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Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TDM900/TDM900A. 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 others from trouble and injury.
This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual.
SAFETY INFORMATION TIONS. motorist’s blind spot. EAU10281 Many accidents involve inexperi- MOTORCYCLES SINGLE Safe riding enced operators. In fact, many op- TRACK VEHICLES. THEIR SAFE Always make pre-operation erators who have been involved in USE AND OPERATION ARE DEPEN- checks. Careful checks may help accidents do not even have a cur- DENT UPON THE USE OF PROPER prevent an accident.
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Modifications made to this motorcycle changing lanes. Make sure that single most critical factor in the preven- not approved by Yamaha, or the re- other motorists can see you. tion or reduction of head injuries. moval of original equipment, may ren- The posture of the operator and Always wear an approved helmet.
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If accessories Maximum load: Genuine Yamaha accessories have are added to the handlebar or TDM900 203 kg (448 lb) been specifically designed for use on front fork area, they must be as TDM900A 200 kg (441 lb) this motorcycle. Since Yamaha cannot...
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SAFETY INFORMATION could cause a dangerous loss of motorcycle in a place where pe- lights or engine power. destrians or children are not like- ly to touch these hot areas. Gasoline and exhaust gas Do not park the motorcycle on a GASOLINE IS HIGHLY FLAMMA- slope or soft ground, otherwise it BLE:...
Do not expose any key to exces- the vehicle along with all three keys to sively high temperatures. a Yamaha dealer to have them re-reg- Do not place any key close to istered. Do not use the key with the red magnets (this includes, but not bow for driving.
INSTRUMENT AND CONTROL FUNCTIONS can be started. The key cannot be re- To lock the steering EAU10471 Main switch/steering lock moved. NOTE: OFF ON The headlight comes on automatically when the engine is started and stays on until the key is turned to “OFF”. EAU10660 LOCK All electrical systems are off.
Indicator and warning lights The steering is locked, and the taillight and auxiliary light are on. The hazard For TDM900 light and turn signal lights can be turned on, but all other electrical systems are off. The key can be removed.
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7. Oil level warning light engine is defective. When this occurs, 8. Immobilizer system indicator light engine oil level is low. have a Yamaha dealer check the The electrical circuit of the warning light self-diagnosis system. EAU38572 can be checked by turning the key to The electrical circuit of the warning light Turn signal indicator lights “...
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ABS may be defective. NOTE: Yamaha dealer check the electrical cir- If this occurs, have a Yamaha dealer Make sure there are no other immobi- cuit. check the system as soon as possible.
INSTRUMENT AND CONTROL FUNCTIONS This tachometer unit is equipped with a EAU11911 EAU12181 Tachometer unit Coolant temperature gauge clock. To set the clock: 1. Push both the “SELECT” and “RE- SET” buttons for at least two sec- onds. 2. When the hour digits start flashing, push the “RESET”...
INSTRUMENT AND CONTROL FUNCTIONS two tripmeters (which show the EAU36610 ECA10020 Multi-function display CAUTION: distance traveled since they were EWA12311 last set to zero) Do not operate the engine if it is WARNING a fuel reserve tripmeter (which overheated. Be sure to stop the vehicle before shows the distance traveled on the making any setting changes to the fuel reserve)
If you do not reset the fuel such an error code, note the code num- reserve tripmeter manually, it will reset ber, and then have a Yamaha dealer itself automatically and the display will check the vehicle. return to the prior mode after refueling...
INSTRUMENT AND CONTROL FUNCTIONS Right position. To cancel the turn signal EAU12344 Handlebar switches lights, push the switch in after it has re- turned to the center position. Left EAU12500 Horn switch “ ” Press this switch to sound the horn. EAU12660 Engine stop switch “...
INSTRUMENT AND CONTROL FUNCTIONS ard lights (simultaneous flashing of all EAU12820 EAU12870 Clutch lever Shift pedal turn signal lights). The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard.
INSTRUMENT AND CONTROL FUNCTIONS dial is aligned with the “ ” mark on the EAU26822 EAU12941 Brake lever Brake pedal brake lever. The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handle- bar grip.
EAU13090 ABS (for ABS models) Fuel tank cap pulsating at the brake lever or The Yamaha ABS (Anti-lock Brake brake pedal when the ABS is oper- System) features a dual electronic con- ating. However, special tools are trol system, which acts on the front and required, so please consult your rear brakes independently.
Do not overfill the fuel tank, oth- erwise it may overflow when the Your Yamaha engine has been de- fuel warms up and expands. signed to use regular unleaded gaso- Avoid spilling fuel on the hot en- line with a research octane number of gine.
