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OWNER'S MANUAL
TDM900
5PS-28199-E1

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Troubleshooting

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   Summary of Contents for YAMAHA TDM900

  • Page 1

    OWNER’S MANUAL TDM900 5PS-28199-E1...

  • Page 2

    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 motorcy- cle, but also in how to safeguard yourself and others from trouble and injury.

  • Page 3: Important Manual Information

    8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. 8 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.

  • Page 4: Important Manual Information

    IMPORTANT MANUAL INFORMATION EW000002 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.

  • Page 5

    EAU04229 TDM900 OWNER’S MANUAL ©2002 by Yamaha Motor Co., Ltd. 1st edition, August 2002 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

  • Page 6: Table Of Contents

    EAU00009 TABLE OF CONTENTS 1 GIVE SAFETY THE RIGHT OF WAY 2 DESCRIPTION 3 INSTRUMENT AND CONTROL FUNCTIONS 4 PRE-OPERATION CHECKS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 7 MOTORCYCLE CARE AND STORAGE 8 SPECIFICATIONS 9 CONSUMER INFORMATION INDEX...

  • Page 8: Give Safety The Right Of Way

    GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY ..........1-1...

  • Page 9

    EAU00021 QGIVE SAFETY THE RIGHT OF WAY Saf e t y i n f o r m at i o n Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and free- dom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics.

  • Page 10: Description

    DESCRIPTION Left view ....................2-1 Right view ..................2-2 Controls and instruments ..............2-3...

  • Page 11: Left View

    EAU00026 DESCRIPTION Par t l o cat i o ns Left view 1. Front fork spring preload adjusting bolt (page 3-15) 8. Grab bar 2. Front fork damping force adjusting 9. Luggage strap holders (page 3-18) screw (page 3-15) 10. Seat lock (page 3-13) 3.

  • Page 12: Right View

    DESCRIPTION 18 19 Right view 15. Tool kit (page 6-1) 20. Engine oil filler cap (page 6-8) 16. Coolant reservoir (page 6-11) 21. Engine oil filter element (page 6-10) 17. Throttle stop screw (page 6-17) 22. Engine oil drain bolt B (page 6-10) 18.

  • Page 13: Controls And Instruments

    DESCRIPTION Controls and instruments 3 4 5 1. Clutch lever (page 3-9) 6. Coolant temperature gauge (page 3-6) 2. Left handlebar switches (page 3-7) 7. Right handlebar switches (page 3-8) 3. Speedometer unit (page 3-4) 8. Brake lever (page 3-9) 4.

  • Page 14: Instrument And Control Functions

    INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock ..............3-1 Indicator and warning lights ...............3-2 Speedometer unit ................3-4 Tachometer unit .................3-5 Coolant temperature gauge ...............3-6 Anti-theft alarm (optional) ..............3-7 Handlebar switches ................3-7 Clutch lever ..................3-9 Shift pedal ..................3-9 Brake lever ..................3-9 Brake pedal ..................3-10 Fuel tank cap ...................3-10 Fuel ....................3-11 Fuel tank breather hose ..............3-12...

  • Page 15: Main Switch/steering Lock

    EAU00027 INSTRUMENT AND CONTROL FUNCTIONS NOTE: The headlight comes on automatical- ly when the engine is started and stays on until the key is turned to “OFF”. EAU00038 All electrical systems are off. The key can be removed. EAU00029 EAU00040 Main switch/steering lock LOCK Mai n swi t c h/ s t e er i n g l o ck...

  • Page 16: Indicator And Warning Lights

    INSTRUMENT AND CONTROL FUNCTIONS EAU01590 (Parking) The steering is locked, and the tail- light and auxiliary light are on, but all other electrical systems are off. The key can be removed. The steering must be locked before the key can be turned to “ ”.

  • Page 17

    The electrical circuit of the warning pushed to the left or right. light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit.

