YAMAHA TDM 900 2006 Service Manual

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OPERATION AND IMPORTANT RIDING POINTS
EAU15950
WARNING

EWA10270

Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.

Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.

Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU26801
Starting the engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.

The transmission is in gear with
the clutch lever pulled and the sid-
estand up.
WARNING

EWA10290

Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-20.

Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
CAUTION:

ECA11781
The following warning lights and in-
dicator light should come on for a
few seconds, then go off.

Oil level warning light

Engine trouble warning light

Immobilizer system indicator
light

ABS warning light (for ABS
models)
If a warning or indicator light does
not go off, see page 3-3 for the corre-
sponding warning and indicator
light circuit check.
2. Shift the transmission into the neu-
tral position.
NOTE:

When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir-
cuit.
3. Start the engine by pushing the
start switch.
NOTE:

If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one

OPERATION AND IMPORTANT RIDING POINTS
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attempt.
CAUTION:

ECA11040
For maximum engine life, never ac-
celerate hard when the engine is
cold!
NOTE:

The engine is warm when it quickly re-
sponds to the throttle.
EAU16671
Shifting
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.
NOTE:

To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
CAUTION:

ECA10260

Even with the transmission inthe neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.

Always use the clutch while
changing gears to avoid damag-
ing the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
1. Shift pedal
2. Neutral position1
1 2 3
4 5 6
N2

OPERATION AND IMPORTANT RIDING POINTS
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EAU16810
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Shift up swiftly, and avoid high en-
gine speeds during acceleration.

Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.

Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16841
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17100
0–1000 km (0–600 mi)
Avoid prolonged operation above
4000 r/min.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above
6000 r/min.
CAUTION:

ECA11150
After 1000 km (600 mi) of operation,the engine oil must be changed, and
the oil filter element replaced.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
CAUTION:

ECA10310

Keep the engine speed out of
the tachometer red zone.

If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-
cle.

OPERATION AND IMPORTANT RIDING POINTS
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EAU17212
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
WARNING

EWA10310

Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.

Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
CAUTION:

ECA10380
Never park in an area where there
are fire hazards such as grass or
other flammable materials.

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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17240
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
WARNING

EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealer
do it for you.
EAU17520
Owner’s tool kit
The owner’s tool kit is located inside the
storage compartment under the seat.
(See page 3-14.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
WARNING

EWA10350
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es.
1. Owner’s tool kit
1

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU17705
Periodic maintenance and lubrication chart
NOTE:


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.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040
1*
Fuel line


Check fuel hoses for cracks or damage.
√√√√ √
2*
Spark plugs

Check condition.

Clean and regap.
√√

Replace.
√√
3*
Valves

Check valve clearance.

Adjust.Every 40000 km
4
Air filter element

Replace.
√
5
Clutch

Check operation.

Adjust.
√√√√√
6*
Front brake

Check operation, fluid level and vehicle for fluid leak-
age.
√√√√√ √

Replace brake pads. Whenever worn to the limit
7*
Rear brake

Check operation, fluid level and vehicle for fluid leak-
age.
√√√√√ √

Replace brake pads. Whenever worn to the limit
8*
Brake hoses

Check for cracks or damage.
√√√√ √

Replace. Every 4 years
9*
Wheels

Check runout and for damage.
√√√√

PERIODIC MAINTENANCE AND MINOR REPAIR
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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
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EAU18680
NOTE:


Air filter

This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed air to avoid damaging it.

The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.

Replace the brake hoses every four years and if cracked or damaged.
25

*
Front and rear brake
switches

Check operation.
√√√√√ √
26

Moving parts and cables

Lubricate.
√√√√ √
27

*
Throttle grip housing
and cable

Check operation and free play.

Adjust the throttle cable free play if necessary.

Lubricate the throttle grip housing and cable.
√√√√ √
28

*
Air induction system

Check the air cut-off valve, reed valve, and hose for
damage.

Replace the entire air induction system if necessary.
√√√√ √
29

*
Muffler and exhaust pipe

Check the screw clamp for looseness.
√√√√√
30

*
Lights, signals and
switches

Check operation.

Adjust headlight beam.
√√√√√ √
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU18712
Removing and installing
cowlings and panels
The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
a cowling or panel needs to be re-
moved and installed.
EAU18991
Cowlings A and B
To remove one of the cowlings
Remove the cowling screws and the
quick fastener, and then pull the cowl-
ing off as shown.
NOTE:

The quick fastener is removed by push-
ing the center pin in with a screwdriver,
and then pulling the fastener out.
1. Cowling A
2. Panel A
2
1

1. Cowling B
2. Panel B
2
1

1. Screw
2. Quick fastener
1. Quick fastener (after removal)
2. Quick fastener (before installation)
1
1
1
2
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To install the cowling
Place the cowling in the original posi-
tion, and then install the screws and the
quick fastener.NOTE:

To install the quick fastener, push the
center pin out so that it will protrude
from the fastener head, insert the fas-
tener into the cowling, and then push
the protruding pin in until it is flush with
the fastener head.
EAU19171
Panels A and B
To remove one of the panels
1. Remove the corresponding cowl-
ing A or B. (See page 6-5.)
2. Remove the seat. (See
page 3-14.)
3. Remove the screw, and then take
the panel off.To install the panel
1. Place the panel in the original po-
sition, and then install the screw.
2. Install the seat and the cowling.

EAU19641
Checking the spark plugs
The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal color
when the vehicle is ridden normally),
and all spark plugs installed in the en-
gine should have the same color. If any
spark plug shows a distinctly different
color, the engine could be defective. Do
not attempt to diagnose such problems
yourself. Instead, have a Yamaha deal-
er check the vehicle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.
1. Screw
1. Panel A
1
1