lock YAMAHA TDM 900 2008 User Guide

INSTRUMENT AND CONTROL FUNCTIONS
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EAU13412
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 fuel tank
breather hose is not blocked, and
clean it if necessary.
EAU13442
Catalytic converters
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.
EAU13861
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 holders, push the rear
of the seat down to lock it in place, and
then remove the key.

1. Fuel tank breather hose
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1. Seat lock
2. Unlock.
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INSTRUMENT AND CONTROL FUNCTIONS
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NOTE:

Make sure that the seat is properly se-
cured before riding.
EAU14412
Storage compartment
This storage compartment is designed
to hold an optional genuine Yamaha
CYCLELOK. (Other locks may not fit.)
When placing a CYCLELOK in the stor-
age compartment, securely fasten it
with the straps. When the CYCLELOK
is not in the storage compartment, be
sure to secure the straps to prevent los-
ing them.
When storing the owner’s manual or
other documents in the storage com-
partment, be sure to wrap them in a
plastic bag so that they will not get wet.When washing the motorcycle, be
careful not to let any water enter the
storage compartment.
1. Projection
2. Seat holder
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1. Yamaha CYCLELOK (optional)
2. Strap
3. CYCLELOK bar (optional)
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PERIODIC MAINTENANCE AND MINOR REPAIR
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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.
EAU22041
Adjusting the clutch lever free
play
The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the clutch le-
ver.
2. To increase the clutch lever free
play, turn the adjusting bolt in di-
rection (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).
NOTE:

If the specified clutch lever free play
could be obtained as described above,
tighten the locknut and skip the rest of
the procedure, otherwise proceed as
follows.
3. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loos-
en the clutch cable.
4. Loosen the locknut at the crank-
case.
5. To increase the clutch lever free
play, turn the adjusting nut in direc-
tion (a). To decrease the clutch le-
1. Locknut (clutch lever)
2. Clutch lever free play adjusting bolt
3. Clutch lever free play
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(a)
(b)

1. Locknut (crankcase)
2. Clutch lever free play adjusting nut
(crankcase)
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(a)(b)

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
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1. Brake pad wear indicator groove
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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)

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4. If the drive chain slack is incorrect,
adjust it as follows.

EAU22951
To adjust the drive chain slack
1. Loosen the axle nut, the brake cal-
iper bracket bolt and the locknut on
each side of the swingarm.
2. To tighten the drive chain, turn the
adjusting bolt on each side of theswingarm in direction (a). To loos-
en the drive chain, turn the adjust-
ing bolt on each side of the
swingarm in direction (b), and then
push the rear wheel forward.
NOTE:

Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same posi-
tion for proper wheel alignment.
CAUTION:

ECA10570
Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.
3. Tighten the locknuts, and then
tighten the axle nut and the brake
caliper bracket bolt to the specified
torques.
1. Drive chain slack
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1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
1. Brake caliper bracket bolt
2. Brake caliper bracket3
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2 (b)
(a)
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EAU23624
Replacing the fuses
The main fuse and the fuse box, which
contains the fuses for the individual cir-
cuits, are located under the seat. (See
page 3-14.)
If a fuse is blown, replace it as follows.1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
CAUTION:

ECA10640
Do not use a fuse of a higher amper-
age rating than recommended toavoid causing extensive damage to
the electrical system and possibly a
fire.
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
1. Backup fuse (for odometer and clock)
2. Radiator fan fuse
3. Turn signal light and hazard fuse
4. Ignition fuse
5. Signaling system fuse
6. Headlight fuse
7. ABS motor fuse
8. ABS motor spare fuse
9. Main fuse
10. Spare fuse
11. Fuel injection system fuse
12. ABS control unit fuse
12 34 5 6 7 8 911 12
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Specified fuses:
Main fuse:
40.0 A
Headlight fuse:
20.0 A
Radiator fan fuse:
20.0 A
Ignition fuse:
10.0 A
Signaling system fuse:
10.0 A
Backup fuse:
10.0 A
Fuel injection system fuse:
10.0 A
Turn signal light and hazard fuse:
10.0 A
ABS motor fuse:
30.0 A
ABS control unit fuse:
10.0 A

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU24080
Replacing the tail/brake light
bulb
1. Remove the seat. (See
page 3-14.)
2. Remove the socket (together with
the bulb) by turning it counter-
clockwise.
3. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
4. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
5. Install the socket (together with the
bulb) by turning it clockwise.
6. Install the seat.
EAU24202
Replacing a turn signal light
bulb
1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
CAUTION:

ECA11190
Do not overtighten the screw, other-
wise the lens may break.
1. Socket
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1. Screw
2. Turn signal light lens
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1. Turn signal light bulb
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9Engine overheating
WARNING

EWA10400

Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.

