ABS YAMAHA TDM 900 2006 User Guide

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
6-21
2
3
4
5
67
8
9 Rear brake (for TDM900A)
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
NOTE:

For TDM900A, the rear brake fluid res-
ervoir is located under the seat. (See
page 3-14.)
Observe these precautions:

When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.

Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.

Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.

Be careful that water or dust does
not enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of the
fluid and may result in vapor lock,
and dirt may clog the ABS hydrau-
lic unit valves.

Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.

As the brake pads wear, it is nor-
mal for the brake fluid level to grad-ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Minimum level mark
1

Recommended brake fluid:
DOT 4

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
1
2
3
4
5
6
7
8
9For TDM900A
The main fuse and the fuse box, which
contains the fuses for the individual cir-
cuits, are located under the seat. (See
page 3-14.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn offthe electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
CAUTION:

ECA10640
Do not use a fuse of a higher amper-
age rating than recommended toavoid causing extensive damage to
the electrical system and possibly a
fire.
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
1. Backup fuse (for odometer and clock)
2. Radiator fan fuse
3. Turn signal light and hazard fuse
4. Ignition fuse
5. Signaling system fuse
6. Headlight fuse
7. ABS motor fuse (for ABS models)
8. ABS motor spare fuse (for ABS models)
9. Main fuse
10. Spare fuse
11. Fuel injection system fuse
12. ABS control unit fuse (for ABS models)
12 34 5 6 7 8 911 12
10

Specified fuses:
Main fuse:
40.0 A
Headlight fuse:
TDM900 15.0 A
TDM900A 20.0 A
Radiator fan fuse:
20.0 A
Ignition fuse:
10.0 A
Signaling system fuse:
10.0 A
Backup fuse:
TDM900 5.0 A
TDM900A 10.0 A
Fuel injection system fuse:
10.0 A
Turn signal light and hazard fuse:
10.0 A
ABS motor fuse:
TDM900A 30.0 A
ABS control unit fuse:
TDM900A 10.0 A

MOTORCYCLE CARE AND STORAGE
7-2
1
2
3
4
5
6
7
8
9
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:

Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the motorcycle with cold wa-
ter and a mild detergent, after the
engine has cooled down.
CAUTION:

ECA10790
Do not use warm water since it in-
creases the corrosive action of the
salt.
2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick-
el-plated, surfaces to prevent cor-
rosion.
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 stain-
less-steel parts, including the ex-
haust system. (Even the thermally
induced discoloring of stain-
less-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,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damagecaused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
WARNING

EWA10930

Make 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 ac-
etone, and wash the tires with
warm water and a mild deter-
gent.

Before operating the motorcy-
cle test its braking performance
and cornering behavior.
CAUTION:

ECA10800

Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.

Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.

Avoid using abrasive polishing
compounds as they will wear

SPECIFICATIONS
8-3
2
3
4
5
6
7
89

Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
150.0 mm (5.91 in)
Rear suspension:
Type:
Swingarm (link suspension)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
133.0 mm (5.24 in)
Electrical system:
Ignition system:
Transistorized coil ignition (digital)
Charging system:
AC magneto
Battery:
Model:
GT12B-4
Voltage, capacity:
12 V, 10.0 Ah
Headlight:
Bulb type:
Halogen bulb
Bulb voltage, wattage
×
quantity:
Headlight:
12 V, 55.0 W
×
2
Tail/brake light:
12 V, 5.0 W/21.0 W
×
1
Front turn signal light:
12 V, 10.0 W
×
2
Rear turn signal light:
12 V, 10.0 W
×
2Auxiliary light:
12 V, 5.0 W
×
1
Meter lighting:
14 V, 2.0 W
×
2
Neutral indicator light:
14 V, 1.2 W
×
1
High beam indicator light:
14 V, 1.4 W
×
1
Oil level warning light:
LED
Turn signal indicator light:
TDM900 14 V, 1.2 W
×
2
TDM900A 14 V, 1.2 W
×
1
Engine trouble warning light:
14 V, 1.4 W
×
1
ABS warning light:
TDM900A 14 V, 1.4 W
×
1
Immobilizer system indicator light:
LED

