OWNER’S MANUAL TDM900 5PS-28199-E2...
EAU26941 DECLARATION of CONFORMITY Company: MORIC CO., LTD. Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan Hereby declare that the product: Kind of equipment: IMMOBILIZER Type-designation: 5SL-00, 5VS-00, 5VX-00, 3HT-00, 5UX-00, 5UX-10, 5KS-00 and 5KS-10 is in compliance with following norm(s) or documents: R&TTE Directive(1999/5/EC) EN300 330-2 v1.1.1(2001-6), EN60950(2000) Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC)
Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TDM900. The owner’s manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury.
This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual.
IMPORTANT MANUAL INFORMATION EAU10200 TDM900 OWNER’S MANUAL ©2003 by Yamaha Motor Co., Ltd. 1st edition, July 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
TABLE OF CONTENTS SAFETY INFORMATION .....1-1 Adjusting the shock absorber Coolant ........6-10 assembly .......3-16 Replacing the air filter DESCRIPTION ......2-1 Luggage strap holders ....3-18 element ......... 6-14 Left view ........2-1 Sidestand ........3-18 Adjusting the engine idling Right view........2-2 Ignition circuit cut-off system ...3-19 speed ........
TABLE OF CONTENTS Checking and lubricating the Storage ........7-3 brake and shift pedals ...6-26 Checking and lubricating the SPECIFICATIONS ....... 8-1 brake and clutch levers ..6-27 Checking and lubricating the CONSUMER INFORMATION ..9-1 sidestand .......6-27 Identification numbers ....9-1 Lubricating the rear suspension ......6-27 Checking the front fork ....6-28...
SAFETY INFORMATION EAU10280 SARY BY MECHANICAL CONDI- Ride where other motorists can MOTORCYCLES SINGLE TIONS. see you. Avoid riding in another TRACK VEHICLES. THEIR SAFE Safe riding motorist’s blind spot. USE AND OPERATION ARE DEPEN- Always make pre-operation Many accidents involve inexperi- DENT UPON THE USE OF PROPER checks.
Modifications made to this motorcycle changing lanes. Make sure that single most critical factor in the preven- not approved by Yamaha, or the re- other motorists can see you. tion or reduction of head injuries. moval of original equipment, may ren- The posture of the operator and Always wear an approved helmet.
If accessories 203 kg (448 lb). When loading within this motorcycle. Since Yamaha cannot are added to the handlebar or this weight limit, keep the following in test all other accessories that may be...
SAFETY INFORMATION Use caution when adding electri- leaving the motorcycle unattended ly. If any gasoline spills on your cal accessories. If electrical acces- and remove the key from the main skin or clothing, immediately wash sories exceed the capacity of the switch.
DESCRIPTION EAU10410 Left view 1. Front fork spring preload adjusting bolt (page 3-15) 8. Grab bar 2. Front fork damping adjusting screw (page 3-15) 9. Luggage strap holder (page 3-18) 3. Air ﬁlter element (page 6-14) 10. Seat lock (page 3-13) 4.
DESCRIPTION EAU10420 Right view 1. Owner’s tool kit (page 6-1) 9. Brake pedal (page 3-11) 2. Coolant reservoir (page 6-10) 10. Rear brake ﬂuid reservoir (page 6-22) 3. Throttle stop screw (page 6-15) 4. Front brake ﬂuid reservoir (page 6-22) 5.
DESCRIPTION EAU10430 Controls and instruments 3 4 5 1. Clutch lever (page 3-9) 9. Throttle grip (page 6-16) 2. Left handlebar switches (page 3-8) 3. Speedometer unit (page 3-5) 4. Main switch/steering lock (page 3-2) 5. Tachometer unit (page 3-6) 6.
Do not submerse any key in wa- the vehicle along with all three keys to ter. a Yamaha dealer to have them re-reg- Do not expose any key to exces- istered. Do not use the key with the red sively high temperatures.
INSTRUMENT AND CONTROL FUNCTIONS keys away from the main switch EAU10471 moved. Main switch/steering lock as they may cause signal inter- NOTE: ference. The headlight comes on automatically OFF ON when the engine is started and stays on until the key is turned to “OFF”. EAU10660 All electrical systems are off.
