8-3
1
2
3
4
5
6
7
8
9Rear suspension:
Type:
Swingarm (link suspension)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
133.0 mm (5.24 in)
Electrical system:
Ignition system:
Transistorized coil ignition (digital)
Charging system:
A.C. magneto
Battery:
Model:
GT12B-4
Voltage, capacity:
12 V, 10.0 Ah
Headlight:
Bulb type:
Halogen bulb
Bulb voltage, wattage x quantity:
Headlight:
12 V, 55.0 W
×
2
Tail/brake light:
12 V, 5 W/21.0 W
×
1
Front turn signal light:
12 V, 10.0 W
×
2
Rear turn signal light:
12 V, 10.0 W
×
2
Auxiliary light:
12 V, 5.0 W
×
1
Meter lighting:
14 V, 2.0 W
×
2 Neutral indicator light:
14 V, 1.2 W
×
1
High beam indicator light:
14 V, 1.4 W
×
1
Oil level warning light:
LED
Turn signal indicator light:
14 V, 1.2 W
×
2
Engine trouble warning light:
14 V, 1.4 W
×
1
Immobilizer system indicator light:
LED
Fuses:
Main fuse:
40.0 A
Headlight fuse:
15.0 A
Signaling system fuse:
10.0 A
Ignition fuse:
10.0 A
Radiator fan fuse:
20.0 A
Turn signal light and hazard fuse:
10.0 A
Electronic fuel injection fuse:
10.0 A
Backup fuse:
5.0 A