ABS 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

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)

DESCRIPTION
2-4
2
3
4
5
6
7
8
9 TDM900A
1
56
7
8 9 10 11 12
23 4

1. Grab bar
2. Owner’s tool kit (page 6-1)
3. Storage compartment (page 3-15)
4. Shock absorber assembly compression damping force adjusting
knob (page 3-17)
5. Idle adjusting screw (page 6-14)
6. Front brake fluid reservoir (page 6-20)
7. Radiator cap (page 6-10)
8. Engine oil filler cap (page 6-7)9. Engine oil filter element (page 6-7)
10. Engine oil drain bolt B (page 6-7)
11. Brake pedal (page 3-11)
12. Rear brake fluid reservoir (page 6-20)

INSTRUMENT AND CONTROL FUNCTIONS
3-4
1
2
3
4
5
6
7
8
9For TDM900A

EAU38572
Turn signal indicator lights “” and
“” (For TDM900)/
Turn signal indicator light “”
(For TDM900A)

For TDM900: The corresponding
indicator light flashes when theturn signal switch is pushed to the
left or right.

For TDM900A: This indicator light
flashes when the turn signal switch
is pushed to the left or right.
EAU11060
Neutral indicator light “”
This indicator light comes on when the
transmission is in the neutral position.
EAU11080
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU38600
Oil level warning light
This warning light comes on when the
engine oil level is low.
The electrical circuit of the warning 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 cir-
cuit.
NOTE:

Even if the oil level is sufficient, the
warning light may flicker when riding on
a slope or during sudden acceleration
or deceleration, but this is not a mal-
function.
EAU11371
Fuel level warning indicator “”
This fuel level warning indicator starts
flashing when the fuel level drops be-
low approximately 3.5 L (0.92 US gal)
(0.77 Imp.gal).
EAU11500
Engine trouble warning light “”
This warning light comes on or flashes
when an electrical circuit monitoring the
engine is defective. When this occurs,
have a Yamaha dealer check the
self-diagnosis system.
The electrical circuit of the warning 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.
1. Fuel level warning indicator “ ”
2. Turn signal indicator light “ ”
3. High beam indicator light “ ”
4. Neutral indicator light “ ”
5. Engine trouble warning light “ ”
6. Anti-lock Brake System (ABS) warning
light “ ” (for ABS models)
7. Oil level warning light
8. Immobilizer system indicator light
12345678
ABS

INSTRUMENT AND CONTROL FUNCTIONS
3-5
2
34
5
6
7
8
9

EAU11543
ABS warning light “” (for ABS
models)
If this warning light comes on or flashes
while riding, the ABS may be defective.
If this occurs, have a Yamaha dealer
check the system as soon as possible.
(See page 3-12.)
WARNING

EWA10081
If the ABS warning light comes on or
flashes while riding, the brake sys-
tem reverts to conventional braking.
Therefore, be careful not to cause
the wheels to lock during emergen-
cy braking. If the warning light
comes on or flashes while riding,
have a Yamaha dealer check the
brake system as soon as possible.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on or
remains on, have a Yamaha dealer
check the electrical circuit.
EAU38610
Immobilizer system indicator light
The electrical circuit of the indicatorlight can be checked by turning the key
to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
When the key is turned to “OFF” and 30
seconds have passed, the indicator
light will start flashing indicating the im-
mobilizer system is enabled. After 24
hours have passed, the indicator light
will stop flashing, however the immobi-
lizer system is still enabled.
NOTE:

This model is also equipped with a
self-diagnosis device for the immobiliz-
er system. If the immobilizer system is
defective, the indicator light will start
flashing a pattern and the odometer/
tripmeter will display a 2-digit code
when the key is turned to “ON”. When
this occurs, have a Yamaha dealer
check the self-diagnosis system. How-
ever, if the indicator light slowly flashes
five times, and then quickly flashes two
times repeatedly, error code 52 will be
displayed. This error could be caused
by signal interference. If this occurs, try
the following.
1. Use the code re-registering key to
start the engine.
NOTE:

Make sure there are no other immobi-
lizer keys close to the main switch, and
do not keep more than one immobilizer
key on the same key ring! Immobilizer
system keys may cause signal interfer-
ence, which may prevent the engine
from starting.
2. If the engine starts, turn it off, and
try starting the engine with the
standard keys.
3. If one or both of the standard keys
do not start the engine, take the
vehicle, the code re-registering
key and both standard keys to a
Yamaha dealer and have the stan-
dard keys re-registered.
ABS

INSTRUMENT AND CONTROL FUNCTIONS
3-12
1
2
3
4
5
6
7
8
9

EAU26792
ABS (for ABS models)
The Yamaha ABS (Anti-lock Brake
System) features a dual electronic con-
trol system, which acts on the front and
rear brakes independently. The ABS is
monitored by an ECU (Electronic Con-
trol Unit), which will have recourse to
manual braking if a malfunction occurs.
WARNING

EWA10090

The ABS performs best on long
braking distances.