INSTRUMENT AND CONTROL FUNCTIONS EAU13410 EAU13441 EAU13860 Fuel tank breather hose Catalytic converter Seat This vehicle is equipped with catalytic converters in the exhaust system. To remove the seat EWA10860 Insert the key into the seat lock, turn it WARNING counterclockwise, and then pull the The exhaust system is hot after op- seat off.
Make sure that the seat is properly se- 3. U-LOCK bar (optional) cured before riding. This storage compartment is designed to hold an optional genuine Yamaha U-LOCK. (Other locks may not fit.) When placing a U-LOCK in the storage compartment, securely fasten it with the straps.
INSTRUMENT AND CONTROL FUNCTIONS suspension, turn the adjusting bolt on Damping force EAU14781 Adjusting the front fork each fork leg in direction (b). This front fork is equipped with spring preload adjusting bolts and damping force adjusting screws. EWA10180 WARNING Always adjust both fork legs equal- ly, otherwise poor handling and loss of stability may result.
INSTRUMENT AND CONTROL FUNCTIONS thereby harden the suspension, turn EAU15030 NOTE: Adjusting the shock absorber the adjusting ring in direction (a). To de- Make sure that the adjusting screw is assembly crease the spring preload and thereby turned to one of the four settings. This shock absorber assembly is soften the suspension, turn the adjust- equipped with a spring preload adjust-...
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Always have a Yamaha dealer range. To obtain a precise adjustment, service the shock absorber. it would be advisable to check the num- ber of clicks of each damping force ad- 1.
Yamaha’s ignition circuit cut-off system has been designed to assist the operator in fulfilling the respon- sibility of raising the sidestand be- fore starting off. Therefore, check this system regularly as described below and have a Yamaha dealer re- 3-19...
Periodically check the operation of the ignition circuit cut-off system according to the following procedure. EWA10250 WARNING If a malfunction is noted, have a Yamaha dealer check the system be- fore riding. 3-20...
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5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.
PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
Coolant If necessary, add recommended coolant to specified level. 6-10 Check cooling system for leakage. Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear. Front brake Replace if necessary. 6-20 Check fluid level in reservoir.
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PAGE Make sure that operation is smooth. Check cable free play. Throttle grip 6-15, 6-25 If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. Make sure that operation is smooth. Control cables 6-24 Lubricate if necessary.
OPERATION AND IMPORTANT RIDING POINTS attempt. the neutral position, do not EAU16671 Shifting coast for long periods of time ECA11040 with the engine off, and do not CAUTION: tow the motorcycle for long dis- For maximum engine life, never ac- tances.
OPERATION AND IMPORTANT RIDING POINTS EAU17212 Parking When parking, stop the engine, and then remove the key from the main switch. EWA10310 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.
Yamaha dealer wrench may be necessary to perform do it for you. 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.
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. ODOMETER READING (× 1000 km)
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PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Check tread depth and for damage. Replace if necessary. √ √ √ √ √ 10 * Tires Check air pressure. Correct if necessary. √...
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PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Front and rear brake √ √ √ √ √ √ 25 * Check operation. switches √ √ √ √ √ Moving parts and cables Lubricate.
PERIODIC MAINTENANCE AND MINOR REPAIR 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.
Do page 3-14.) not attempt to diagnose such problems 3. Remove the screw, and then take yourself. Instead, have a Yamaha deal- the panel off. er check the vehicle. If a spark plug shows signs of electrode erosion and excessive carbon or other deposits, it should be replaced.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU19830 Engine oil and oil filter Specified spark plug: Tightening torque: NGK/DPR8EA-9 Spark plug: element DENSO/X24EPR-U9 17.5 Nm (1.75 m·kgf, 12.7 ft·lbf) The engine oil level should be checked before each ride. In addition, the oil Before installing a spark plug, the spark NOTE: must be changed and the oil filter ele-...
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PERIODIC MAINTENANCE AND MINOR REPAIR the oil level. 4. If the engine oil is below the mini- mum level mark, add sufficient oil NOTE: of the recommended type to raise The engine oil should be between the it to the correct level. minimum and maximum level marks.
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PERIODIC MAINTENANCE AND MINOR REPAIR installing the bolts, then tightening them to the specified torque. Tightening torque: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) NOTE: Make sure that the O-rings are properly seated. 1. Engine oil drain bolt A 1.
