2004 YAMAHA TDM 900 suspension
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TABLE OF CONTENTS
Checking and lubricating the
brake and shift pedals ........... 6-26
Checking and lubricating the
brake and clutch levers ......... 6-27
Checking and lubricating the
sidestand ............................... 6-27
Lubricating the rear
suspension ............................ 6-27
Checking the front fork ............ 6-28
Checking the steering ............. 6-28
Checking the wheel
bearings ................................ 6-29
Battery ..................................... 6-29
Replacing the fuses ................. 6-30
Replacing a headlight bulb ...... 6-31
Replacing the tail/brake light
bulb ....................................... 6-33
Replacing a turn signal light
bulb ....................................... 6-33
Supporting the motorcycle ...... 6-34
Front wheel ............................. 6-35
Rear wheel .............................. 6-36
Troubleshooting ...................... 6-38
Troubleshooting charts ............ 6-39
MOTORCYCLE CARE AND
STORAGE..................................... 7-1
Care .......................................... 7-1Storage ..................................... 7-3
SPECIFICATIONS ....................... 8-1
CONSUMER INFORMATION ...... 9-1
Identification numbers ............... 9-1
Page 10 of 92
SAFETY INFORMATION
1-3
1
Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit of
203 kg (448 lb). 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 slowsteering 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.
Page 29 of 92
INSTRUMENT AND CONTROL FUNCTIONS
3-15
2
34
5
6
7
8
9
EAU14781
Adjusting the front fork
This front fork is equipped with spring
preload adjusting bolts and damping
force adjusting screws.
WARNING
EWA10180
Always adjust both fork legs equal-
ly, otherwise poor handling and loss
of stability may result.
Spring preload
To increase the spring preload 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 thesuspension, turn the adjusting bolt on
each fork leg in direction (b).
NOTE:
Align the appropriate groove on the ad-
justing mechanism with the top of the
front fork cap bolt.
Damping force
1. Turn the adjusting screw on each
fork leg in direction (a) until the
screw moves almost a 1/2 turn
without clicking.
2. Continue turning the adjusting
screw in direction (a) until it clicks.
This is the minimum setting.
3. To increase the 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 move half a turn
before returning to the minimum
1. Spring preload adjusting bolt
1
(a)(b)
1. Standard setting
2. Current setting
3. Front fork cap bolt
Spring preload setting:
Minimum (soft):
8
Standard:
7
Maximum (hard):
1
2
31
7654321
8
1. Damping force adjusting screw
(a) 1
1
2
3 4
Page 30 of 92
INSTRUMENT AND CONTROL FUNCTIONS
3-16
1
2
3
4
5
6
7
8
9
setting.
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 and
thereby harden the suspension, turnthe 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)
Page 44 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
1
2
3
4
5
6
7
8
9
10
*
Tires
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
√
√
√
√
√
11
*
Wheel bearings
Check bearing for looseness or damage.
√
√
√
√
12
*
Swingarm
Check operation and for excessive play.
√
√
√
√
Lubricate with lithium-soap-based grease. Every 50000 km
13
Drive chain
Check chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate.Every 1000 km and after washing the motorcycle or
riding in the rain
14
*
Steering bearings
Check bearing play and steering for roughness.
√
√
√
√
√
Lubricate with lithium-soap-based grease. Every 20000 km
15
*
Chassis 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 leakage.
√
√
√
√
19
*
Shock absorber assem-
bly
Check operation and shock absorber for oil leakage.
√
√
√
√
20
*
Rear suspension relay
arm and connecting arm
pivoting points
Check operation.
√
√
√
√
Lubricate with lithium-soap-based grease.
√
√
21
*
Electronic fuel injection
Adjust engine idling speed and synchronization.
√
√
√
√
√
√
22
Engine oil
Change.
Check oil level and vehicle for oil leakage.
√
√
√
√
√
√
23
Engine oil filter element
Replace.
√
√
√
24
*Cooling system
Check coolant level and vehicle for coolant leakage.√ √ √ √ √ Change. Every 3 years NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
Page 58 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
1
2
3
4
5
6
7
8
9
WARNING
EWA11020
Because loading has an enormous
impact on the handling, braking,
performance and safety characteris-
tics of your motorcycle, you shouldkeep the following precautions in
mind.
NEVER OVERLOAD THE MO-
TORCYCLE! 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,
passenger, cargo, and accesso-
ries does not exceed the speci-
fied maximum load for the
vehicle.
Do not carry along loosely
packed items, which can shift
during a ride.
Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.
Adjust the suspension and tire
air pressure with regard to the
load.
Check the tire condition and air
pressure before each ride.Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
NOTE:
The tire tread depth limits may differ
from country to country. Always comply
Tire air pressure (measured on
cold tires):
0–90 kg (0–198 lb) :
Front:
225 kPa (33 psi) (2.25 kgf/cm
2
)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2
)
90–203 kg (198–448 lb) :
Front:
225 kPa (33 psi) (2.25 kgf/cm
2
)
Rear:
290 kPa (42 psi) (2.90 kgf/cm
2
)
High-speed riding:
Front:
225 kPa (33 psi) (2.25 kgf/cm
2
)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2
)
Maximum load*:
203 kg (448 lb)
* Total weight of rider, passenger,
cargo and accessories
1. Tire tread depth
2. Tire sidewall
Minimum tire tread depth (front
and rear):
1.6 mm (0.06 in)
21
Page 68 of 92
PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
1
2
3
4
5
6
7
8
9
EAU23140
Checking and lubricating the
brake and clutch levers
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
EAU23200
Checking and lubricating the
sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
WARNING
EWA10730
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
EAU23250
Lubricating the rear
suspension
The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
Page 87 of 92
SPECIFICATIONS
8-2
2
3
4
5
6
7
89
Operation:
Left foot operation
Gear ratio:
1st:
33/12 (2.750)
2nd:
37/19 (1.947)
3rd:
34/22 (1.545)
4th:
31/25 (1.240)
5th:
26/25 (1.040)
6th:
24/26 (0.923)
Chassis:
Frame type:
Diamond
Caster angle:
25.5 °
Trail:
114.0 mm (4.49 in)
Front tire:
Type:
Tubeless
Size:
120/70 ZR18M/C (59W)
Manufacturer/model:
METZELER/MEZ4 FRONT
Manufacturer/model:
DUNLOP/D220FSTJ
Rear tire:
Type:
Tubeless
Size:
160/60 ZR17M/C (69W)
Manufacturer/model:
METZELER/MEZ4
Manufacturer/model:
DUNLOP/D220STJ
Loading:
Maximum load:
203 kg (448 lb)
(Total weight of rider, passenger, cargo
and accessories)
Tire air pressure (measured on cold
tires):
Loading condition:
0–90 kg (0–198 lb)
Front:
225 kPa (33 psi) (2.25 kgf/cm
2
)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2
)
Loading condition:
90–203 kg (198–448 lb)
Front:
225 kPa (33 psi) (2.25 kgf/cm
2
)
Rear:
290 kPa (42 psi) (2.90 kgf/cm
2
)
High-speed riding:
Front:
225 kPa (33 psi) (2.25 kgf/cm 2
)
Rear:
250 kPa (36 psi) (2.50 kgf/cm
2
)
Front wheel:
Wheel type:
Cast wheel
Rim size:
18M/C x MT3.50
Rear wheel:
Wheel type:
Cast wheel
Rim size:
17M/C x MT5.00
Front brake:
Type:
Dual disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:
Type:
Single disc brake
Operation:
Right foot operation
Recommended fluid:
DOT 4
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
150.0 mm (5.91 in)