Yamaha TDM900 User manual

5PS-28199-E4
TDM900A
OWNER’S MANUAL
TDM900

EAU26942

INTRODUCTION
EAU10100
Welcome to the Yamaha world of motorcycling!
As the owner of the TDM900/TDM900A, you are benefiting from Yamaha’s vast experience and newest technology regard-
ing the design and manufacture of high-quality products, which have earned 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.
In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any
further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

IMPORTANT MANUAL INFORMATION
EAU10151
Particularly important information is distinguished in this manual by the following notations:
NOTE:
●
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. If you have any questions concerning this manual, please consult your Yamaha dealer.
WARNING
EWA10030
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
*Product and specifications are subject to change without notice.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander, or a person inspecting or repairing the motorcy-
cle.
A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

IMPORTANT MANUAL INFORMATION
EAU10200
TDM900/TDM900A
OWNER’S MANUAL
©2005 by Yamaha Motor Co., Ltd.
1st edition, July 2005
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.

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 ....................................3-17
Luggage 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 ............................................ 6-15
Valve 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

TABLE OF CONTENTS
Replacing the tail/brake light
bulb ............................................6-32
Replacing a turn signal light bulb ..6-32
Replacing an auxiliary light bulb ....6-33
Supporting the motorcycle .............6-33
Troubleshooting .............................6-34
Troubleshooting charts ..................6-35
MOTORCYCLE CARE AND
STORAGE ...........................................7-1
Care .................................................7-1
Storage ............................................7-3
SPECIFICATIONS ..............................8-1
CONSUMER INFORMATION ..............9-1
Identification numbers .....................9-1

1-1
1
SAFETY INFORMATION
EAU10281
MOTORCYCLES ARE SINGLE
TRACK VEHICLES. THEIR SAFE
USE AND OPERATION ARE DEPEN-
DENT UPON THE USE OF PROPER
RIDING TECHNIQUES AS WELL AS
THE EXPERTISE OF THE OPERA-
TOR. EVERY OPERATOR SHOULD
KNOW THE FOLLOWING REQUIRE-
MENTS BEFORE RIDING THIS MO-
TORCYCLE.
HE OR SHE SHOULD:
● OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
● OBSERVE THE WARNINGS
AND MAINTENANCE REQUIRE-
MENTS IN THE OWNER’S MAN-
UAL.
● OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.
● OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECES-
SARY BY MECHANICAL CONDI-
TIONS.
Safe riding
● Always make pre-operation
checks. Careful checks may help
prevent an accident.
● This motorcycle is designed to car-
ry the operator and a passenger.
● The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.
Therefore:
● Wear a brightly colored jacket.
● Use extra caution when you are
approaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur.
● Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
● Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent motorcycle license.
● Make sure that you are qualified
and that you only lend your mo-
torcycle to other qualified opera-
tors.
● Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
● We recommend that you prac-
tice riding your motorcycle
where there is no traffic until you
have become thoroughly famil-
iar with the motorcycle and all of
its controls.
● Many accidents have been caused
by error of the motorcycle opera-
tor. A typical error made by the op-
erator is veering wide on a turn
due to EXCESSIVE SPEED or un-
dercornering (insufficient lean an-
gle for the speed).
● Always obey the speed limit and
never travel faster than warrant-

SAFETY INFORMATION
1-2
1
ed by road and traffic conditions.
● Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
● The posture of the operator and
passenger is important for proper
control.
● The operator should keep both
hands on the handlebar and
both feet on the operator foot-
rests during operation to main-
tain control of the motorcycle.
● The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
● Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.
● Never ride under the influence of
alcohol or other drugs.
● This motorcycle is designed for
on-road use only. It is not suitable
for off-road use.
Protective apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the preven-
tion or reduction of head injuries.
● Always wear an approved helmet.
● Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
● The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.
● Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
● Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protec-
tive clothing that covers your legs,
ankles, and feet.
● A passenger should also observe
the above precautions.
Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the re-
moval of original equipment, may ren-
der the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your mo-
torcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your
motorcycle can adversely affect stabili-
ty and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use ex-
treme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here are some general guidelines to
follow if loading cargo or adding acces-
sories to your motorcycle:
Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.

