warning YAMAHA TDM 900 2009 Owner's Manual

OPERATION AND IMPORTANT RIDING POINTS
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EAU17213
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
WARNING

EWA10311
●
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 and be burned.
●
Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn, increasing the
risk of a fuel leak and fire.
●
Do not park near grass or other
flammable materials which
might catch fire.

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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU17241
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, depending on the
weather, terrain, geographical location,
and individual use, the maintenance in-
tervals may need to be shortened.
WARNING

EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance
activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle
service, have a Yamaha dealer per-
form service.
WARNING

EWA15121
Turn off the engine when performing
maintenance unless otherwise
specified.
●
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
●
Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more in-
formation about carbon monox-
ide.
EAU17521
Owner’s tool kit
The owner’s tool kit is located inside the
storage compartment under the seat.
(See page 3-16.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
TIP

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
1. Owner’s tool kit
1

PERIODIC MAINTENANCE AND ADJUSTMENT
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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.
TIP

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.
EAU19835
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. A slight tilt to the side can
result in a false reading.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
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
the oil level.
WARNING! Never re-
move the engine oil tank cap af-
ter high-speed operation,
otherwise hot engine oil could

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 ADJUSTMENT
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minimum level mark, remove pan-
el B for TDM900 or panel A for
TDM900A (See page 6-6.), re-
move the reservoir cap, add cool-
ant to the maximum level mark,
and then install the reservoir cap
and the panel.
WARNING! Re-
move only the coolant reservoir
cap. Never attempt to remove
the radiator cap when the en-
gine is hot.

[EWA15161]

NOTICE:
If
coolant is not available, use dis-
tilled water or soft tap water in-
stead. 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 coolant as soon as possi-
ble, otherwise the cooling sys-
tem will not be protected
against frost and corrosion. If
water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be re-
duced.
[ECA10472]

For TDM900
For TDM900A
EAU27054
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 3-16.)
2. Remove cowlings A and B as well
as panels A and B. (See
page 6-6.)
3. Remove the fuel tank bolts.
TIP

For TDM900, skip steps 4 and 12.
1. Coolant reservoir cap
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
1

1. Bolt
1

PERIODIC MAINTENANCE AND ADJUSTMENT
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4. Remove the rear brake fluid reser-
voir holder by removing the bolt.
For TDM900A
5. Lift the fuel tank away from the air
filter case, but do not disconnect
the fuel hoses.
6. Remove the air filter case cover by
removing the screws.7. Pull the air filter element out.
8. Insert a new air filter element into
the air filter case.
NOTICE:
Make
sure that the air filter element is
properly seated in the air filtercase. The engine should never
be operated without the air filter
element installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.

[ECA10481]

9. Install the air filter case cover by in-
stalling the screws.
10. Place the fuel tank in its original
position. Make sure that the fuel
hoses are properly connected and
routed, and are not pinched. Be
sure to place the fuel tank breath-
er/overflow hose in its original po-
sition.
WARNING! Before
installing the fuel tank, make
sure that the fuel hoses are not
damaged. If any fuel hose is
damaged, do not start the en-
gine but have a Yamaha dealer
replace the hose, otherwise fuel
may leak, creating a fire haz-
ard.
[EWA11331]

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

1. Air filter case cover
2. Screw
1. Air filter element
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU21382
Checking the throttle cable
free play
The throttle cable free play should mea-
sure 3.0–5.0 mm (0.12–0.20 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, have a Yamaha dealer adjust it.
EAU21401
Valve clearance
The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU33042
Tires
To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING

EWA10501
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.
●
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
●
The tire air pressure must be ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
1. Throttle cable free play
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PERIODIC MAINTENANCE AND ADJUSTMENT
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for this model.
WARNING

EWA10511
Never overload your vehicle. Opera-
tion of an overloaded vehicle could
cause an accident.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.
TIP

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.
Tire air pressure (measured on cold
tires):
0–90 kg (0–198 lb):
Front:
225 kPa (2.25 kgf/cm
2

, 33 psi)
Rear:
250 kPa (2.50 kgf/cm
2

, 36 psi)
TDM900 90–201 kg (198–443 lb)
TDM900A 90–198 kg (198–437 lb):
Front:
225 kPa (2.25 kgf/cm
2

, 33 psi)
Rear:
290 kPa (2.90 kgf/cm
2

, 42 psi)
High-speed riding:
Front:
225 kPa (2.25 kgf/cm
2

, 33 psi)
Rear:
250 kPa (2.50 kgf/cm
2

, 36 psi)
Maximum load*:
TDM900 201 kg (443 lb)
TDM900A 198 kg (437 lb)
*Total weight of rider, passenger,
cargo and accessories
1. Tire tread depth
2. Tire sidewall
Minimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
21

PERIODIC MAINTENANCE AND ADJUSTMENT
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9Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
WARNING

EWA10901
●
The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motorcy-
cle may be different, which
could lead to an accident.
●
Always make sure that the valve
caps are securely installed to
prevent air pressure leakage.
●
Use only the tire valves andvalve cores listed below to
avoid tire deflation during a ride.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
WARNING

EWA10600
This motorcycle is fitted with su-per-high-speed tires. Note the fol-
lowing points in order to make the
most efficient use of these tires.
●
Use only the specified replace-
ment tires. Other tires may run
the danger of bursting at super
high speeds.
●
Brand-new tires can have a rela-
tively poor grip on certain road
surfaces until they have been
“broken in”. Therefore, it is ad-
visable before doing any
high-speed riding to ride con-
servatively for approximately
100 km (60 mi) after installing a
new tire.
●
The tires must be warmed up
before a high-speed run.
●
Always adjust the tire air pres-
sure according to the operating
conditions.
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
123

Front tire:
Size:
120/70 ZR18M/C (59W)
Manufacturer/model:
TDM900 METZELER/MEZ4
FRONT
TDM900A DUNLOP/D220FSTJ
TDM900 DUNLOP/D220FSTJ
Tire air valve:
TR412
Valve core:
#9100 (original)
Rear tire:
Size:
160/60 ZR17M/C (69W)
Manufacturer/model:
TDM900 METZELER/MEZ4
TDM900A DUNLOP/D220STJ
TDM900 DUNLOP/D220STJ
Tire air valve:
TR412
Valve core:
#9100 (original)

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU23101
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING! Damage to the outer
sheath may interfere with proper ca-
ble operation and will cause the in-
ner cable to rust. Replace a
damaged cable as soon as possible
to prevent unsafe conditions.
[EWA10721]

EAU23111
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
EAU44271
Checking and lubricating the
brake and shift pedals
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
Recommended lubricant:
Engine oil
Recommended lubricant:
Lithium-soap-based grease

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU23142
Checking and lubricating the
brake and clutch levers
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
EAU23202
Checking and lubricating the
sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
WARNING

EWA10731
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. Otherwise,
the sidestand could contact the
ground and distract the operator, re-
sulting in a possible loss of control.
EAU23250
Lubricating the rear
suspension
The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease