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Yamaha TDM900 Owner'S Manual Download Page 53

PERIODIC MAINTENANCE AND MINOR REPAIR

6-8

6

NOTE:

_ 

If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. 

_

U5PSE0.book  Page 8  Thursday, December 13, 2001  4:29 PM

Summary of Contents for TDM900

Page 1: ...5PS 28199 E0 OWNER S MANUAL TDM900...

Page 2: ...Shiro fm Page 1 Thursday June 7 2001 11 38 AM...

Page 3: ...enjoy all advantages of your TDM900 The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and oth ers from trouble...

Page 4: ...e taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE U5PSE0 book Page 2 Thursday December 13 2001 4 29 PM...

Page 6: ...L 2001 by Yamaha Motor Co Ltd 1st edition October 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in J...

Page 7: ...T AND CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INF...

Page 8: ...U5PSE0 book Page 2 Thursday December 13 2001 4 29 PM...

Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF WAY 1 1 U5PSE0 book Page 1 Thursday December 13 2001 4 29 PM...

Page 10: ...ven small amounts of alcohol there is a tendency to take dangerous risks Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers Always wear a com...

Page 11: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 U5PSE0 book Page 1 Thursday December 13 2001 4 29 PM...

Page 12: ...ting ring page 3 15 5 Battery page 6 33 6 Fuses page 6 34 7 Storage compartment page 3 11 8 Grab bar 9 Luggage strap holder page 3 17 10 Seat lock page 3 11 11 Shock absorber assembly rebound damping...

Page 13: ...page 6 18 18 Front brake master cylinder page 6 25 19 Radiator cap page 6 14 20 Engine oil filler cap page 6 9 21 Engine oil filter element page 6 11 22 Engine oil drain bolt B page 6 10 23 Brake peda...

Page 14: ...r switches page 3 6 3 Speedometer unit page 3 3 4 Main switch steering lock page 3 1 5 Tachometer page 3 5 6 Coolant temperature gauge page 3 5 7 Right handlebar switches page 3 7 8 Brake lever page 3...

Page 15: ...andlebar switches 3 6 Clutch lever 3 7 Shift pedal 3 8 Brake lever 3 8 Brake pedal 3 8 Fuel tank cap 3 9 Fuel 3 9 Fuel tank breather hose for Germany only 3 10 Seat 3 11 Storage compartment 3 11 Adjus...

Page 16: ...and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while st...

Page 17: ...when the fuel level drops be low approximately 3 5 L EAU04121 Turn signal indicator lights and The corresponding indicator light flash es when the turn signal switch is pushed to the left or right EA...

Page 18: ...key to ON 2 If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical circuit NOTE _ Even if the oil level is sufficient the warning light may flic...

Page 19: ...automatically and the display will return to TRIP 1 after refueling and traveling 5 km NOTE _ After resetting the fuel reserve tripme ter the display will return to TRIP 1 unless a different mode had...

Page 20: ...art the clock NOTE _ After setting the clock be sure to push the SELECT button before turning the key to OFF other wise the clock will not be set When the key is turned to OFF the clock display will r...

Page 21: ...turns to the cen ter position To cancel the turn signal lights push the switch in after it has re turned to the center position EAU00129 Horn switch Press this switch to sound the horn EAU03826 Hazard...

Page 22: ...to crank the engine with the starter EC000005 CAUTION See page 5 1 for starting instruc tions prior to starting the engine EAU00152 Clutch lever The clutch lever is located at the left handlebar grip...

Page 23: ...pped with a po sition adjusting dial To adjust the dis tance between the brake lever and the handlebar grip turn the adjusting dial while holding the lever pushed away from the handlebar grip Make sur...

Page 24: ...ver NOTE The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked EWA00025 WARNING Make sure that the fuel t...

Page 25: ...ed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premium unleaded fuel Use of unleaded fuel will...

Page 26: ...y NOTE _ Make sure that the seat is properly se cured before riding _ EAU04292 Storage compartment This storage compartment is designed to hold an optional genuine Yamaha U LOCK Other locks may not fi...