On certain (rough or gravel)
roads, the braking distance may
be longer with than without the
ABS. Therefore, always keep a
sufficient distance to the vehi-
cle ahead to match the riding
speed.
NOTE:


When the ABS is activated, the
brakes are operated in the usual
way. A pulsating action may be felt
at the brake lever or brake pedal,
but this does not indicate a mal-
function.

This ABS has a test mode whichallows the owner to experience the
pulsating at the brake lever or
brake pedal when the ABS is oper-
ating. However, special tools are
required, so please consult your
Yamaha dealer when performing
this test.
EAU13090
Fuel tank cap
To open the fuel tank cap
Open the fuel tank cap lock cover, in-
sert the key into the lock, and then turn
it 1/8 turn clockwise. The lock will be re-
leased and the fuel tank cap can be
opened.
To close the fuel tank cap
1. Push the fuel tank cap into position
with the key inserted in the lock.
2. Turn the key counterclockwise to
the original position, remove it, and
then close the lock cover.

1. Fuel tank cap lock cover
2. Unlock.
1
2

INSTRUMENT AND CONTROL FUNCTIONS
3-17
2
34
5
6
7
8
9
NOTE:

Make sure that the adjusting screw is
turned to one of the four settings.
EAU15030
Adjusting the shock absorber
assembly
This shock absorber assembly is
equipped with a spring preload adjust-
ing ring and rebound and compression
damping force adjusting knobs.
CAUTION:

ECA10100
Never attempt to turn an adjusting
mechanism beyond the maximum or
minimum settings.
Spring preload
To increase the spring preload andthereby harden the suspension, turn
the adjusting ring in direction (a). To de-
crease the spring preload and thereby
soften the suspension, turn the adjust-
ing ring in direction (b).
Rebound damping force
To increase the rebound damping force
and thereby harden the rebound damp-
ing, turn the adjusting knob in direction

Damping setting:
Minimum (soft):
1
Standard:
2
Maximum (hard):
4
1. Spring preload adjusting ring
2. Special wrench
3. Position indicator
(a) (b)3
1
2
1 2 3 4 5 6 7 8 9

Spring preload setting:
Minimum (soft):
1
Standard:
5
Maximum (hard):
9
1. Rebound damping force adjusting knob
1
(a)
(b)

INSTRUMENT AND CONTROL FUNCTIONS
3-18
1
2
3
4
5
6
7
8
9
(a). To decrease the rebound damping
force and thereby soften the rebound
damping, turn the adjusting knob in di-
rection (b).
Compression damping force
To increase the compression dampingforce and thereby harden the compres-
sion damping, turn the adjusting knob
in direction (a). To decrease the com-
pression damping force and thereby
soften the compression damping, turn
the adjusting knob in direction (b).
NOTE:

Although the total number of clicks of a
damping force adjusting mechanism
may not exactly match the above spec-
ifications due to small differences in
production, the actual number of clicks
always represents the entire adjusting
range. To obtain a precise adjustment,
it would be advisable to check the num-
ber of clicks of each damping force ad-
justing mechanism and to modify the
specifications as necessary.
WARNING

EWA10220
This shock absorber contains highly
pressurized nitrogen gas. For prop-
er handling, read and understand
the following information before
handling the shock absorber. The
manufacturer cannot be held re-
sponsible for property damage or
personal injury that may result from
improper handling.

Do not tamper with or attempt to
open the gas cylinder.

Do not subject the shock ab-
sorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.

Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping per-
formance.

Always have a Yamaha dealer
service the shock absorber.
Rebound damping setting:
Minimum (soft):
20 clicks in direction (b)*
Standard:
12 clicks in direction (b)*
Maximum (hard):
3 clicks in direction (b)*
* With the adjusting knob fully turned in
direction (a)
1. Compression damping force adjusting
knob
1
(a)
(b)

Compression damping setting:
Minimum (soft):
12 clicks in direction (b)*
Standard:
11 clicks in direction (b)*
Maximum (hard):
1 click in direction (b)*
* With the adjusting knob fully turned in
direction (a)

5-1
2
3
4
56
7
8
9

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