brake YAMAHA TDM 900 2008 User Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU1770A
Periodic maintenance and lubrication chart
NOTE:


The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.

From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).

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
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
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 (24000 mi)
4
Air filter element

Replace.
√
5
Clutch

Check operation.

Adjust.
√√√√√
6*
Front brake

Check operation, fluid level
and vehicle for fluid leakage.
√√√√√√

Replace brake pads. Whenever worn to the limit
7*
Rear brake

Check operation, fluid level
and vehicle for fluid leakage.
√√√√√√

Replace brake pads. Whenever worn to the limit
8*
Brake hoses

Check for cracks or damage.
√√√√√

Replace. Every 4 years

PERIODIC MAINTENANCE AND MINOR REPAIR
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9*
Wheels

Check runout and for damage.
√√√√
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 exces-
sive play.
√√√√

Lubricate with lith-
ium-soap-based grease.Every 50000 km (30000 mi)
13

Drive chain

Check chain slack, alignment
and condition.

Adjust and lubricate chain with
a special O-ring chain lubricant
thoroughly.Every 1000 km (600 mi) and after washing the motorcycle or riding in the rain
14

*
Steering bearings

Check bearing play and steer-
ing for roughness.
√√√√√

Lubricate with lith-
ium-soap-based grease.Every 20000 km (12000 mi)
15

*
Chassis fasteners

Make sure that all nuts, bolts
and screws are properly tight-
ened.
√√√√√
16

Brake lever pivot
shaft

Lubricate with silicone grease.
√√√√√
17

Brake pedal pivot
shaft

Lubricate with lith-
ium-soap-based grease.
√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)

PERIODIC MAINTENANCE AND MINOR REPAIR
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18

Clutch lever pivot
shaft

Lubricate with lith-
ium-soap-based grease.
√√√√√
19

Shift pedal pivot
shaft

Lubricate with lith-
ium-soap-based grease.
√√√√√
20

Sidestand

Check operation.

Lubricate.
√√√√√
21

*
Sidestand switch

Check operation.
√√√√√√
22

*
Front fork

Check operation and for oil
leakage.
√√√√
23

*
Shock absorber
assembly

Check operation and shock
absorber for oil leakage.
√√√√
24

*
Rear suspension
relay arm and con-
necting arm pivoting
points

Check operation.
√√√√

Lubricate with lith-
ium-soap-based grease.
√√
25

*
Fuel injection

Adjust engine idling speed and
synchronization.
√√√√√√
26

Engine oil

Change.

Check oil level and vehicle for
oil leakage.
√√√√√√
27

Engine oil filter ele-
ment

Replace.
√√√
28

*
Cooling system

Check coolant level and vehi-
cle for coolant leakage.
√√√√√

Change. Every 3 years
29

*
Front and rear brake
switches

Check operation.
√√√√√√
30

Moving parts and
cables

Lubricate.
√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU18680
NOTE:


Air filter

This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed air to avoid damaging it.

The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.

Replace the brake hoses every four years and if cracked or damaged.
31

*
Throttle grip hous-
ing and cable

Check operation and free play.

Adjust the throttle cable free
play if necessary.

Lubricate the throttle grip
housing and cable.
√√√√√
32

*
Air induction system

Check the air cut-off valve,
reed valve, and hose for dam-
age.

Replace the entire air induction
system if necessary.
√√√√√
33

*
Muffler and exhaust
pipe

Check the screw clamp for
looseness.
√√√√√
34

*
Lights, signals and
switches

Check operation.

Adjust headlight beam.
√√√√√√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU42350
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 3-14.)
2. Remove cowlings A and B as well
as panels A and B. (See
page 6-6.)
3. Remove the fuel tank bolts.
4. Remove the rear brake fluid reser-
voir holder by removing the bolt,
and then lift the fuel tank awayfrom the air filter case. (Do not dis-
connect the fuel hoses!)
WARNING

EWA10410

Make sure that the fuel tank is
well supported.

Do not tilt or pull the fuel tank
too much, otherwise the fuel
hoses may come loose, which
could cause fuel leakage.
5. Remove the air filter case cover by
removing the screws.6. Pull the air filter element out.
7. Insert a new air filter element into
the air filter case.
1. Bolt
1

1. Rear brake fluid reservoir holder
2. Rear brake fluid reservoir
3. Bolt
12
3

1. Air filter case cover
2. Screw
1. Air filter element
1 2
2 21

PERIODIC MAINTENANCE AND MINOR REPAIR
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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.
8. Install the air filter case cover by in-
stalling the screws.
9. 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
routed, and not pinched.

Be sure to place the fuel tank
breather hose and the fuel tankoverflow hose in the original po-
sition.
10. Install the rear brake fluid reservoir
holder by installing the bolt.11. Install the panels and cowlings.
12. Install the seat.
1. Fuel tank breather/overflow hose
2. Fuel hose
1. Original position (paint mark)
12
1

PERIODIC MAINTENANCE AND MINOR REPAIR
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9 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
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.
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
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ver free play, turn the adjusting nut
in direction (b).
6. Tighten the locknut at the clutch le-
ver and the crankcase.

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).
EAU22390
Checking the front and rear
brake pads
The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22420
Front brake pads
Each front brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wear
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1
2 (a)(b)

1. Brake pad wear indicator groove
1

PERIODIC MAINTENANCE AND MINOR REPAIR
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indicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.

EAU22500
Rear brake pads
Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 0.8 mm (0.03 in),
have a Yamaha dealer replace the
brake pads as a set.
EAU36680
Checking the brake fluid level
Front brake
Rear brake
Insufficient brake fluid may allow air toenter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
NOTE:

The rear brake fluid reservoir is located
under the seat. (See page 3-14.)
Observe these precautions:

When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.

Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.

Refill with the same type of brake
fluid. Mixing fluids may result in a
1. Lining thickness
1

1. Minimum level mark
1. Minimum level mark
1
1

Recommended brake fluid:
DOT 4

PERIODIC MAINTENANCE AND MINOR REPAIR
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harmful chemical reaction and
lead to poor braking performance.


Be careful that water or dust does
not enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of the
fluid and may result in vapor lock,
and dirt may clog the ABS hydrau-
lic unit valves.

Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.

As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22730
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

Oil seals: Replace every two
years.

Brake hoses: Replace every four
years.
EAU22760
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22773
To check the drive chain slack
1. Place the motorcycle on the side-
stand.
NOTE:

When checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.
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.
Drive chain slack:
50.0–60.0 mm (1.97–2.36 in)