Page 27: ...manual or other documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the motorcycle be careful not to let any water enter the storage...

Page 28: ...d 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 the suspension turn the adjusting bolt on each fork leg...

Page 29: ...he 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...

Page 30: ...the suspension turn the adjust ing ring in direction b CI 10E Rebound damping force To increase the rebound damping force and thereby harden the rebound damping turn the adjusting knob in di rection...

Page 31: ...s as necessary _ EAU00315 WARNING This shock absorber contains high ly pressurized nitrogen gas For proper handling read and under stand the following information be fore handling the shock absorber T...

Page 32: ...for an explanation of the ignition circuit cut off system EW000044 WARNING The motorcycle must not be ridden with the sidestand down or if the sidestand cannot be properly moved up or does not stay u...

Page 33: ...clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch lever is pulled but the sidestand is still down It cuts the running engine when the transmission is in...

Page 34: ...clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the...

Page 35: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 U5PSE0 book Page 1 Thursday December 13 2001 4 29 PM...

Page 36: ...ck vehicle for oil leakage 6 9 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 12 6 13 Front brake Check operation I...

Page 37: ...pivoting points if necessary 6 29 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 29 Sidestand Make sure that operation is smooth Lubricate pi...

Page 38: ...on can be accomplished in a very short time and the added safety it assures is more than worth the time involved _ EWA00033 WARNING _ If any item in the Pre operation check list is not working properl...

Page 39: ...IDING POINTS 5 Starting the engine 5 1 Shifting 5 3 Recommended shift points for Switzerland only 5 3 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 U5PSE0 book Page 1 Thursday...

Page 40: ...ting 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 sidestand up EW000054 WARNING _ Before sta...

Page 41: ...rting 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 attempt _ ECA00045 CAUTION _ For maximum engine life never ac celerate ha...

Page 42: ...le 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 d...

Page 43: ...d the following ma terial carefully Since the engine is brand new do not put an excessive load on it for the first 1 600 km The various parts in the en gine wear and polish themselves to the correct o...

Page 44: ...e key from the main switch EW000058 WARNING 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 o...

Page 45: ...level 6 25 Changing the brake fluid 6 26 Drive chain slack 6 26 Lubricating the drive chain 6 28 Checking and lubricating the cables 6 28 Checking and lubricating the throttle grip and cable 6 29 Chec...

Page 46: ...cle maintenance work have a Yamaha dealer do it for you EAU01299 Owner s tool kit The owner s tool kit is located inside the storage compartment under the seat See page 3 11 for seat removal procedure...

Page 47: ...CK 1 10 20 30 40 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 40 000 km 4 Air filter element Repl...

Page 48: ...hassis 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 le...

Page 49: ...rear brake switches Check operation 26 Moving parts and cables Lubricate 27 Air induction system Check the air cut off valve read valve and hose for damage Replace the entire air induction system if n...

Page 50: ...led EAU04039 Cowling A and B To remove one of the cowlings Remove the screws and the quick fas tener and then pull the cowling off as shown NOTE _ The quick fastener is removed by push ing the center...

Page 51: ...17 Panels A and B To remove one of the panels 1 Remove the corresponding cowl ing A or B See page 6 5 for cowl ing removal and installation procedures 2 Remove the seat See page 3 11 for seat removal...

Page 52: ...spark plugs installed in the engine should have the same color If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to diagnose such problems yourself I...

Page 53: ...ench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon a...

Page 54: ...3 Wait a few minutes until the oil set tles remove the oil filler cap wipe the dipstick clean insert it back into the oil filler hole without screwing it in and with the arrow mark pointing upward as...

Page 55: ...ngine oil with or without oil filter element replace ment 1 Start the engine warm it up for several minutes and then turn it off 2 Place an oil pan under the engine to collect the used oil 3 Remove th...

Page 56: ...s of a higher grade than CD In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase _ 9 Start the engine and then let it idle for se...

