fork YAMAHA TDM 900 2006 Owners Manual

TABLE OF CONTENTS
SAFETY INFORMATION
...................1-1
DESCRIPTION
...................................2-1
Left view ...........................................2-1
Right view .........................................2-3
Controls and instruments..................2-5
INSTRUMENT AND CONTROL
FUNCTIONS
........................................3-1
Immobilizer system ..........................3-1
Main switch/steering lock .................3-2
Indicator and warning lights .............3-3
Tachometer unit ...............................3-6
Coolant temperature gauge .............3-6
Multi-function display .......................3-7
Anti-theft alarm (optional) ................3-8
Handlebar switches .........................3-9
Clutch lever ....................................3-10
Shift pedal ......................................3-10
Brake lever ....................................3-11
Brake pedal ...................................3-11
ABS (for ABS models) ...................3-12
Fuel tank cap .................................3-12
Fuel ................................................3-13
Fuel tank breather hose .................3-14
Catalytic converter .........................3-14
Seat ...............................................3-14
Storage compartment ....................3-15
Adjusting the front fork ...................3-16
Adjusting the shock absorber
assembly ....................................3-17Luggage strap holders .................. 3-19
Sidestand ...................................... 3-19
Ignition circuit cut-off system ......... 3-20
PRE-OPERATION CHECKS
.............. 4-1
Pre-operation check list ................... 4-2
OPERATION AND IMPORTANT
RIDING POINTS
.................................. 5-1
Starting the engine .......................... 5-1
Shifting ............................................ 5-2
Tips for reducing fuel
consumption ................................ 5-3
Engine break-in ............................... 5-3
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR
.................................. 6-1
Owner’s tool kit ................................ 6-1
Periodic maintenance and lubrication
chart ............................................. 6-2
Removing and installing cowlings and
panels .......................................... 6-5
Checking the spark plugs ................ 6-6
Engine oil and oil filter element ....... 6-7
Coolant .......................................... 6-10
Replacing the air filter element ...... 6-12
Adjusting the engine idling
speed ......................................... 6-14
Checking the throttle cable free
play ............................................ 6-15Valve clearance ............................ 6-15
Tires .............................................. 6-15
Cast wheels .................................. 6-18
Adjusting the clutch lever free play 6-18
Adjusting the rear brake light
switch ......................................... 6-19
Checking the front and rear brake
pads ........................................... 6-20
Checking the brake fluid level ....... 6-20
Changing the brake fluid ............... 6-22
Drive chain slack ........................... 6-22
Cleaning and lubricating the drive
chain .......................................... 6-24
Checking and lubricating the
cables ........................................ 6-24
Checking and lubricating the throttle
grip and cable ............................ 6-25
Checking and lubricating the brake
and shift pedals ......................... 6-25
Checking and lubricating the brake
and clutch levers ........................ 6-25
Checking and lubricating the
sidestand ................................... 6-26
Lubricating the rear
suspension ................................ 6-26
Checking the front fork .................. 6-26
Checking the steering ................... 6-27
Checking the wheel bearings ........ 6-28
Battery ........................................... 6-28
Replacing the fuses ...................... 6-29
Replacing a headlight bulb ........... 6-31

SAFETY INFORMATION
1-3
1
When loading within this weight limit,
keep the following in mind:

Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Make
sure to distribute the weight as
evenly as possible on both sides of
the motorcycle to minimize imbal-
ance or instability.

Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.

Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a slow
steering response.Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re-
sponsible for the proper selection, in-
stallation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any ac-
cessories.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.


Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.

Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.

Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds. These ac-
cessories may also cause
instability when passing or being
passed by large vehicles.

Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.

Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
Maximum load:
TDM900 203 kg (448 lb)
TDM900A 200 kg (441 lb)

2-1
1
2
3
4
5
6
7
8
9

DESCRIPTION
EAU32220
Left view
TDM900
12
345678
9 9 10 11 12 13 1412
345678
9 9 10 11 12 13 14

1. Front fork spring preload adjusting bolt (page 3-16)
2. Front fork damping adjusting screw (page 3-16)
3. Air filter element (page 6-12)
4. Shock absorber assembly compression damping force adjusting
knob (page 3-17)
5. Battery (page 6-28)
6. Fuses (page 6-29)
7. Storage compartment (page 3-15)8. Grab bar
9. Luggage strap holder (page 3-19)
10. Seat lock (page 3-14)
11. Shock absorber assembly rebound damping force adjusting knob
(page 3-17)
12. Shock absorber assembly spring preload adjusting ring (page 3-17)
13. Shift pedal (page 3-10)
14. Engine oil drain bolt A (page 6-7)

DESCRIPTION
2-2
2
3
4
5
6
7
8
9 TDM900A
12
3456
7 7 8 9 10 11 1212
3456

1. Front fork spring preload adjusting bolt (page 3-16)
2. Front fork damping adjusting screw (page 3-16)
3. Air filter element (page 6-12)
4. Coolant reservoir (page 6-10)
5. Battery (page 6-28)
6. Fuses (page 6-29)
7. Luggage strap holder (page 3-19)
8. Seat lock (page 3-14)9. Shock absorber assembly rebound damping force adjusting knob
(page 3-17)
10. Shock absorber assembly spring preload adjusting ring (page 3-17)
11. Shift pedal (page 3-10)
12. Engine oil drain bolt A (page 6-7)

INSTRUMENT AND CONTROL FUNCTIONS
3-16
1
2
3
4
5
6
7
8
9

EAU14781
Adjusting the front fork
This front fork is equipped with spring
preload adjusting bolts and damping
force adjusting screws.
WARNING