PERIODIC MAINTENANCE AND MINOR REPAIR check the oil level and correct it if EAU20070 Coolant Recommended engine oil: necessary. See page 8-1. The coolant level should be checked Oil quantity: before each ride. In addition, the cool- Without oil filter element replace- ant must be changed at the intervals ment: specified in the periodic maintenance...
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PERIODIC MAINTENANCE AND MINOR REPAIR For TDM900 minimum level mark, remove pan- For TDM900A el B for TDM900 or panel A for TDM900A (See page 6-5.), re- move the reservoir cap, add cool- ant to the maximum level mark, and then install the reservoir cap and the panel.
If the engine overheats, see page filter case. (Do not disconnect the 6-35 for further instructions. (×2) fuel hoses!) 6. Remove the air filter case cover by removing the screws. 1. Bolt NOTE: For TDM900, skip steps 4 and 11. 6-12...
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Before installing the fuel tank, make sure that the fuel hoses are not damaged. If any fuel hose is damaged, do not start the engine but have a Yamaha dealer replace the hose, other- wise fuel may leak. 1. Air filter element Make sure that the fuel hoses 8.
To in- obtained as described above, have a crease the engine idling speed, turn the Yamaha dealer make the adjustment. screw in direction (a). To decrease the engine idling speed, turn the screw in direction (b).
To prevent this cle, note the following points regarding from occurring, the valve clearance the specified tires. must be adjusted by a Yamaha dealer at the intervals specified in the periodic Tire air pressure maintenance and lubrication chart.
Rear: trol, or severe injury. Make sure 250 kPa (36 psi) (2.50 kgf/cm that the total weight of rider, TDM900 90–203 kg (198–448 lb) passenger, cargo, and accesso- TDM900A 90–200 kg (198–441 lb): ries does not exceed the speci- Front: fied maximum load for the 225 kPa (33 psi) (2.25 kgf/cm...
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EWA10470 WARNING prevent air pressure leakage. Use only the tire valves and Have a Yamaha dealer replace valve cores listed below to excessively worn tires. Besides avoid tire deflation during a ride. being illegal, operating the vehi-...
If any damage is surfaces until they have been found, have a Yamaha dealer re- “broken in”. Therefore, it is ad- place the wheel. Do not attempt visable...
PERIODIC MAINTENANCE AND MINOR REPAIR ver free play, turn the adjusting nut EAU22270 NOTE: Adjusting the rear brake light in direction (b). If the specified clutch lever free play switch 6. Tighten the locknut at the clutch le- could be obtained as described above, ver and the crankcase.
EAU22390 EAU38640 Checking the front and rear Checking the brake fluid level peared, have a Yamaha dealer replace brake pads the brake pads as a set. Front brake The front and rear brake pads must be...
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However, if the make sure that the top of the brake brake fluid level goes down sud- fluid reservoir is level. denly, have a Yamaha dealer Use only the recommended quality check the cause. brake fluid, otherwise the rubber...
EAU22730 EAU22760 Changing the brake fluid Drive chain slack Have a Yamaha dealer change the The drive chain slack should be brake fluid at the intervals specified in checked before each ride and adjusted the NOTE after the periodic mainte- if necessary.
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PERIODIC MAINTENANCE AND MINOR REPAIR swingarm in direction (a). To loos- Tightening torque: en the drive chain, turn the adjust- Axle nut: ing bolt on each side of the 150 Nm (15.0 m·kgf, 108.5 ft·lbf) swingarm in direction (b), and then Brake caliper bracket bolt: push the rear wheel forward.
If a cable is damaged wet areas. Service the drive chain as or does not move smoothly, have a follows. Yamaha dealer check or replace it. ECA10581 CAUTION: Recommended lubricant: Engine oil...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23111 EAU23131 EAU23140 Checking and lubricating the Checking and lubricating the Checking and lubricating the throttle grip and cable brake and shift pedals brake and clutch levers The operation of the throttle grip should be checked before each ride. In addi- tion, the cable should be lubricated at the intervals specified in the periodic maintenance chart.
2. While applying the front brake, If the sidestand does not move up push down hard on the handlebars and down smoothly, have a Yamaha several times to check if the front dealer check or repair it. fork compresses and rebounds smoothly.
If any damage is found or the front fork does not operate smoothly, Securely support the vehicle so that have a Yamaha dealer check or re- there is no danger of it falling over. pair it. 2. Hold the lower ends of the front fork legs and try to move them for- ward and backward.
If there is play in the wheel working near batteries. In case hub or if the wheel does not turn of contact, administer the fol- smoothly, have a Yamaha dealer check lowing FIRST AID. the wheel bearings. EXTERNAL: Flush with plenty of water.