  • Page 18: Speedometer Unit

    INSTRUMENT AND CONTROL FUNCTIONS 8 a fuel reserve tripmeter (which If the fuel level warning symbol flash- shows the distance traveled on es (see page 3-2), the odometer dis- the fuel reserve) play will automatically change to the 8 a fuel gauge fuel reserve tripmeter mode “TRIP F”...

  • Page 19: Tachometer Unit

    If the odometer/tripmeter indicates such an error code, note the code Fuel gauge 1. Tachometer number, and then have a Yamaha The fuel gauge indicates the amount 2. Tachometer red zone dealer check the motorcycle. 3. Clock of fuel in the fuel tank.

  • Page 20: Coolant Temperature Gauge

    INSTRUMENT AND CONTROL FUNCTIONS EC000003 NOTE: 8 After setting the clock, be sure to Do not operate the engine in the push “SELECT” button tachometer red zone. before turning the key to “OFF”, Red zone: 8,000 r/min and above otherwise the clock will not be set.

  • Page 21: Anti-theft Alarm (optional)

    Do not operate the engine if it is This motorcycle can be equipped overheated. with an optional anti-theft alarm by a Yamaha dealer. Contact a Yamaha dealer for more information. 1. Pass switch “&” 2. Hazard switch “0” 3. Dimmer switch “&/%”...

  • Page 22

    INSTRUMENT AND CONTROL FUNCTIONS EAU03889 EC000006 Turn signal switch “4/6” Tur n si g nal swi t c h To signal a right-hand turn, push this Do not use the hazard light for an switch to “6”. To signal a left-hand extended length of time, otherwise turn, push this switch to “4”.

  • Page 23: Clutch Lever

    INSTRUMENT AND CONTROL FUNCTIONS 1. Clutch lever 1. Shift pedal 1. Brake lever 2. Brake lever position adjusting dial EAU00152 EAU00157 3. Arrow mark Clutch lever Shift pedal a. Distance between brake lever and handlebar grip Cl u t c h l e ver Shi f t pedal The clutch lever is located at the left The shift pedal is located on the left...

  • Page 24: Brake Pedal

    INSTRUMENT AND CONTROL FUNCTIONS To adjust the distance between the brake lever and the handlebar grip, turn the adjusting dial while holding the lever pushed away from the han- dlebar grip. Make sure that the appropriate setting on the adjusting dial is aligned with the arrow mark on the brake lever.

  • Page 25: Fuel

    INSTRUMENT AND CONTROL FUNCTIONS EAU00185 2. Turn the key counterclockwise to the original position, remove it, Immediately wipe off spilled fuel and then close the lock cover. with a clean, dry, soft cloth, since NOTE: fuel may deteriorate painted sur- The fuel tank cap cannot be closed faces or plastic parts.

  • Page 26: Fuel Tank Breather Hose

    The exhaust system is hot after system. operation. Make sure that the 1. Fuel tank breather hose exhaust system has cooled down Your Yamaha engine has been before doing any maintenance designed to use regular unleaded EAU02955 Fuel tank breather hose work.

  • Page 27: Seat

    INSTRUMENT AND CONTROL FUNCTIONS EC000114 The following precautions must be observed to prevent a fire hazard or other damages. 8 Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter. 1. Seat lock 1.

  • Page 28: Storage Compartment

    This storage compartment designed 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. When the U- LOCK is not in the storage compart- ment, be sure to secure the straps to prevent losing them.

  • Page 29: Damping Force

    INSTRUMENT AND CONTROL FUNCTIONS 1. Spring preload adjusting bolt 1. Standard setting 1. Damping force adjusting screw 2. Current setting Spring preload 3. Front fork cap bolt Damping force To increase the spring preload and 1. Turn the adjusting screw on each NOTE: fork leg in direction a until the thereby harden the suspension, turn...

  • Page 30: Adjusting The Shock Absorber Assembly

    INSTRUMENT AND CONTROL FUNCTIONS EAU04930 3. To increase the damping force, Adjusting the shock continue turning the adjusting absorber assembly screw in direction a. The third Shock absor b er assembl y , adj u st i n g This shock absorber assembly is click after the minimum setting is equipped with...

