TDM900 : Periodic Maintenance


From the Workshop Manual / User's Manual (2010).
Break-in Interval Engine and misc Check or Maintenance job
10,000 km - 12 months Engine oil • Replace.
• Check oil level and leakage.
20,000 km Engine oil filter element • Replace.
10,000 km - 12 months Cooling system (*) • Check coolant level and leakage.
10,000 km - 12 months Fuel line (*) • Check fuel hoses for cracks or damage.
10,000 km - 12 months Electronic fuel injection (*) • Adjust engine idling speed and synchronization.
10,000 km - 12 months Air induction system (*) • Check the air cut-off valve, reed valve, and hose for damage.
• Replace the entire air induction system if necessary.
10,000 km - 12 months Muffler and exhaust pipe (*) • Check the screw clamp for looseness.
10,000 km Spark plugs • Check condition.
• Clean and regap.
20,000 km Spark plugs • Replace.
20,000 km Clutch • Check operation.
• Adjust.
20,000 km Air filter • Clean.
40,000 km Air filter • Replace.
40,000 km Valves (*) • Check valve clearance.
• Adjust.

Break-in Interval Chassis Check or Maintenance job
1,000 km and after washing the motorcycle or riding in the rain Drive chain • Check chain slack.
• Make sure that the rear wheel is properly aligned.
• Clean and lubricate.
10,000 km - 12 months Tires (*) • Check tread depth and for damage
• Replace if necessary.
• Check air pressure and Correct if necessary.
10,000 km - 12 months Front brake (*) • Check operation, fluid level and vehicle for fluid leakage.
10,000 km - 12 months Rear brake (*) • Check operation, fluid level and vehicle for fluid leakage.
10,000 km - 12 months Brake hoses (*) • Check for cracks or damage.
10,000 km Wheels (*) • Check run out and for damage.
10,000 km Wheel bearings (*) • Check bearing for looseness or damage.
10,000 km Swing-arm (*) • Check operation and for excessive play.
50,000 km Swing-arm (*) • Lubricate (lithium grease).
10,000 km Steering bearings (*) • Check bearing play and steering for roughness.
20,000 km Steering bearings (*) • Lubricate (lithium grease).
10,000 km - 12 months Chassis fasteners (*) • Make sure that all nuts, bolts and screws are properly tightened.
10.000 km - 12 months Front break lever pivoting point • Lubricate (silicon grease).
10.000 km - 12 months Rear brake pedal pivoting point • Lubricate (lithium grease).
10.000 km - 12 months Clutch lever pivoting point • Lubricate (lithium grease).
10.000 km - 12 months Selector pivoting point • Lubricate (lithium grease).
10,000 km - 12 months Sidestand • Check operation.
• Lubricate (lithium grease).
10,000 km Front fork (*) • Check operation and for oil leakage.
20,000 km Front fork (*) • Replace fork oil.
10,000 km Rear shock absorber (*) • Check operation and for oil leakage.
10,000 km Rear suspension pivoting points (*) • Check operation.
20,000 km Rear suspension pivoting points (*) • Lubricate (lithium grease).
10,000 km - 12 months Moving parts • Lubricate.
10,000 km - 12 months Throttle grip housing (*) • Check operation and free play.
• Adjust free play.
• Lubricate.

Break-in Interval Wiring Check or Maintenance job
10,000 km - 12 months Front and rear brake switches (*) • Check operation.
10,000 km - 12 months Side stand switch (*) • Check operation.
10,000 km - 12 months Lights, signals and switches (*) • Check operation.
• Adjust headlight beam.

Yamaha notes

• Break-in maintenance should be done at 1000km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
• The first column shows the break-in 1000 km maintenance.
• The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Replace coolant every three years.

Hydraulic brake service
• Replace brake pads whenever worn to the limit.
• 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.

My own service advices

Engine oil change
• Change break-in oil before 500km and at 1000km
• Change oil filter element along with every oil change.
• Use 100% synthetic oil which offers better service and lubrication quality.
• Don't use mineral oil : your bike is not a lawn-mowers.
• Reduce oil change interval in case semi-synthetic oil is used.
• You may use standard car oil only when it don't have additive that may render the clutch slippy.

Hydraulic brake service
• Use only Yamaha genuine brake pads (Sumitomo). Other brand may look cheaper or more effective but they also wear the disks quickly.
• Clean the front brake pistons on a regular basis, they bind easily with dirt. Check here.
• Clean the brake discs with acetone.

Other points
• Clean air filter element every 10,000 km.
• Replace front fork oil every 10,000 km.
• Do not lubricate the clutch & throttle cables as they are covered with Teflon. Lubricating is useless and even worse as oil will degrade Teflon !
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