ABS YAMAHA TDM 900 2003 Owners Manual

2-1
EAU00026
DESCRIPTIONPart locations
2
1. Front fork spring preload adjusting bolt (page 3-15)
2. Front fork damping force adjusting
screw (page 3-15)
3. Air filter element (page 6-16)
4. Shock absorber assembly compression
damping force adjusting knob (page 3-17)
5. Battery (page 6-33)
6. Fuses (page 6-34)
7. Storage compartment (page 3-14)8. Grab bar
9. Luggage strap holders (page 3-18)
10. Seat lock (page 3-13)
11. Shock absorber assembly rebound
damping force adjusting knob (page 3-17)
12. Shock absorber assembly spring
preload adjusting ring (page 3-16)
13. Shift pedal (page 3-9)
14. Engine oil drain bolt A (page 6-9)
12
345678
9 9 10 11 12 13 1412
345678
9 9 10 11 12 13 14Left view
5PS-28199-E1 8/29/02 9:16 AM Page 10

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
Catalytic converter ...........................................................................3-12
Seat .................................................................................................3-13
Storage compartment ......................................................................3-14
Adjusting the front fork .....................................................................3-14
Adjusting the shock absorber assembly ..........................................3-16
Luggage strap holders .....................................................................3-18
Sidestand .........................................................................................3-18
Ignition circuit cut-off system ...........................................................3-19
3
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3-16
INSTRUMENT AND CONTROL FUNCTIONS
3 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
adjusting screw is turned further
in direction a, it will move half a
turn before returning to the mini-
mum setting.
NOTE:
Make sure that the adjusting screw is
turned to one of the four settings.
Setting
Minimum (soft) 1
Standard 2
Maximum (hard) 4
EAU04930
Adjusting the shock
absorber assembly
Shock absorber assembly, adjustingThis shock absorber assembly is
equipped with a spring preload
adjusting ring and rebound and com-
pression damping force adjusting
knobs.
EC000015
cC
Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.Spring preload
To increase the spring preload and
thereby harden the suspension, turn
the adjusting ring in direction a. To
decrease the spring preload and
thereby soften the suspension, turn
the adjusting ring in direction b.
1. Spring preload adjusting ring
2. Special wrench
3. Position indicator
Setting
Minimum (soft) 1
Standard 5
Maximum (hard) 9
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3-18
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU00315
w
This shock absorber contains
highly pressurized nitrogen gas.
For proper handling, read and
understand the following informa-
tion before handling the shock
absorber. The manufacturer can-
not be held responsible for proper-
ty damage or personal injury that
may result from improper han-
dling.
8Do not tamper with or attempt
to open the gas cylinder.
8Do not subject the shock
absorber to an open flame or
other high heat sources, other-
wise it may explode due to
excessive gas pressure.
8Do not deform or damage the
gas cylinder in any way, as
this will result in poor damp-
ing performance.
8Always have a Yamaha dealer
service the shock absorber.
EAU00324
Luggage strap holdersLuggage strap holdersThere are four luggage strap holders
below the passenger seat, two of
which can be turned out for easier
access.
1. Luggage strap holder (×4)
EAU00330
SidestandSidestandThe sidestand is located on the left
side of the frame. Raise the side-
stand or lower it with your foot while
holding the motorcycle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain situ-
ations. (See further down for an
explanation of the ignition circuit cut-
off system.)
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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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 50,000 km
13 Drive chain•Check chain slack.
•Make sure that the rear wheel is properly aligned.
•Clean and lubricate.Every 1,000 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 20,000 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
assembly•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
*Electronic fuel injection•Adjust engine idling speed and synchronization.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
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7
7-3
MOTORCYCLE CARE AND STORAGE
1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
cC
Do not use warm water since it
increases the corrosive action of
the salt.
2. After drying the motorcycle,
apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, sur-
faces to prevent corrosion.After cleaning
1. Dry the motorcycle with a
chamois or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainless-
steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, includ-
ing chrome- and nickel-plated,
surfaces.
5. Use spray oil as a universal
cleaner to remove any remaining
dirt.
6. Touch up minor paint damage
caused by stones, etc.7. Wax all painted surfaces.
8. Let the motorcycle dry complete-
ly before storing or covering it.
EWA00001
w
8Make sure that there is no oil
or wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild
detergent.
8Before operating the motorcy-
cle test its braking perfor-
mance and cornering behav-
ior.
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8
8-3
SPECIFICATIONS
Maximum load* 203 kg
Tire air pressure
(measured on cold tires)
Up to 90 kg*
Front
225 kPa (2.25 kgf/cm2, 2.25 bar)
Rear250 kPa (2.50 kgf/cm2, 2.50 bar)
90 kg load–Maximum*
Front
225 kPa (2.25 kgf/cm2, 2.25 bar)
Rear290 kPa (2.90 kgf/cm2, 2.90 bar)
High-speed riding
Front
225 kPa (2.25 kgf/cm2, 2.25 bar)
Rear250 kPa (2.50 kgf/cm2, 2.50 bar)
*Total weight of rider, passenger, cargo and accessories
Wheels
Front
Type Cast wheel
Size 18 M/C ×MT 3.50
Rear
Type Cast wheel
Size 17 M/C ×MT 5.00Brakes
Front
Type Dual disc brake
Operation Right hand
Fluid DOT 4
Rear
Type Single disc brake
Operation Right foot
Fluid DOT 4
Suspension
Front
Type Telescopic fork
Rear
Type Swingarm (link suspension)
Spring/shock absorber
Front Coil spring/oil damper
Rear Coil spring/gas-oil damper
Wheel travel
Front 150 mm
Rear 133 mm
5PS-28199-E1 8/29/02 9:17 AM Page 100

Shift points (for Switzerland only) ...........5-3
Shifting ...................................................5-2
Shock absorber assembly, adjusting ....3-16
Sidestand .............................................3-18
Sidestand, checking and lubricating .....6-30
Spark plugs, checking ............................6-7
Specifications .........................................8-1
Speedometer unit ...................................3-4
Starting the engine .................................5-1
Steering, checking ................................6-32
Storage ...................................................7-4
Storage compartment ...........................3-14
Supporting the motorcycle ....................6-38
T
Tachometer unit .....................................3-5
Tail/brake light bulb, replacing ..............6-37
Throttle cable free play, adjusting ........6-18
Throttle grip and cable, checking
and lubricating ...................................6-29
Tires .....................................................6-18
Tool kit ....................................................6-1
Troubleshooting ....................................6-43
Troubleshooting charts .........................6-44
Turn signal light bulb, replacing ............6-37
V
Valve clearance, adjusting ...................6-18
Vehicle identification number .................9-1W
Wheel (front)..........................................6-39
Installing .............................................6-40
Removing ...........................................6-39
Wheel (rear) .........................................6-40
Installing .............................................6-42
Removing ...........................................6-40
Wheel bearings, checking ....................6-32
Wheels .................................................6-22
INDEX
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