2002 YAMAHA TDM 900 ABS

2-1
2
EAU00026
2-DESCRIPTION Left view1. Front fork spring preload adjusting bolt (page 3-13)
2. Front fork damping force adjusting screw (page 3-14)
3. Air filter element (page 6-16)
4. Shock absorber assembly spring
preload adjusting ring (page 3-15)
5. Battery (page 6-33)
6. Fuses (page 6-34)
7. Storage compartment (page 3-11)
8. Grab bar9. Luggage strap holder (page 3-17)
10. Seat lock (page 3-11)
11. Shock absorber assembly rebound
damping force adjusting knob (page 3-15)
12. Shock absorber assembly compression
damping force adjusting knob (page 3-16)
13. Shift pedal (page 3-8)
14. Engine oil drain bolt A (page 6-10)
U5PSE0.book Page 1 Thursday, December 13, 2001 4:29 PM

INSTRUMENT AND CONTROL FUNCTIONS
3
Main switch/steering lock .................................................................. 3-1
Indicator and warning lights ............................................................. 3-2
Speedometer unit .............................................................................. 3-3
Tachometer unit ................................................................................. 3-5
Coolant temperature gauge .............................................................. 3-5
Anti-theft alarm (optional) .................................................................. 3-6
Handlebar 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
Adjusting the front fork .................................................................... 3-13
Adjusting the shock absorber assembly .......................................... 3-15
Luggage strap holders .................................................................... 3-17
Sidestand ........................................................................................ 3-17
Ignition circuit cut-off system ........................................................... 3-18
U5PSE0.book Page 1 Thursday, December 13, 2001 4:29 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-15
3
EAU01864
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.
EC000015
CAUTION:_ Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings. _
Spring preload
To increase the spring preload and
thereby 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.CI-10E
Rebound damping force
To increase the rebound damping
force and thereby harden the rebound
damping, turn the adjusting knob in di-
rection
a. To decrease the rebound
damping force and thereby soften the
rebound damping, turn the adjusting
knob in direction
b.CI-03E
1. Spring preload adjusting ring
2. Special wrench
3. Position indicator
Setting
Minimum (soft) 1
Standard 5
Maximum (hard) 9
1. Rebound damping force adjusting knobMinimum (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
U5PSE0.book Page 15 Thursday, December 13, 2001 4:29 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-16
3
Compression damping force
To increase the compression damping
force 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.
CI-03E
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. _
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.
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.
@
1. Compression damping force adjusting knobMinimum (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
U5PSE0.book Page 16 Thursday, December 13, 2001 4:29 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
10
*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearingsCheck bearing for looseness or damage.√√√√
12*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50,000 km
13 Drive chainCheck chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate.Every 1,000 km and after washing
the motorcycle or riding in the rain
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20,000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.√√√√ √
16 SidestandCheck operation.
Lubricate.√√√√ √
17*Sidestand switchCheck operation.√√√√√ √
18*Front forkCheck operation and for oil leakage.√√√√
19*Shock absorber
assemblyCheck operation and shock absorber for oil leakage.√√√√
20*Rear suspension relay
arm and connecting arm
pivoting pointsCheck operation.√√√√
Lubricate with lithium-soap-based grease.√√
21*Electronic fuel injectionAdjust engine idling speed and synchronization.√√√√√ √
22 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
23 Engine oil filter elementReplace.√√√
24*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
U5PSE0.book Page 3 Thursday, December 13, 2001 4:29 PM

MOTORCYCLE CARE AND STORAGE
7-3
71. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
CAUTION:_ Do not use warm water since it in-
creases the corrosive action of the
salt. _2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick-
el-plated, surfaces to prevent cor-
rosion.After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the 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,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
EWA00001
WARNING
_

Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent.


Before operating the motor-
cycle, test its braking perfor-
mance and cornering behavior.
_
U5PSE0.book Page 3 Thursday, December 13, 2001 4:29 PM

SPECIFICATIONS
8-3
8
Maximum load* 203 kg
Tire air pressure
(measured on cold tires)
Up to 90 kg*
Front 250 kPa (2.50 kgf/cm
2, 2.50 bar)
Rear 250 kPa (2.50 kgf/cm2, 2.50 bar)
90 kg–maximum*
Front 250 kPa (2.50 kgf/cm2, 2.50 bar)
Rear 290 kPa (2.90 kgf/cm2, 2.90 bar)
High-speed riding
Front 250 kPa (2.50 kgf/cm2, 2.50 bar)
Rear 250 kPa (2.50 kgf/cm2, 2.50 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 5.00Brakes
Front
Type Dual disc brake
Operation Right hand
Fluid DOT 4
Rear
Type Single disc brake
Operation Right foot
Fluid DOT 4
Suspension
Front Telescopic fork
Rear Swingarm (monocross)
Spring/shock absorber
Front Coil spring / oil damper
Rear Coil spring / gas-oil damper
Wheel travel
Front 150 mm
Rear 133 mm
U5PSE0.book Page 3 Thursday, December 13, 2001 4:29 PM

10-INDEXAAir filter element, cleaning ...................... 6-16
Anti-theft alarm ........................................3-6BBattery ................................................... 6-33
Brake and clutch levers, checking and
lubricating ............................................ 6-29
Brake and shift pedals, checking and
lubricating ............................................ 6-29
Brake fluid, changing ............................. 6-26
Brake fluid level, checking...................... 6-25
Brake lever...............................................3-8
Brake light switch (rear), adjusting ......... 6-23
Brake pads, checking............................. 6-24
Brake pedal..............................................3-8
Brake pedal position, adjusting .............. 6-23CCables, checking and lubricating............ 6-28
Care.........................................................7-1
Clutch lever ..............................................3-7
Clutch lever free play, adjusting ............. 6-22
Conversion table ......................................8-5
Coolant .................................................. 6-12
Changing .......................................... 6-13
Checking .......................................... 6-12
Coolant temperature gauge .....................3-5
Cowlings and panels, removing and
installing ................................................6-5DDimmer switch .........................................3-6
Drive chain, lubricating ........................... 6-28
Drive chain slack ................................... 6-26
Adjusting .......................................... 6-27
Checking .......................................... 6-26EEngine break-in ....................................... 5-4
Engine oil and oil filter element ................ 6-9
Engine stop switch................................... 3-7
Engine trouble warning light .................... 3-3FFront 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 ........................................... 3-9
Fuses, replacing .................................... 6-34HHandlebar switches ................................. 3-6
Hazard switch .......................................... 3-6
Headlight bulb, replacing ....................... 6-35
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-6IIdentification numbers ............................. 9-1
Idling speed, adjusting ........................... 6-17
Ignition circuit cut-off system.................. 3-18
Indicator and warning lights ..................... 3-2
KKey identification number .........................9-1LLight switch ..............................................3-7
Luggage strap holders ...........................3-17MMain switch/steering lock .........................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-2OOil level warning light ...............................3-3PParking.....................................................5-5
Part locations ...........................................2-1
Pass switch ..............................................3-6
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list ............................4-1RRear suspension, lubricating ..................6-30SSafety information ....................................1-1
Seat .......................................................3-11
Shifting .....................................................5-3
Shift pedal ................................................3-8
Shift points (for Switzerland only) .............5-3
Shock absorber assembly, adjusting ......3-15
Sidestand ...............................................3-17
U5PSE0.book Page 1 Thursday, December 13, 2001 4:29 PM