Page 57: ...orcycle is positioned straight up when checking the coolant level A slight tilt to the side can result in a false reading _ 2 Check the coolant level in the coolant reservoir NOTE _ The coolant should...

Page 58: ...WARNING _ Never attempt to remove the radia tor cap when the engine is hot _ NOTE _ The radiator fan is automatically switched on or off according to the coolant temperature in the radia tor If the e...

Page 59: ...servoir upward and away from the motorcycle 10 Drain the remaining coolant from the coolant reservoir by opening the cap then turning the reservoir upside down 11 Install the coolant reservoir by plac...

Page 60: ...e content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced _ 15 Install the radiator cap start the engine let it idle for several min utes and then turn it...

Page 61: ...the cooling system EAU04431 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter...

Page 62: ...he bolts EWA00013 WARNING _ Make sure that the fuel hose and breather hose are properly connect ed and routed and not pinched Re place any damaged hoses _ 9 Install the panels and cowlings 10 Install...

Page 63: ...rottle cable free play The throttle cable free play should measure 3 5 mm at the throttle grip Periodically check the throttle cable free play and if necessary have a Yamaha dealer adjust it EAU00637...

Page 64: ...ecautions in mind NEVER OVERLOAD THE MOTORCYCLE Operation of an overloaded motorcycle may re sult in tire damage loss of con trol or severe injury Make sure that the total weight of rider pas senger c...

Page 65: ...Yamaha dealer replace excessively worn tires Besides being illegal operating the motorcycle with excessively worn tires decreases riding sta bility and can lead to loss of control The replacement of...

Page 66: ...r to make the most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor g...

Page 67: ...To increase the clutch lever free play turn the adjusting bolt in di rection a To decrease the clutch lever free play turn the adjusting bolt in direction b 3 Tighten the locknut NOTE If the specified...

Page 68: ...lic system will diminish the braking performance which may result in loss of control and an accident EAU00713 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by t...

Page 69: ...tor which allows you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the position of the wear indicator while applying the brake If a brake pad ha...

Page 70: ...ke 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 l...

Page 71: ...The drive chain slack should be checked before each ride and adjusted if necessary To check the drive chain slack 1 Place the motorcycle on a level surface and hold it in an upright position NOTE When...

Page 72: ...hat both chain pullers are in the same posi tion for proper wheel alignment _ EC000096 CAUTION _ Improper drive chain slack will over load the engine as well as other vital parts of the motorcycle and...

Page 73: ...Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant ECA00052 CAUTION Do not use engine oil or any other lubricants for the drive chain as they may con...

Page 74: ...and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary EAU03164 Checking and lubricating the brake and...

Page 75: ...00113 WARNING If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EAU04282 Lubricating the rear suspension The pivoting points of the rear suspen sion must be l...

Page 76: ...2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoothly EC000098 CAUTION If any damage is found or the front fork...

Page 77: ...dealer check or repair the steer ing EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion cha...

Page 78: ...medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space...

Page 79: ...n the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage EC000103 CAUTION _ Do not use a fuse of a higher amper ag...

Page 80: ...b burns out replace it as follows 1 Disconnect the headlight coupler and then remove the bulb cover 2 Unhook the headlight bulb holder and then remove the defective bulb EW000119 WARNING _ Headlight b...

Page 81: ...nnect the coupler 5 Have a Yamaha dealer adjust the headlight beam if necessary EAU04411 Replacing a tail brake light bulb 1 Remove the seat See page 3 11 for seat removal and installation procedures...

Page 82: ...a centerstand follow these precautions when removing the front and rear wheel or performing other mainte nance requiring the motorcycle to stand upright Check that the motor cycle is in a stable and l...

Page 83: ...that there is no danger of it falling over _ 1 Loosen the front wheel axle pinch bolt then the brake caliper bolts 2 Loosen the wheel axle with a19 mm hexagon wrench 3 Lift the front wheel off the gro...