INSTRUMENT AND CONTROL FUNCTIONS left or right. loss of control or an accident. Make EAU11001 Indicator and warning lights 1. Push the key in from the “OFF” po- sure that the vehicle is stopped be- sition, and then turn it to “LOCK” fore turning the key to “OFF”...
INSTRUMENT AND CONTROL FUNCTIONS EAU11060 EAU11370 Yamaha dealer check the electrical cir- Neutral indicator light “ ” Fuel level warning symbol “ ” cuit. This indicator light comes on when the This fuel level warning symbol starts When the key is turned to “OFF” and 30 transmission is in the neutral position.
The speedometer unit is equipped with (see page 3-3), the odometer display key and both standard keys to a the following: will automatically change to the fuel re- Yamaha dealer and have the stan- digital speedometer (which serve tripmeter mode “TRIP F” and dard keys re-registered.
Yamaha dealer the display will return to “TRIP 1” after check the vehicle. refueling and traveling 5 km (3 mi).
INSTRUMENT AND CONTROL FUNCTIONS clock. EAU12180 ECA10020 Coolant temperature gauge CAUTION: To set the clock: Do not operate the engine if it is 1. Push both the “SELECT” and “RE- overheated. SET” buttons for at least two sec- onds. 2. When the hour digits start flashing, push the “RESET”...
EAU12342 Right Anti-theft alarm (optional) Handlebar switches This model can be equipped with an Left optional anti-theft alarm by a Yamaha dealer. Contact a Yamaha dealer for more information. 1. Engine stop switch “ ” 2. Start switch “ ”...
INSTRUMENT AND CONTROL FUNCTIONS turned to the center position. might be a traffic hazard. EAU12820 Clutch lever EAU12500 ECA10060 Horn switch “ ” CAUTION: Press this switch to sound the horn. Do not use the hazard light for an ex- EAU12660 tended length of time, otherwise the Engine stop switch “...
INSTRUMENT AND CONTROL FUNCTIONS EAU12870 EAU26821 dial is aligned with the “ ” mark on the Shift pedal Brake lever brake lever. The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handle- bar grip.
INSTRUMENT AND CONTROL FUNCTIONS EAU12941 EAU13090 less the key is in the lock. In addition, Brake pedal Fuel tank cap the key cannot be removed if the cap is not properly closed and locked. EWA11090 WARNING Make sure that the fuel tank cap is properly closed before riding.
Do not overfill the fuel tank, oth- as well as to the exhaust system. erwise it may overflow when the fuel warms up and expands. Your Yamaha engine has been de- Avoid spilling fuel on the hot en- signed to use regular unleaded gaso- gine.
INSTRUMENT AND CONTROL FUNCTIONS EAU13410 EAU13440 EAU13860 Fuel tank breather hose Catalytic converter Seat This vehicle is equipped with a catalytic To remove the seat Insert the key into the seat lock, turn it converter in the muffler. counterclockwise, and then pull the EWA10860 WARNING seat off.
Make sure that the seat is properly se- This storage compartment is designed cured before riding. to hold an optional genuine Yamaha U-LOCK. (Other locks may not fit.) When placing a U-LOCK in the storage compartment, securely fasten it with the straps.
INSTRUMENT AND CONTROL FUNCTIONS EAU14781 suspension, turn the adjusting bolt on Damping force Adjusting the front fork each fork leg in direction (b). This front fork is equipped with spring preload adjusting bolts and damping force adjusting screws. EWA10180 WARNING Always adjust both fork legs equal- ly, otherwise poor handling and loss of stability may result.
INSTRUMENT AND CONTROL FUNCTIONS setting. EAU15030 the adjusting ring in direction (a). To de- Adjusting the shock absorber crease the spring preload and thereby NOTE: assembly soften the suspension, turn the adjust- Make sure that the adjusting screw is This shock absorber assembly is ing ring in direction (b).
To obtain a precise adjustment, Always have a Yamaha dealer 1. Compression damping force adjusting it would be advisable to check the num- service the shock absorber.