SAFETY INFORMATION
1-3
1
When loading within this weight limit,
keep the following in mind:
● Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Make
sure to distribute the weight as
evenly as possible on both sides of
the motorcycle to minimize imbal-
ance or instability.
● Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.
● Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a slow
steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re-
sponsible for the proper selection, in-
stallation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any ac-
cessories.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
● Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.
● Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
● Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds. These ac-
cessories may also cause
instability when passing or being
passed by large vehicles.
● Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.
● Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
Maximum load:
TDM900 203 kg (448 lb)
TDM900A 200 kg (441 lb)

SAFETY INFORMATION
1-4
1
could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas
● GASOLINE IS HIGHLY FLAMMA-
BLE:
● Always turn the engine off when
refueling.
● Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.
● Never refuel while smoking or in
the vicinity of an open flame.
● Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has ad-
equate ventilation.
● Always turn the engine off before
leaving the motorcycle unattended
and remove the key from the main
switch. When parking the motorcy-
cle, note the following:
● The engine and exhaust system
may be hot, therefore, park the
motorcycle in a place where pe-
destrians or children are not like-
ly to touch these hot areas.
● Do not park the motorcycle on a
slope or soft ground, otherwise it
may fall over.
● Do not park the motorcycle near
a flammable source, (e.g., a ker-
osene heater, or near an open
flame), otherwise it could catch
fire.
● When transporting the motorcycle
in another vehicle, make sure that
it is kept upright. If the motorcycle
should lean over, gasoline may
leak out of the fuel tank.
● If you should swallow any gaso-
line, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediate-
ly. If any gasoline spills on your
skin or clothing, immediately wash
the affected area with soap and
water and change your clothes.

2-1
1
2
3
4
5
6
7
8
9
DESCRIPTION
EAU32220
Left view
TDM900
123 4 5 6 7 8
991011121314
12345678
991011121314
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
123 4 5 6
7789101112
123456
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
2-3
1
2
3
4
5
6
7
8
9
EAU32230
Right view
TDM900
1234
5
678910
1. Owner’s tool kit (page 6-1)
2. Coolant reservoir (page 6-10)
3. Idle adjusting screw (page 6-14)
4. Front brake fluid reservoir (page 6-20)
5. Radiator cap (page 6-10)
6. Engine oil filler cap (page 6-7)
7. Engine oil filter element (page 6-7)
8. Engine oil drain bolt B (page 6-7)
9. Brake pedal (page 3-11)
10. Rear brake fluid reservoir (page 6-20)

DESCRIPTION
2-4
2
3
4
5
6
7
8
9
TDM900A
156
7
89101112
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)

DESCRIPTION
2-5
1
2
3
4
5
6
7
8
9
EAU10430
Controls and instruments
1 2 345 6 7 8 9
1. Clutch lever (page 3-10)
2. Left handlebar switches (page 3-9)
3. Multi-function display (page 3-7)
4. Main switch/steering lock (page 3-2)
5. Tachometer unit (page 3-6)
6. Coolant temperature gauge (page 3-6)
7. Right handlebar switches (page 3-9)
8. Brake lever (page 3-11)
9. Throttle grip (page 6-15)

