warning YAMAHA TDM 900 2005 Owners Manual

IMPORTANT MANUAL INFORMATION
EAU10150
Particularly important information is distinguished in this manual by the following notations:
NOTE:


This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle
is subsequently sold.

Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most
current product information available at the time of printing, there may be minor discrepancies between your motorcycle
and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
WARNING

EWA10030
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in se
vere injur
y or death
to the
motorcycle operator, a bystander, or a person inspecting or repairing the motorcy-
cle.
A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:NOTE:

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

1-1
1
SAFETY INFORMATION
EAU10281
MOTORCYCLES ARE SINGLE
TRACK VEHICLES. THEIR SAFE
USE AND OPERATION ARE DEPEN-
DENT UPON THE USE OF PROPER
RIDING TECHNIQUES AS WELL AS
THE EXPERTISE OF THE OPERA-
TOR. EVERY OPERATOR SHOULD
KNOW THE FOLLOWING REQUIRE-
MENTS BEFORE RIDING THIS MO-
TORCYCLE.
HE OR SHE SHOULD:

OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.

OBSERVE THE WARNINGS
AND MAINTENANCE REQUIRE-
MENTS IN THE OWNER’S MAN-
UAL.

OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.

OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECES-
SARY BY MECHANICAL CONDI-
TIONS.
Safe riding

Always make pre-operation
checks. Careful checks may help
prevent an accident.

This motorcycle is designed to car-
ry the operator and a passenger.

The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.

Therefore:

Wear a brightly colored jacket.

Use extra caution when you are
approaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur.

Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.

Many accidents involve inexperi-enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent motorcycle license.

Make sure that you are qualified
and that you only lend your mo-
torcycle to other qualified opera-
tors.

Know your skills and limits.
Staying within your limits may
help you to avoid an accident.

We recommend that you prac-
tice riding your motorcycle
where there is no traffic until you
have become thoroughly famil-
iar with the motorcycle and all of
its controls.

Many accidents have been caused
by error of the motorcycle opera-
tor. A typical error made by the op-
erator is veering wide on a turn
due to EXCESSIVE SPEED or un-
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

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
3-11
2
34
5
6
7
8
9
dial is aligned with the “” mark on the
brake lever.

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.
EAU26792
ABS (for ABS models)
The Yamaha ABS (Anti-lock Brake
System) features a dual electronic con-
trol system, which acts on the front and
rear brakes independently. The ABS is
monitored by an ECU (Electronic Con-
trol Unit), which will have recourse to
manual braking if a malfunction occurs.
WARNING

EWA10090

The ABS performs best on long
braking distances.

On certain (rough or gravel)
roads, the braking distance may
be longer with than without the
ABS. Therefore, always keep a
sufficient distance to the vehi-
cle ahead to match the riding
speed.
NOTE:


When the ABS is activated, the
brakes are operated in the usual
way. A pulsating action may be felt
at the brake lever or brake pedal,
but this does not indicate a mal-
function.

This ABS has a test mode which
1. Brake pedal
1

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

INSTRUMENT AND CONTROL FUNCTIONS
3-14
1
2
3
4
5
6
7
8
9

EAU13441
Catalytic converter
This vehicle is equipped with catalytic
converters in the exhaust system.
WARNING

EWA10860
The exhaust system is hot after op-
eration. Make sure that the exhaust
system has cooled down before do-
ing any maintenance work.
CAUTION:

ECA10700
The following precautions must be
observed to prevent a fire hazard or
other damages.

Use only unleaded gasoline.
The use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.

Never park the vehicle near pos-
sible fire hazards such as grass
or other materials that easily
burn.

Do not allow the engine to idle
too long.
EAU13860
Seat
To remove the seat
Insert the key into the seat lock, turn it
counterclockwise, and then pull the
seat off.
To install the seat
Insert the projections on the front of the
seat into the seat holder, push the rear
of the seat down to lock it in place, and
then remove the key.
NOTE:

Make sure that the seat is properly se-
cured before riding.
1. Seat lock
2. Unlock.1
2

1. Projection
2. Seat holder
1
2