EAU15300 regularly as described below and Luggage strap holders Sidestand have a Yamaha dealer repair it if it The sidestand is located on the left side does not function properly. of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright.
Periodically check the operation of the ignition circuit cut-off system according to the following procedure. EWA10250 WARNING If a malfunction is noted, have a Yamaha dealer check the system be- fore riding. 3-19...
5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.
PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
Coolant If necessary, add recommended coolant to speciﬁed level. 6-10 Check cooling system for leakage. Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear. Front brake Replace if necessary. 6-22 Check ﬂuid level in reservoir.
PAGE Make sure that operation is smooth. Check cable free play. Throttle grip 6-16, 6-26 If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. Make sure that operation is smooth. Control cables 6-26 Lubricate if necessary.
2. Shift the transmission into the neu- following conditions must be met: their functions before riding. tral position. The transmission is in the neutral Consult a Yamaha dealer re- NOTE: position. garding any control or function When the transmission is in the neutral...
OPERATION AND IMPORTANT RIDING POINTS cold! EAU16671 ECA10260 Shifting CAUTION: NOTE: Even with the transmission in The engine is warm when it quickly re- the neutral position, do not sponds to the throttle. coast for long periods of time with the engine off, and do not tow the motorcycle for long dis- tances.
OPERATION AND IMPORTANT RIDING POINTS EAU16810 EAU16841 Tips reducing fuel Engine break-in Shift up points: 1st → 2nd: 20 km/h (12 mi/h) consumption There is never a more important period 2nd → 3rd: 30 km/h (19 mi/h) in the life of your engine than the period Fuel consumption depends largely on 3rd →...
Yamaha dealer check the vehi- Do not park on a slope or on soft cle. ground, otherwise the vehicle may overturn.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU17240 EAU17520 a Yamaha dealer perform it for you. Safety is an obligation of the owner. Pe- Owner’s tool kit EWA10350 riodic inspection, adjustment and lubri- WARNING cation will keep your vehicle in the Modifications...
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in- stead. From 50000 km, repeat the maintenance intervals starting from 10000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km)
PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Check tread depth and for damage. Replace if necessary. √ √ √ √ √ 10 * Tires Check air pressure. Correct if necessary. √...
PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Front and rear brake √ √ √ √ √ √ 25 * Check operation. switches √ √ √ √ √ Moving parts and cables Lubricate.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU18711 Removing installing cowlings and panels The cowlings and panels shown need to be removed to perform some of the (×6) maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be re- moved and installed.
3. Remove the screw, and then take color, the engine could be defective. Do the panel off. not attempt to diagnose such problems yourself. Instead, have a Yamaha deal- er check the vehicle. If a spark plug shows signs of electrode 1. Panel B erosion and excessive carbon or other deposits, it should be replaced.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU19830 Engine filter Specified spark plug: Tightening torque: NGK/DPR8EA-9 Spark plug: element DENSO/X24EPR-U9 17.5 Nm (1.75 m·kgf, The engine oil level should be checked 12.7 ft·lbf) before each ride. In addition, the oil Before installing a spark plug, the spark must be changed and the oil filter ele- plug gap should be measured with a NOTE:...
PERIODIC MAINTENANCE AND MINOR REPAIR and then remove it again to check tank cap. the oil level. 4. If the engine oil is below the mini- NOTE: mum level mark, add sufficient oil The engine oil should be between the of the recommended type to raise minimum and maximum level marks.
PERIODIC MAINTENANCE AND MINOR REPAIR installing the bolts, then tightening them to the specified torque. Tightening torque: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) NOTE: Make sure that the O-rings are properly seated. 1. Engine oil drain bolt A 1.
PERIODIC MAINTENANCE AND MINOR REPAIR for several minutes while checking EAU20070 Coolant Recommended engine oil: it for oil leakage. If oil is leaking, im- See page 8-1. The coolant level should be checked mediately turn the engine off and Oil quantity: before each ride.
PERIODIC MAINTENANCE AND MINOR REPAIR ing system 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 reduced.
PERIODIC MAINTENANCE AND MINOR REPAIR 3. Remove cowling B and panel B. drain the cooling system. the coolant reservoir by opening (See page 6-5.) the cap, then turning the reservoir 4. Remove the fuel tank bolts, and upside down. then lift the fuel tank to position it 11.