3-1
2
3
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU10972
Immobilizer system
This vehicle is equipped with an immo-
bilizer system to help prevent theft by
re-registering codes in the standard
keys. This system consists of the fol-
lowing.
● a code re-registering key (with a
red bow)
● two standard keys (with a black
bow) that can be re-registered with
new codes
● a transponder (which is installed in
the code re-registering key)
● an immobilizer unit
● an ECU
● an immobilizer system indicator
light (See page 3-3.)
The key with the red bow is used to reg-
ister codes in each standard key. Since
re-registering is a difficult process, take
the vehicle along with all three keys to
a Yamaha dealer to have them re-reg-
istered. Do not use the key with the red
bow for driving. It should only be used
for re-registering the standard keys. Al-
ways use a standard key for driving.
CAUTION:
ECA11820
●
DO NOT LOSE THE CODE
RE-REGISTERING KEY! CON-
TACT YOUR DEALER IMMEDI-
ATELY IF IT IS LOST! If the code
re-registering key is lost, regis-
tering new codes in the stan-
dard keys is impossible. The
standard keys can still be used
to start the vehicle, however if
code re-registering is required
(i.e., if a new standard key is
made or all keys are lost) the en-
tire immobilizer system must be
replaced. Therefore, it is highly
recommended to use either
standard key and keep the code
re-registering key in a safe
place.
● Do not submerse any key in wa-
ter.
● Do not expose any key to exces-
sively high temperatures.
● Do not place any key close to
magnets (this includes, but not
limited to, products such as
speakers, etc.).
● Do not place heavy items on any
key.
● Do not grind any key or alter its
shape.
● Do not disassemble the plastic
part of any key.
● Do not put two keys of any im-
mobilizer system on the same
key ring.
● Keep the standard keys as well
as keys of other immobilizer
systems away from this vehi-
cle’s code re-registering key.
● Keep other immobilizer system
keys away from the main switch
as they may cause signal inter-
ference.
1. Code re-registering key (red bow)
2. Standard keys (black bow)

INSTRUMENT AND CONTROL FUNCTIONS
3-2
1
2
3
4
5
6
7
8
9
EAU10471
Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering.
NOTE:
Be sure to use the standard key (black
bow) for regular use of the vehicle. To
minimize the risk of losing the code
re-registering key (red bow), keep it in a
safe place and only use it for code
re-registering.
EAU10570
ON
All electrical circuits are supplied with
power; the meter lighting, taillight and
auxiliary light come on, and the engine
can be started. The key cannot be re-
moved.
NOTE:
The headlight comes on automatically
when the engine is started and stays on
until the key is turned to “OFF”.
EAU10660
OFF
All electrical systems are off. The key
can be removed.
EAU10690
LOCK
The steering is locked, 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 or right.
2. Push the key in from the “OFF” po-
sition, and then turn it to “LOCK”
while still pushing it.
3. Remove the key.
OFF ON
LOCK
P
1. Push.
2. Turn.

INSTRUMENT AND CONTROL FUNCTIONS
3-3
2
3
4
5
6
7
8
9
To unlock the steering
Push the key into the main switch, and
then turn it to “OFF” while still pushing
it.
WARNING
EWA10060
Never turn the key to “OFF”or
“LOCK”while the vehicle is moving,
otherwise the electrical systems will
be switched off, which may result in
loss of control or an accident. Make
sure that the vehicle is stopped be-
fore turning the key to “OFF”or
“LOCK”.
EAU33000
(Parking)
The steering is locked, and the taillight
and auxiliary light are on. The hazard
light and turn signal lights can be turned
on, but all other electrical systems are
off. The key can be removed.
The steering must be locked before the
key can be turned to “ ”.
CAUTION:
ECA11020
Do not use the parking position for
an extended length of time, other-
wise the battery may discharge.
EAU38561
Indicator and warning lights
For TDM900
1. Push.
2. Turn.
1. Fuel level warning indicator “ ”
2. Left turn signal indicator light “ ”
3. High beam indicator light “ ”
4. Neutral indicator light “ ”
5. Engine trouble warning light “ ”
6. Right turn signal indicator light “ ”
7. Oil level warning light
8. Immobilizer system indicator light
12345678

INSTRUMENT AND CONTROL FUNCTIONS
3-4
1
2
3
4
5
6
7
8
9
For TDM900A
EAU38572
Turn signal indicator lights “”and
“”(For TDM900)/
Turn signal indicator light “”
(For TDM900A)
●
For TDM900: The corresponding
indicator light flashes when the
turn 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