  • Page 31: Rebound Damping Force

    INSTRUMENT AND CONTROL FUNCTIONS NOTE: Although the total number of clicks of a damping force adjusting mecha- nism may not exactly match the above specifications due to small dif- ferences in production, the actual number of clicks always represents the entire adjusting range. To obtain a precise adjustment, it would be 1.

  • Page 32: Luggage Strap Holders

    8 Do not deform or damage the gas cylinder in any way, as this will result in poor damp- ing performance. 8 Always have a Yamaha dealer service the shock absorber. 3-18...

  • Page 33: Ignition Circuit Cut-off System

    Therefore, check this system sidestand is still down. 8 It cuts the running engine when regularly as described below and have a Yamaha dealer repair it if it the transmission is in gear and does not function properly. the sidestand is moved down.

  • Page 34

    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.

  • Page 36: Pre-operation Checks

    PRE-OPERATION CHECKS Pre-operation check list ..............4-1...

  • Page 37: Pre-operation Check List

    • If necessary, add recommended coolant to specified level. 6-11–6-15 • Check cooling system for leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. Front brake • Check fluid level in reservoir. 3-9–3-10, 6-24–6-26 •...

  • Page 38

    • Make sure that operation is smooth. • Check cable free play. Throttle grip 6-18, 6-29 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 6-29 •...

  • Page 39

    PRE-OPERATION CHECKS NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved. EWA00033 If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operat- ing the motorcycle.

  • Page 40: Operation And Important Riding Points

    OPERATION AND IMPORTANT RIDING POINTS Starting the engine ................5-1 Shifting ....................5-2 Recommended shift points (for Switzerland only) ......5-3 Tips for reducing fuel consumption ............5-3 Engine break-in .................5-3 Parking ....................5-4...

  • Page 41: Operation And Important Riding Points

    3-20. should be on, otherwise have a that there is adequate ventila- 8 Never ride with the sidestand Yamaha dealer check the electrical tion. 8 Before starting out, make sure down. circuit.

  • Page 42: Shifting

    OPERATION AND IMPORTANT RIDING POINTS EC000048 NOTE: If the engine fails to start, release the 8 Even with the transmission in start switch, wait a few seconds, and the neutral position, do not then try again. Each starting attempt coast for long periods of time should be as short as possible to pre- with the engine off, and do not serve the battery.

  • Page 43: Recommended Shift Points (for Switzerland Only)

    OPERATION AND IMPORTANT RIDING POINTS EAU02937 EAU04754 EAU01128 Recommended shift points Tips for reducing fuel Engine break-in (for Switzerland only) consumption Engi n e br e ak- i n There is never a more important peri- Shi f t poi n t s ( f o r Swi t z er l a nd onl y ) Fuel consumpt i o n, t i p s f o r r e duci n g The recommended shift points during Fuel consumption depends largely on...

  • Page 44: Parking

    The vehicle can now be operated motorcycle may overturn. normally. EC000053 8 Keep the engine speed out of the tachometer red zone. 8 If any engine trouble should occur during the engine break- in period, immediately have a Yamaha dealer check the vehi- cle.

  • Page 46: Periodic Maintenance And Minor Repair

    PERIODIC MAINTENANCE AND MINOR REPAIR Owner’s tool kit .............6-1 Checking and lubricating the brake and Periodic maintenance and lubrication chart ..6-2 shift pedals ............6-30 Removing and installing cowlings and panels ..6-5 Checking and lubricating the brake and Checking the spark plugs ........6-7 clutch levers ............6-30 Engine oil and oil filter element ......6-8 Checking and lubricating the sidestand ....6-30...

  • Page 47: Owner's Tool Kit

    If you do not have the tools or experi- Periodic inspection, adjustment and ence required for a particular job, lubrication will keep your vehicle in have a Yamaha dealer perform it for the safest and most efficient condi- you. tion possible. The most important...

  • Page 48: Periodic Maintenance And Lubrication Chart

    8 The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. 8 From 50,000 km, repeat the maintenance intervals starting from 10,000 km. 8 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

  • Page 49

    PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK • Check tread depth and for damage. • Replace if necessary. √ √ √ √ √ Tires • Check air pressure. • Correct if necessary. √...