Yamaha the coolant as soon as possible, engines dealer replace the hose, other- otherwise the effectiveness of Coolant quantity: wise fuel may leak.
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- (×2) wise fuel may leak. 1. Air ﬁlter element...
To in- Yamaha dealer make the adjustment. crease the engine idling speed, turn the screw in direction (a). To decrease the engine idling speed, turn the screw in direction (b).
To prevent this cle, note the following points regarding from occurring, the valve clearance the specified tires. must be adjusted by a Yamaha dealer Tire air pressure The tire air pressure should be checked at the intervals specified in the periodic and, if necessary, adjusted before each maintenance and lubrication chart.
Securely pack the heaviest glass fragments in it, or if the sidewall is 250 kPa (36 psi) (2.50 kgf/cm items close to the center of the cracked, have a Yamaha dealer re- Maximum load*: motorcycle and distribute the place the tire immediately.
EWA10470 Use only the tire valves and WARNING valve cores listed below to Have a Yamaha dealer replace avoid tire deflation during a ride. excessively worn tires. Besides being illegal, operating the vehi- cle with excessively worn tires decreases riding stability and can lead to loss of control.
TR412 fore each ride. If any damage is high-speed riding to ride con- Valve core: found, have a Yamaha dealer re- #9000A (original) servatively for approximately place the wheel. Do not attempt Rear tire: 100 km (60 mi) after installing a...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22040 3. If the specified clutch lever free in direction (b). Adjusting the clutch lever free play could be obtained as de- 7. Tighten the locknut at the clutch le- play scribed above, tighten the locknut ver and the crankcase.
(a). To air in the hydraulic system, have a make the brake light come on later, turn Yamaha dealer bleed the system be- the adjusting nut in direction (b). fore operating the motorcycle. Air in...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22390 peared, have a Yamaha dealer replace EAU22580 Checking the front and rear Checking the brake fluid level the brake pads as a set. brake pads Front brake EAU22500 Rear brake pads The front and rear brake pads must be...
Changing the brake fluid is above the minimum level mark and lower the boiling point of the fluid Have a Yamaha dealer change the replenish if necessary. A low brake fluid and may result in vapor lock. brake fluid at the intervals specified in...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22760 1. Loosen the axle nut, the brake cal- Drive chain slack iper bracket bolt and the locknut on The drive chain slack should be each side of the swingarm. checked before each ride and adjusted if necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR tion for proper wheel alignment. EAU23020 ECA11110 Lubricating the drive chain CAUTION: ECA10570 The drive chain must be cleaned and Do not use engine oil or any other lu- CAUTION: lubricated at the intervals specified in bricants for the drive chain, as they Improper drive chain slack will over- the periodic maintenance and lubrica-...
If a cable is damaged periodic maintenance chart. or does not move smoothly, have a Yamaha dealer check or replace it. Recommended lubricant: Engine oil The operation of the brake and shift...
Recommended lubricant: Recommended lubricant: EWA10730 Lithium-soap-based grease Lithium-soap-based grease WARNING (all-purpose grease) If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 6-27...
Securely support the vehicle so that have a Yamaha dealer check or re- To check the operation there is no danger of it falling over. 1. Place the vehicle on a level sur- pair it.
If there is play in the wheel no need to check the electrolyte or to hub or if the wheel does not turn add distilled water. smoothly, have a Yamaha dealer check ECA10620 CAUTION: the wheel bearings. Never attempt to remove the battery cell seals, as this would permanent- ly damage the battery.
5. Signaling system fuse To charge the battery To charge a sealed-type (MF) 6. Headlight fuse Have a Yamaha dealer charge the bat- battery, a special (constant-volt- 7. Spare fuse tery as soon as possible if it seems to 8. Electronic fuel injection fuse age) battery charger is required.
Specified fuses: bulb headlights. If a headlight bulb 4. If the fuse immediately blows Main fuse: burns out, replace it as follows. again, have a Yamaha dealer 40.0 A 1. Disconnect the headlight coupler, check the electrical system. Headlight fuse: and then remove the headlight 15.0 A...