After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing
sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
NOTE:

If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible.
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See NOTE.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.

INDEX
A
ABS ......................................................... 3-12
ABS warning light...................................... 3-4
Air filter element, replacing ..................... 6-13
Anti-theft alarm (optional).......................... 3-8
Auxiliary light bulb, replacing .................. 6-33
B
Battery..................................................... 6-28
Brake and clutch levers, checking and
lubricating ............................................. 6-26
Brake and shift pedals, checking and
lubricating ............................................. 6-25
Brake fluid, changing .............................. 6-22
Brake fluid level, checking ...................... 6-21
Brake lever .............................................. 3-11
Brake pedal ............................................. 3-11
C
Cables, checking and lubricating ............ 6-25
Care .......................................................... 7-1
Catalytic converters ................................ 3-14
Clutch lever ............................................. 3-10
Clutch lever free play, adjusting .............. 6-19
Coolant.................................................... 6-11
Coolant temperature gauge ...................... 3-6
Cowlings and panels, removing and
installing.................................................. 6-6
D
Dimmer switch .......................................... 3-9
Drive chain, cleaning and lubricating ...... 6-24
Drive chain slack ..................................... 6-22
E
Engine break-in ......................................... 5-3
Engine idling speed................................. 6-15
Engine oil and oil filter element ................. 6-8Engine stop switch .....................................3-9
Engine trouble warning light ......................3-4
F
Front and rear brake pads, checking .......6-20
Front fork, adjusting .................................3-16
Front fork, checking .................................6-27
Fuel ..........................................................3-13
Fuel consumption, tips for reducing ...........5-3
Fuel level warning indicator .......................3-4
Fuel tank breather hose ...........................3-14
Fuel tank cap ...........................................3-12
Fuses, replacing ......................................6-30
H
Handlebar switches ...................................3-9
Hazard switch ..........................................3-10
Headlight bulb, replacing .........................6-31
High beam indicator light ...........................3-4
Horn switch ................................................3-9
I
Identification numbers................................9-1
Ignition circuit cut-off system ...................3-20
Immobilizer system ....................................3-1
Immobilizer system indicator light ..............3-5
Indicator and warning lights .......................3-4
K
Key identification number ..........................9-1
L
Luggage strap holders .............................3-19
M
Main switch/steering lock ...........................3-2
Matte color, caution ...................................7-1
Model label ................................................9-2
Multi-function display .................................3-7
N
Neutral indicator light................................. 3-4
O
Oil level warning light ................................ 3-4
P
Parking ...................................................... 5-4
Part locations............................................. 2-1
Pass switch ............................................... 3-9
Periodic maintenance and lubrication
chart ........................................................ 6-2
Pre-operation check list ............................. 4-2
R
Rear brake light switch, adjusting............ 6-20
Rear suspension, lubricating ................... 6-26
S
Safety information ..................................... 1-1
Seat ......................................................... 3-14
Shifting ...................................................... 5-2
Shift pedal ............................................... 3-10
Shock absorber assembly, adjusting....... 3-17
Sidestand ................................................ 3-19
Sidestand, checking and lubricating ........ 6-26
Spark plugs, checking ............................... 6-7
Specifications ............................................ 8-1
Starting the engine .................................... 5-1
Start switch ................................................ 3-9
Steering, checking ................................... 6-27
Storage ...................................................... 7-3
Storage compartment .............................. 3-15
Supporting the motorcycle....................... 6-33
T
Tachometer unit ........................................ 3-6
Tail/brake light bulb, replacing................. 6-32
Throttle cable free play, checking............ 6-15