  • Page 50

    PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK • Change. √ √ √ √ √ √ Engine oil • Check oil level and vehicle for oil leakage. √ √ √ Engine oil filter element • Replace. √...

  • Page 51: Removing And Installing Cowlings And Panels

    PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cowling A 1. Cowling B 1. Screw (×6) 2. Panel A 2. Panel B 2. Quick fastener EAU01139 EAU04937 Removing and installing Cowlings A and B cowlings and panels To remove one of the cowlings Cowl i n gs and panel s , r e movi n g and i n st a l l i n g Remove the cowling screws and the The cowlings and panels shown...

  • Page 52

    PERIODIC MAINTENANCE AND MINOR REPAIR After removal Before installation 1. Quick fastener 1. Screw 1. Panel B 2. Pin EAU03317 To install the panel To install the cowling Panels A and B 1. Place the panel in the original Place the cowling in the original posi- To remove one of the panels position, and then install the tion, and then install the screws and...

  • Page 53: Checking The Spark Plugs

    The spark plugs are important engine or other deposits, it should be components, which should replaced. checked periodically, preferably by a Yamaha dealer. Since heat and Specified spark plug: deposits will cause any spark plug to DPR8EA-9 (NGK) or slowly erode, they...

  • Page 54: Engine Oil And Oil Filter Element

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU04619 NOTE: Engine oil and oil filter If a torque wrench is not available element when installing a spark plug, a good Engi n e oi l and oi l f i l t e r el e ment The engine oil level should be estimate of the correct torque is checked before each ride.

  • Page 55

    PERIODIC MAINTENANCE AND MINOR REPAIR EW000065 Never remove the engine oil tank cap after high-speed operation, otherwise hot engine oil could spout out and cause damage or injury. Always let the engine oil cool down sufficiently before removing the oil tank cap. 1.

  • Page 56

    PERIODIC MAINTENANCE AND MINOR REPAIR 7. Install the engine oil drain bolts, and then tighten them to the specified torques. Tightening torques: Engine oil drain bolt A: 35 Nm (3.5 m·kgf) Engine oil drain bolt B: 30 Nm (3.0 m·kgf) 1.

  • Page 57: Coolant

    PERIODIC MAINTENANCE AND MINOR REPAIR ECA00133 EAU04879 Coolant Cool a nt 8 In order to prevent clutch slip- The coolant level should be checked page (since the engine oil also before each ride. In addition, the lubricates the clutch), do not coolant must be changed at the inter- mix any chemical additives.

  • Page 58

    8 If water has been added to the cap, add coolant to the maximum coolant, have a Yamaha dealer level mark, and then install the check the antifreeze content of reservoir cap and the panel.

  • Page 59

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU04461 To change the coolant Changi n g 1. Place the motorcycle on a level surface and let the engine cool if necessary. 2. Remove the seat. (See page 3-13 for seat removal and instal- lation procedures.) 3.

  • Page 60

    PERIODIC MAINTENANCE AND MINOR REPAIR 13. Install the coolant drain bolts, Antifreeze/water mixture ratio: and then tighten them to the specified torque. Recommended antifreeze: High-quality ethylene glycol NOTE: antifreeze containing corrosion Check the washers for damage and inhibitors for aluminum engines replace them if necessary.

  • Page 61

    If necessary, add suffi- to the engine. the engine but have a Yamaha cient coolant until it reaches the 8 If water has been used instead dealer replace the hose, other-...

  • Page 62: Replacing The Air Filter Element

    PERIODIC MAINTENANCE AND MINOR REPAIR 1. Bolt (×2) 1. Air filter case cover 1. Air filter element 2. Screw (×8) EAU04973 6. Insert a new air filter element into Replacing the air filter 3. Remove the fuel tank bolts, and the air filter case.