EWA10180
Always adjust both fork legs equal-
ly, otherwise poor handling and loss
of stability may result.
Spring preload
To increase the spring preload and
thereby harden the suspension, turn
the adjusting bolt on each fork leg in di-
rection (a). To decrease the spring pre-
load and thereby soften thesuspension, turn the adjusting bolt on
each fork leg in direction (b).
NOTE:

Align the appropriate groove on the ad-
justing mechanism with the top of the
front fork cap bolt.
Damping force
1. Turn the adjusting screw on each
fork leg in direction (a) until the
screw moves almost a 1/2 turn
without clicking.
2. Continue turning the adjusting
screw in direction (a) until it clicks.
This is the minimum setting.
3. To increase the damping force,
continue turning the adjusting
screw in direction (a). The third
click after the minimum setting is
the maximum setting. If the adjust-
ing screw is turned further in direc-
tion (a), it will move half a turn
before returning to the minimum
setting.
1. Spring preload adjusting bolt
1
(a)(b)

1. Standard setting
2. Current setting
3. Front fork cap bolt
Spring preload setting:
Minimum (soft):
8
Standard:
7
Maximum (hard):
1
2
31
7654321
8

1. Damping force adjusting screw
(a) 1
1
2
3 4

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

10

*
Tires

Check tread depth and for damage.

Replace if necessary.

Check air pressure.

Correct if necessary.
√√√√ √
11

*
Wheel bearings

Check bearing for looseness or damage.
√√√√
12

*
Swingarm

Check operation and for excessive play.
√√√√

Lubricate with lithium-soap-based grease. Every 50000 km
13

Drive chain

Check chain slack, alignment and condition.

Adjust and lubricate chain with a special O-ring chain
lubricant thoroughly.Every 1000 km and after washing the motorcycle or
riding in the rain
14

*
Steering bearings

Check bearing play and steering for roughness.
√√√√√

Lubricate with lithium-soap-based grease. Every 20000 km
15

*
Chassis fasteners

Make sure that all nuts, bolts and screws are properly
tightened.
√√√√ √
16

Sidestand

Check operation.

Lubricate.
√√√√ √
17

*
Sidestand switch

Check operation.
√√√√√ √
18

*
Front fork

Check operation and for oil leakage.
√√√√
19

*
Shock absorber assem-
bly

Check operation and shock absorber for oil leakage.
√√√√
20

*
Rear suspension relay
arm and connecting arm
pivoting points

Check operation.
√√√√

Lubricate with lithium-soap-based grease.
√√
21

*
Fuel injection

Adjust engine idling speed and synchronization.
√√√√√ √
22

Engine oil

Change.

Check oil level and vehicle for oil leakage.
√√√√√ √
23

Engine oil filter element

Replace.
√√√
24

*
Cooling system

Check coolant level and vehicle for coolant leakage.
√√√√ √

Change. Every 3 years
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
1
2
3
4
5
6
7
8
9

EAU23200
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

EWA10730
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
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.
EAU23271
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.

Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
Recommended lubricant:
Lithium-soap-based grease

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
2
3
4
5
67
8
9
CAUTION:

ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.

7-1
2
3
4
5
6
78
9

MOTORCYCLE CARE AND STORAGE
EAU26040
Care
While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a motor-
cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your mo-
torcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlets with plas-
tic bags after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug caps, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
CAUTION:

ECA10770

Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.

Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.

Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasivecleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.

Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.

For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.

SPECIFICATIONS
8-2
1
2
3
4
5
6
7
8
9

Operation:
Left foot operation
Gear ratio:
1st:
33/12 (2.750)
2nd:
37/19 (1.947)
3rd:
34/22 (1.545)
4th:
31/25 (1.240)
5th:
26/25 (1.040)
6th:
24/26 (0.923)
Chassis:
Frame type:
Diamond
Caster angle:
25.50 °
Trail:
114.0 mm (4.49 in)
Front tire:
Type:
Tubeless
Size:
120/70 ZR18M/C (59W)
Manufacturer/model:
TDM900 METZELER/MEZ4 FRONT
TDM900A DUNLOP/D220FSTJ
Manufacturer/model:
TDM900 DUNLOP/D220FSTJ
Rear tire:
Type:
Tubeless
Size:
160/60 ZR17M/C (69W)
Manufacturer/model:
TDM900 METZELER/MEZ4
TDM900A DUNLOP/D220STJ
Manufacturer/model:
TDM900 DUNLOP/D220STJ
Loading:
Maximum load:
TDM900 203 kg (448 lb)
TDM900A 200 kg (441 lb)
* (Total weight of rider, passenger, cargo
and accessories)

Tire air pressure (measured on cold
tires):
Loading condition:
0–90 kg (0–198 lb)
Front:
225 kPa (33 psi) (2.25 kgf/cm
2

)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2

)
Loading condition:
TDM900 90–203 kg (198–448 lb)
TDM900A 90–200 kg (198–441 lb)
Front:
225 kPa (33 psi) (2.25 kgf/cm
2

)
Rear:
290 kPa (42 psi) (2.90 kgf/cm
2

)
High-speed riding:
Front:
225 kPa (33 psi) (2.25 kgf/cm
2

)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2

)
Front wheel:
Wheel type:
Cast wheel
Rim size:
18M/C x MT3.50
Rear wheel:
Wheel type:
Cast wheel
Rim size:
17M/C x MT5.00
Front brake:
Type:
Dual disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:
Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4
Front suspension:
Type:
Telescopic fork