Page 84: ...talling the bolts 6 Tighten the wheel axle the front wheel axle pinch bolt and the brake caliper bolts to the specified torques 7 Push down hard on the handlebar several times to check for proper fork...

Page 85: ...the swingarm 6 Turn the drive chain slack adjust ing bolts fully in direction a 7 Push the wheel forward tighten the caliper bracket bolt and then remove the drive chain from the rear sprocket NOTE _...

Page 86: ...osen the brake caliper bracket bolt 4 Adjust the drive chain slack See page 6 27 for drive chain slack ad justment procedures 5 Install the axle nut and then lower the rear wheel so that it is on the...

Page 87: ...roubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technici...

Page 88: ...compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace th...

Page 89: ...ng sound has stopped press down on the cap while turning it counterclockwise and then remove the cap _ CT 2AE NOTE If coolant is not available tap water can be temporarily used instead provided that i...

Page 90: ...U5PSE0 book Page 45 Thursday December 13 2001 4 29 PM...

Page 91: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 U5PSE0 book Page 1 Thursday December 13 2001 4 29 PM...

Page 92: ...ical 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...

Page 93: ...stic may leave scratches on the wind shield Test the product on a small hidden part of the wind shield to make sure that it does not leave any marks If the wind shield is scratched use a quali ty plas...

Page 94: ...thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 4 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal inclu...

Page 95: ...0014 CAUTION _ Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet will allow water and humid ity to seep in and cause rust To prevent corrosion avoid...

Page 96: ...rning the engine over _ 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 5 Check and if necessary correct the tire air pressure a...

Page 97: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 U5PSE0 book Page 1 Thursday December 13 2001 4 29 PM...

Page 98: ...tem Electric starter Lubrication system Dry sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter element replacement 3 8 L With oil fil...

Page 99: ...on system Chain drive Secondary reduction ratio 2 625 Number of drive chain sprocket teeth front rear 16 42 Transmission type Constant mesh 6 speed Operation Left foot Gear ratio 1st 2 750 2nd 1 947 3...

Page 100: ...50 bar Total weight of rider passenger cargo and accessories Wheels Front Type Cast wheel Size 18 MT 3 50 18 M C MT 3 50 Rear Type Cast wheel Size 17 MT 5 00 17 M C MT 5 00 Brakes Front Type Dual disc...

Page 101: ...gnal light 12 V 10 W 4 Meter lighting 12 V 2 W 2 Neutral indicator light 14 V 1 2 W 1 High beam indicator light 14 V 1 4 W 1 Turn signal indicator light 14 V 1 2 W 2 Oil level warning light L E D Engi...

Page 102: ...ERIAL SYSTEM Metric unit Conversion factor Imperial unit Torque m kgf m kgf cm kgf cm kgf 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km h 0 6214 mi h Dist...

Page 103: ...CONSUMER INFORMATION 9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 U5PSE0 book Page 1 Thursday December 13 2001 4 29 PM...

Page 104: ...EAU01041 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU01043 Vehicle...

Page 105: ...rame under the seat See page 3 11 for seat removal and installation procedures Record the information on this label in the space provided This information will be needed when ordering spare parts from...

Page 106: ...g light 3 3 F Front fork adjusting 3 13 Front fork checking 6 31 Fuel 3 9 Fuel consumption tips for reducing 5 4 Fuel level warning symbol 3 2 Fuel tank breather hose Germany only 3 10 Fuel tank cap 3...

Page 107: ...hrottle cable free play adjusting 6 18 Throttle grip and cable checking and lubricating 6 29 Tires 6 19 Tool kit 6 1 Troubleshooting 6 42 Troubleshooting charts 6 43 Turn signal indicator lights 3 2 T...

Page 108: ...Shiro fm Page 1 Thursday June 7 2001 11 38 AM...

Page 109: ...Shiro fm Page 1 Thursday June 7 2001 11 38 AM...

Page 110: ...PRINTED IN JAPAN 2001 11 1 0 3 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD...

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