  • Page 63: Adjusting The Engine Idling Speed

    If any fuel 1. Throttle stop screw making this adjustment. hose is damaged, do not start the engine but have a Yamaha Check the engine idling speed and, if NOTE: dealer replace the hose, other- necessary, adjust it to specification The engine is warm when it quickly wise fuel may leak.

  • Page 64: Adjusting The Throttle Cable Free Play

    To prevent regarding the specified tires. this from occurring, the valve clear- ance must be adjusted by a Yamaha Tire air pressure dealer at the intervals specified in the The tire air pressure should be a.

  • Page 65

    PERIODIC MAINTENANCE AND MINOR REPAIR EWA00012 8 Adjust the suspension and tire Tire air pressure (measured on cold tires) air pressure with regard to the Load* Front Rear Because loading has an enormous load. 225 kPa 250 kPa impact on the handling, braking, 8 Check the tire condition and Up to 90 kg (2.25 kgf/cm...

  • Page 66

    PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: The tire tread depth limits may differ from country to country. Always com- ply with the local regulations. EW000079 8 Have a Yamaha dealer replace excessively worn tires. 1. Tire sidewall 1. Tire air valve Besides being illegal, operat- a.

  • Page 67

    FRONT & REAR approved for this model by the danger of bursting at Tire air valve TR412 Yamaha Motor Co., Ltd. super high speeds. Valve core #9000A (original) 8 Always make sure that the 8 Brand-new tires can have a...

  • Page 68: Cast Wheels

    If any 1. Locknut (clutch lever) damage found, have 2. Clutch lever free play adjusting bolt Yamaha dealer replace c. Clutch lever free play wheel. Do not attempt even the EAU00694 Adjusting the clutch lever smallest repair to the wheel.

  • Page 69: Adjusting The Brake Pedal Position

    4. Fully turn the adjusting bolt at the pedal position and, if necessary, clutch lever in direction a to 7. Tighten the locknut at the clutch have a Yamaha dealer adjust it. loosen the clutch cable. lever and the crankcase. 6-23...

  • Page 70: Adjusting The Rear Brake Light Switch

    If there is air in the hydraulic sys- specified in the periodic maintenance tem, have a Yamaha dealer bleed and lubrication chart. the system before operating the motorcycle. Air in the hydraulic 1.

  • Page 71: Checking The Brake Fluid Level

    To check the brake pad wear, 0.8 mm, have a Yamaha dealer Before riding, check that the brake check the wear indicator groove. If a replace the brake pads as a set.

  • Page 72: Changing The Brake Fluid

    Changing the brake fluid fluid. Mixing fluids may result in a Br a ke f l u i d , changi n g Have a Yamaha dealer change the harmful chemical reaction and brake fluid at the intervals specified in...

  • Page 73: Drive Chain Slack

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU00744 Drive chain slack Dr i v e chai n sl a ck The drive chain slack should be checked before each ride and adjust- ed if necessary. To check the drive chain slack Checki n g 1.

  • Page 74: Lubricating The Drive Chain

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU03006 3. Tighten the locknuts, and then Lubricating the drive chain tighten the axle nut and the Dr i v e chai n , l u br i c at i n g The drive chain must be cleaned and brake caliper bracket bolt to the lubricated at the intervals specified in specified torques.

  • Page 75: Checking And Lubricating The Cables

    Yamaha dealer could damage the O-rings. check or replace it. Recommended lubricant: Engine oil...

  • Page 76: Checking And Lubricating The Brake And Shift Pedals

    Recommended lubricant: Recommended lubricant: EW000113 Lithium-soap-based grease Lithium-soap-based grease (all-purpose grease) (all-purpose grease) If the sidestand does not move up down smoothly, have Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 6-30...

  • Page 77: Lubricating The Rear Suspension

    Recommended lubricant: rebounds smoothly. Lithium-soap-based grease EC000098 If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it. 6-31...

  • Page 78: Checking The Steering

    Yamaha 1. Place a stand under the engine dealer check the wheel bearings. to raise the front wheel off the ground.

  • Page 79: Battery

    9 EXTERNAL: manently damage the battery. Flush with To charge the battery plenty of water. Have a Yamaha dealer charge the 9 INTERNAL: Drink large battery as soon as possible if it quantities of water or milk seems to have discharged. Keep in...