Fuses:
Main fuse:
40.0 A
Headlight fuse:
TDM900 15.0 A
TDM900A 20.0 A
Signaling system fuse:
10.0 A
Ignition fuse:
10.0 A
Radiator fan fuse:
20.0 A
Turn signal light and hazard fuse:
10.0 AFuel injection system fuse:
10.0 A
ABS control unit fuse:
TDM900A 10.0 A
ABS motor fuse:
TDM900A 30.0 A
Backup fuse:
TDM900 5.0 A
TDM900A 10.0 A

INDEX
A
ABS (for ABS models) ............................ 3-12
ABS warning light (for ABS models) ......... 3-5
Air filter element, replacing ..................... 6-12
Anti-theft alarm (optional).......................... 3-8
Auxiliary light bulb, replacing .................. 6-33
B
Battery..................................................... 6-28
Brake and clutch levers, checking and
lubricating ............................................. 6-25
Brake and shift pedals, checking and
lubricating ............................................. 6-25
Brake fluid, changing .............................. 6-22
Brake fluid level, checking ...................... 6-20
Brake lever .............................................. 3-11
Brake pedal ............................................. 3-11
C
Cables, checking and lubricating ............ 6-24
Care .......................................................... 7-1
Catalytic converter .................................. 3-14
Clutch lever ............................................. 3-10
Clutch lever free play, adjusting .............. 6-18
Coolant.................................................... 6-10
Coolant temperature gauge ...................... 3-6
Cowlings and panels, removing and
installing.................................................. 6-5
D
Dimmer switch .......................................... 3-9
Drive chain, cleaning and lubricating ...... 6-24
Drive chain slack ..................................... 6-22
E
Engine break-in ......................................... 5-3
Engine idling speed................................. 6-14
Engine oil and oil filter element ................. 6-7Engine stop switch .....................................3-9
Engine trouble warning light ......................3-4
F
Front and rear brake pads, checking .......6-20
Front fork, adjusting .................................3-16
Front fork, checking .................................6-26
Fuel ..........................................................3-13
Fuel consumption, tips for reducing ...........5-3
Fuel level warning indicator .......................3-4
Fuel tank breather hose ...........................3-14
Fuel tank cap ...........................................3-12
Fuses, replacing ......................................6-29
H
Handlebar switches ...................................3-9
Hazard switch ............................................3-9
Headlight bulb, replacing .........................6-31
High beam indicator light ...........................3-4
Horn switch ................................................3-9
I
Identification numbers................................9-1
Ignition circuit cut-off system ...................3-20
Immobilizer system ....................................3-1
Immobilizer system indicator light ..............3-5
Indicator and warning lights .......................3-3
K
Key identification number ..........................9-1
L
Luggage strap holders .............................3-19
M
Main switch/steering lock ...........................3-2
Model label ................................................9-2
Multi-function display .................................3-7
N
Neutral indicator light .................................3-4
O
Oil level warning light ................................ 3-4
P
Parking ...................................................... 5-4
Part locations............................................. 2-1
Pass switch ............................................... 3-9
Periodic maintenance and lubrication
chart ........................................................ 6-2
Pre-operation check list ............................. 4-2
R
Rear brake light switch, adjusting............ 6-19
Rear suspension, lubricating ................... 6-26
S
Safety information ..................................... 1-1
Seat ......................................................... 3-14
Shifting ...................................................... 5-2
Shift pedal ............................................... 3-10
Shock absorber assembly, adjusting....... 3-17
Sidestand ................................................ 3-19
Sidestand, checking and lubricating ........ 6-26
Spark plugs, checking ............................... 6-6
Specifications ............................................ 8-1
Starting the engine .................................... 5-1
Start switch ................................................ 3-9
Steering, checking ................................... 6-27
Storage ...................................................... 7-3
Storage compartment .............................. 3-15
Supporting the motorcycle....................... 6-33
T
Tachometer unit ........................................ 3-6
Tail/brake light bulb, replacing................. 6-32
Throttle cable free play, checking............ 6-15
Throttle grip and cable, checking and
lubricating .............................................. 6-25