PERIODIC MAINTENANCE AND MINOR REPAIR To charge the battery battery, a special (constant-volt- EAU38591 Replacing the fuses Have a Yamaha dealer charge the bat- age) battery charger is required. tery as soon as possible if it seems to Using a conventional battery For TDM900 have discharged.
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Main fuse: 40.0 A 4. If the fuse immediately blows Headlight fuse: again, have a Yamaha dealer TDM900 15.0 A check the electrical system. 1 2 3 4 5 6 TDM900A 20.0 A Radiator fan fuse: 20.0 A...
4. Install the bulb cover, and then Do not touch the glass part of the connect the coupler. headlight bulb to keep it free from 5. Have a Yamaha dealer adjust the oil, otherwise the transparency of headlight beam if necessary. 6-31...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24080 EAU24202 Replacing the tail/brake light Replacing a turn signal light bulb bulb 1. Remove seat. (See 1. Remove the turn signal light lens page 3-14.) by removing the screw. 2. Remove the socket (together with the bulb) by turning it counter- clockwise.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU38900 EAU24350 Replacing the auxiliary light Supporting the motorcycle bulb Since this model is not equipped with a centerstand, follow these precautions 1. Remove the auxiliary light lens by when removing the front and rear removing the screws.
The following troubleshooting 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 technicians have the necessary tools, experience, and know-how to service the motorcycle properly.
Remove the spark plugs and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.
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Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. NOTE: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.
MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets, sprock- cleaning products, solvent or EAU26040 Care ets, the drive chain and wheel thinner, fuel (gasoline), rust re- While the open design of a motorcycle axles. Always rinse the dirt and de- movers or inhibitors, brake flu- reveals the attractiveness of the tech- greaser off with water.
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MOTORCYCLE CARE AND STORAGE After normal use salt. caused by stones, etc. Remove dirt with warm water, a mild 7. Wax all painted surfaces. 2. After drying the motorcycle, apply detergent, and a soft, clean sponge, 8. Let the motorcycle dry completely a corrosion protection spray on all and then rinse thoroughly with clean before storing or covering it.
EAU26201 Storage 3. Perform the following steps to pro- NOTE: tect the cylinders, piston rings, etc. Consult a Yamaha dealer for advice on Short-term from corrosion. what products to use. Always store your motorcycle in a cool, a. Remove the spark plug caps dry place and, if necessary, protect it and spark plugs.
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MOTORCYCLE CARE AND STORAGE pivoting points of all levers and pedals as well as of the sidestand/ centerstand. 5. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alterna- tively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one...
DENSO/X24EPR-U9 Recommended engine oil grade: With oil and fuel: Spark plug gap: API service SE, SF, SG type or higher TDM900 221.0 kg (487 lb) 0.8–0.9 mm (0.031–0.035 in) Engine oil quantity: TDM900A 224.0 kg (494 lb) Clutch: Without oil filter element replacement: Engine: 3.80 L (4.02 US qt) (3.34 Imp.qt)
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18M/C x MT3.50 31/25 (1.240) Loading: Rear wheel: 5th: Maximum load: Wheel type: 26/25 (1.040) TDM900 203 kg (448 lb) Cast wheel 6th: TDM900A 200 kg (441 lb) Rim size: 24/26 (0.923) * (Total weight of rider, passenger, cargo 17M/C x MT5.00...
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TDM900A 10.0 A Coil spring/gas-oil damper Wheel travel: Turn signal indicator light: 133.0 mm (5.24 in) TDM900 14 V, 1.2 W × 2 Electrical system: TDM900A 14 V, 1.2 W × 1 Ignition system: Engine trouble warning light: Transistorized coil ignition (digital) 14 V, 1.4 W ×...
Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: 1.
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1. Model label The model label is affixed to the frame under the seat. (See page 3-14.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
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INDEX Tires............6-15 Tool kit ............6-1 Troubleshooting ........6-34 Troubleshooting charts ......6-35 Turn signal indicator lights ......3-4 Turn signal light bulb, replacing ....6-32 Turn signal switch ........3-9 Valve clearance ........6-15 Vehicle identification number.....9-1 Wheel bearings, checking .......6-28 Wheels.............6-18...
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YAMAHA MOTOR CO., LTD. YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED ON RECYCLED PAPER PRINTED IN JAPAN PRINTED IN JAPAN 2005.8–0.1×1 ! 2005.8–0.1×1 !