engine YAMAHA TDM 900 2008 Owner's Manual

OPERATION AND IMPORTANT RIDING POINTS
5-2
1
2
3
4
5
6
7
8
9
CAUTION:

ECA11040
For maximum engine life, never ac-
celerate hard when the engine is
cold!
EAU16671
Shifting
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.
NOTE:

To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
CAUTION:

ECA10260

Even with the transmission inthe neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.

Always use the clutch while
changing gears to avoid damag-
ing the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
1. Shift pedal
2. Neutral position
1
1 2 3
4 5 6
N2

OPERATION AND IMPORTANT RIDING POINTS
5-3
2
3
4
56
7
8
9

EAU16810
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Shift up swiftly, and avoid high en-
gine speeds during acceleration.

Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.

Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16841
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17100
0–1000 km (0–600 mi)
Avoid prolonged operation above 4000
r/min.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 6000
r/min.
CAUTION:

ECA11150
After 1000 km (600 mi) of operation,the engine oil must be changed, and
the oil filter element replaced.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
CAUTION:

ECA10310

Keep the engine speed out of
the tachometer red zone.

If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-
cle.

OPERATION AND IMPORTANT RIDING POINTS
5-4
1
2
3
4
5
6
7
8
9

EAU17212
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
WARNING

EWA10310

Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.

Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
CAUTION:

ECA10380
Never park in an area where there
are fire hazards such as grass or
other flammable materials.

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

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
6-7
2
3
4
5
67
8
9
To install the cowling
Place the cowling in the original posi-
tion, and then install the screws and the
quick fastener.NOTE:

To install the quick fastener, push the
center pin out so that it will protrude
from the fastener head, insert the fas-
tener into the cowling, and then push
the protruding pin in until it is flush with
the fastener head.
EAU19171
Panels A and B
To remove one of the panels
1. Remove the corresponding cowl-
ing A or B. (See page 6-6.)
2. Remove the seat. (See
page 3-14.)
3. Remove the screw, and then take
the panel off.To install the panel
1. Place the panel in the original po-
sition, and then install the screw.
2. Install the seat and the cowling.

EAU19642
Checking the spark plugs
The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal color
when the vehicle is ridden normally),
and all spark plugs installed in the en-
gine should have the same color. If any
spark plug shows a distinctly different
color, the engine could be operating im-
properly. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the vehicle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.
1. Screw
1. Panel A
1
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
1
2
3
4
5
6
7
8
9
Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
NOTE:

If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
EAU19832
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:

Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.
2. Start the engine, warm it up for 15
minutes, and then turn it off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in and with the arrow
mark pointing upward as shown),
and then remove it again to check
Specified spark plug:
NGK/DPR8EA-9
DENSO/X24EPR-U9
1. Spark plug gap
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
1

Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.7 ft·lbf)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
2
3
4
5
67
8
9
the oil level.
NOTE:

The engine oil should be between the
minimum and maximum level marks.
CAUTION:

ECA10010
Do not operate the vehicle until you
know that the engine oil level is suf-
ficient.
WARNING

EWA10360
Never remove the engine oil tank
cap after high-speed operation, oth-
erwise hot engine oil could spout
out and cause damage or injury. Al-
ways let the engine oil cool down
sufficiently before removing the oil
tank cap.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Install the oil filler cap.
NOTE:


The engine oil tank is located be-
hind the cylinders.

The engine oil should be between
the minimum and maximum level
marks.
To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolts to drain the oil from
the crankcase.
1. Engine oil filler cap
1

1. Engine oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
1
2
3
4

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
1
2
3
4
5
6
7
8
9
NOTE:

Skip steps 4–6 if the oil filter element is
not being replaced.
4. Remove the oil filter element cover
by removing the bolts.5. Remove and replace the oil filter
element and O-rings.
6. Install the oil filter element cover byinstalling the bolts, then tightening
them to the specified torque.
NOTE:

Make sure that the O-rings are properly
seated.
7. Install the engine oil drain bolts,
and then tighten them to the spec-
ified torques.
8. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
1. Engine oil drain bolt A
1

1. Engine oil drain bolt B
2. Oil filter element cover
3. Bolt
1. Oil filter element
2. O-ring12
2
3
1
2

Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torques:
Engine oil drain bolt A:
35 Nm (3.5 m·kgf, 25 ft·lbf)
Engine oil drain bolt B:
30 Nm (3.0 m·kgf, 21.7 ft·lbf)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
2
3
4
5
67
8
9
NOTE:

Be sure to wipe off spilled oil on any
parts after the engine and exhaust sys-
tem have cooled down.
CAUTION:

ECA11620

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

Make sure that no foreign mate-
rial enters the crankcase.
9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU20252
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:


The coolant level must be checked
on a cold engine since the level
varies with engine temperature.

Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.
NOTE:

The coolant should be between the
minimum and maximum level marks.
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
3.80 L (4.02 US qt) (3.34 Imp.qt)
With oil filter element replacement:
3.90 L (4.12 US qt) (3.43 Imp.qt)
1. “CD” specification
2. “ENERGY CONSERVING II”
1
2

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
1
2
3
4
5
6
7
8
9
3. If the coolant is at or below the
minimum level mark, remove pan-
el A (See page 6-6.), remove the
reservoir cap, add coolant to the
maximum level mark, and then in-
stall the reservoir cap and the pan-
el.
CAUTION:

ECA10471

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 cooling system will not
be protected against frost and
corrosion.

If water has been added to thecoolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
WARNING

EWA10380
Never attempt to remove the radiator
cap when the engine is hot.
NOTE:


The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.

If the engine overheats, see page
6-35 for further instructions.
1. Maximum level mark
2. Coolant reservoir
3. Minimum level mark
3 1
2

1. Coolant reservoir cap
Coolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt) (0.22 Imp.qt)
1