  • Page 80: Replacing The Fuses

    6. Headlight fuse battery charger, have 7. Spare fuse (×5) the battery leads are properly 8. Electronic fuel injection system fuse Yamaha dealer charge your connected to the battery termi- 9. Main fuse battery. nals. EAU04880 Replacing the fuses Fuses, r e pl a ci n g...

  • Page 81: Replacing A Headlight Bulb

    4. If the fuse immediately blows Specified fuses: again, have a Yamaha dealer Main fuse: 40 A check the electrical system. Headlight fuse: 15 A...

  • Page 82

    Do not touch the glass part of the bulb. and then connect the coupler. EC000104 2. Unhook the headlight bulb hold- 5. Have a Yamaha dealer adjust er, and then remove the defec- the headlight beam if necessary. Take care not to damage the fol- tive bulb.

  • Page 83: Replacing A Tail/brake Light Bulb

    PERIODIC MAINTENANCE AND MINOR REPAIR 5. Install the socket (together with the bulb) by turning it clockwise. 6. Install the seat. 1. Socket 1. Screw 2. Turn signal light lens EAU04411 EAU03497 Replacing a tail/brake light Replacing a turn signal light bulb bulb Tai l / b r a ke l i g ht bul b , r e pl a ci n g...

  • Page 84: Supporting The Motorcycle

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 To service the rear wheel Supporting the motorcycle Raise the rear wheel off the ground Suppor t i n g t h e mot o r c ycl e Since this model is not equipped with by using a motorcycle stand or, if a a centerstand, follow these precau- motorcycle stand is not available, by...

  • Page 85: Front Wheel

    EW000122 page 6-38. 4. Remove the brake hose holders 8 It is advisable to have a by removing the bolts. Yamaha dealer service the 5. Remove the brake calipers by wheel. removing the bolts. 8 Securely support the motorcy- 6. Pull the wheel axle out, and then cle so that there is no danger remove the wheel.

  • Page 86: Rear Wheel

    EW000122 5. Install the brake hose holders by 8 It is advisable to have a installing the bolts. Yamaha dealer service the 6. Tighten the wheel axle, the front wheel. wheel axle pinch bolt and the 8 Securely support the motorcy-...

  • Page 87

    PERIODIC MAINTENANCE AND MINOR REPAIR 1. Remove the drive chain cover by removing the quick fasteners and the bolts. 1. Axle nut 1. Bolt 2. Drive chain slack adjusting bolt 2. Brake caliper bracket 3. Locknut 4. Remove the axle nut. 4.

  • Page 88

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU04456 After removal Before installation To install the rear wheel I n st a l l i n g 1. Install the wheel by inserting the wheel axle from the right hand side. NOTE: Make sure that there is enough space between brake...

  • Page 89: Troubleshooting

    Use only genuine Yamaha replace- ment parts. Imitation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills. 6-43...

  • Page 90: Troubleshooting Charts

    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.

  • Page 91

    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.

  • Page 92: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE Care ....................7-1 Storage ....................7-4...

  • Page 93

    EAU04454 MOTORCYCLE CARE AND STORAGE Before cleaning Cleaning Care 1. Cover the muffler outlets with ECA00010 Car e While the open design of a motorcy- plastic bags after the engine has cle reveals the attractiveness of the 8 Avoid using strong acidic cooled down.

  • Page 94

    MOTORCYCLE CARE AND STORAGE 8 Do not use any harsh chemical 8 For motorcycles equipped After normal use products on plastic parts. Be with a windshield: Do not use Remove dirt with warm water, a mild sure to avoid using cloths or strong cleaners hard...

  • Page 95

    MOTORCYCLE CARE AND STORAGE 1. Clean the motorcycle with cold After cleaning 7. Wax all painted surfaces. water and a mild detergent, after 1. Dry motorcycle with 8. Let the motorcycle dry complete- the engine has cooled down. chamois or an absorbing cloth. ly before storing or covering it.