PERIODIC MAINTENANCE AND MINOR REPAIR oil, otherwise the transparency of 5. Have a Yamaha dealer adjust the the glass, the luminosity of the bulb, headlight beam if necessary. and the bulb life will be adversely af- fected. Thoroughly clean off any dirt...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24080 6. Install the seat. EAU24201 Replacing the tail/brake light Replacing a turn signal light bulb bulb 1. Remove seat. (See 1. Remove the turn signal light lens page 3-13.) by removing the screw. 2. Remove the socket (together with the bulb) by turning it counter- clockwise.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24350 frame in front of the rear wheel or under Supporting the motorcycle each side of the swingarm. Since this model is not equipped with a centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand up- right.
5. Remove the brake calipers by re- 3. Lower the front wheel so that it is moving the bolts. It is advisable to have a Yamaha on the ground. dealer service the wheel. 4. Install the brake calipers by install- Securely support the motorcy- ing the bolts.
EAU25330 fork operation. To remove the rear wheel EWA10820 WARNING It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcy- cle so that there is no danger of 1. Axle nut it falling over.
PERIODIC MAINTENANCE AND MINOR REPAIR 3. Lift the rear wheel off the ground remove the wheel. 6. Tighten the axle nut and the brake according to the procedure on ECA11510 caliper bracket bolt to the specified CAUTION: page 6-34. torques. Do not apply the brake after the 4.
The following troubleshooting charts represent quick and easy procedures for checking these vital systems your- self. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly.
Remove the spark plugs and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.
Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. 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.
MOTORCYCLE CARE AND STORAGE EAU26040 brush, but never apply such prod- sponges which have been in Care ucts onto seals, gaskets, sprock- contact with strong or abrasive While the open design of a motorcycle ets, the drive chain and wheel cleaning products, solvent or reveals the attractiveness of the tech- axles.
MOTORCYCLE CARE AND STORAGE any marks. If the windshield is ter and a mild detergent, after the mended to apply a corrosion pro- scratched, use a quality plastic engine has cooled down. tection spray metal, polishing compound after including chrome- and nickel-plat- ECA10790 CAUTION: washing.
Remove the spark plug caps NOTE: To prevent corrosion, avoid and spark plugs. Consult a Yamaha dealer for advice on damp cellars, stables (because b. Pour a teaspoonful of engine oil what products to use. of the presence of ammonia) into each spark plug bore.
MOTORCYCLE CARE AND STORAGE from the spark plugs, and then place and charge it once a month. install the spark plugs and the Do not store the battery in an ex- spark plug caps. cessively cold or warm place (less than 0 °C or more than 30 °C).
SPECIFICATIONS EAU26333 Engine oil: Fuel: Dimensions: Type: Recommended fuel: Overall length: SAE10W30 or SAE10W40 or SAE15W40 Regular unleaded gasoline only 2180 mm (85.8 in) or SAE20W40 or SAE20W50 Fuel tank capacity: Overall width: 20.0 L (5.28 US gal) (4.40 Imp.gal) -20 -10 10 20 30 40 50 ˚C 800 mm (31.5 in)
SPECIFICATIONS Operation: Rear tire: Rear: Left foot operation 250 kPa (36 psi) (2.50 kgf/cm Type: Gear ratio: Front wheel: Tubeless 1st: Size: Wheel type: 33/12 (2.750) 160/60 ZR17M/C (69W) Cast wheel 2nd: Manufacturer/model: Rim size: 37/19 (1.947) METZELER/MEZ4 18M/C x MT3.50 Rear wheel: 3rd: Manufacturer/model:...
SPECIFICATIONS Rear suspension: Neutral indicator light: 14 V, 1.2 W × 1 Type: High beam indicator light: Swingarm (link suspension) 14 V, 1.4 W × 1 Spring/shock absorber type: Oil level warning light: Coil spring/gas-oil damper Wheel travel: Turn signal indicator light: 133.0 mm (5.24 in) 14 V, 1.2 W ×...
Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: 1.
1. Model label The model label is affixed to the frame under the seat. (See page 3-13.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.8–0.4×1 !