  • Page 96

    NOTE: and spark plugs. humidity to seep in and cause Consult a Yamaha dealer for advice b. Pour a teaspoonful of engine rust. on what products to use. oil into each spark plug bore.

  • Page 97

    MOTORCYCLE CARE AND STORAGE d. Turn the engine over several 5. Check and, if necessary, correct NOTE: times with the starter. (This the tire air pressure, and then lift Make any necessary repairs before will coat the cylinder walls with the motorcycle so that both of its storing the motorcycle.

  • Page 98: Specifications

    SPECIFICATIONS Specifications ..................8-1 Conversion table ................8-5...

  • Page 99

    EAU01038 SPECIFICATIONS Specifications Speci f i c at i o ns Model TDM900 Engine oil Type Dimensions Overall length 2,180 mm Overall width 800 mm Overall height 1,290 mm Seat height 825 mm Wheelbase 1,485 mm Ground clearance 160 mm...

  • Page 100

    SPECIFICATIONS Cooling system capacity Operation Left foot (total amount) 1.7 L Gear ratio 2.750 Air filter Oil-coated paper element 1.947 Fuel 1.545 Type REGULAR UNLEADED 1.240 GASOLINE ONLY 1.040 Fuel tank capacity 20 L 0.923 Fuel reserve amount 3.5 L Chassis Spark plug Frame type...

  • Page 101

    SPECIFICATIONS Brakes Maximum load* 203 kg Front Tire air pressure (measured on cold tires) Type Dual disc brake Up to 90 kg* Operation Right hand Front 225 kPa (2.25 kgf/cm , 2.25 bar) Fluid DOT 4 Rear 250 kPa (2.50 kgf/cm , 2.50 bar) Rear 90 kg load–Maximum*...

  • Page 102

    SPECIFICATIONS Electrical system Fuses Ignition system T.C.I. (digital) Main fuse 40 A Charging system Headlight fuse 15 A Type A.C. magneto Signaling system fuse 10 A Standard output 14 V, 31.5 A @ 5,000 r/min Ignition fuse 10 A Battery Turn signal light and hazard fuse 10 A...

  • Page 103: Conversion Table

    SPECIFICATIONS EAU04513 Conversion table Conversion table METRIC SYSTEM TO IMPERIAL SYSTEM Conver s i o n t a bl e All specification data in this manual are listed in SI and Metric unit Conversion factor Imperial unit METRIC UNITS. × m·kgf 7.233 ft·lbf...

  • Page 104: Consumer Information

    CONSUMER INFORMATION Identification numbers ...............9-1 Key identification number ..............9-1 Vehicle identification number .............9-1 Model label ..................9-2...

  • Page 105: Identification Numbers

    Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. Key identification number 1.

  • Page 106: Model Label

    The model label is affixed to the frame under the seat. (See page 3-13 for seat removal and installation pro- cedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.

  • Page 107

    INDEX Checking ..........6-27 Indicator and warning lights ....3-2 Air filter element, replacing ....6-16 Drive chain, lubricating ......6-28 Fuel level warning symbol ....3-2 Anti-theft alarm (optional) .......3-7 Turn signal indicator lights ....3-3 High beam indicator light .....3-3 Engine break-in ........5-3 Neutral indicator light ......3-3 Battery ..........6-33 Engine idling speed ......6-17 Engine trouble warning light ....3-3...

  • Page 108

    INDEX Shift points (for Switzerland only) ...5-3 Shifting ...........5-2 Wheel (front)..........6-39 Shock absorber assembly, adjusting ..3-16 Installing ..........6-40 Sidestand ..........3-18 Removing ...........6-39 Sidestand, checking and lubricating ..6-30 Wheel (rear) .........6-40 Spark plugs, checking ......6-7 Installing ..........6-42 Specifications .........8-1 Removing ...........6-40 Speedometer unit ........3-4 Wheel bearings, checking ....6-32 Starting the engine .........5-1...

  • Page 110

    YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2002.9-0.5x1 !

This manual also for:

Tdm900a, Tdm twin 900

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