2006 YAMAHA TDM 900 brake light

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

INSTRUMENT AND CONTROL FUNCTIONS
3-4
1
2
3
4
5
6
7
8
9For TDM900A

EAU38572
Turn signal indicator lights “” and
“” (For TDM900)/
Turn signal indicator light “”
(For TDM900A)

For TDM900: The corresponding
indicator light flashes when theturn 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

INSTRUMENT AND CONTROL FUNCTIONS
3-5
2
34
5
6
7
8
9

EAU11543
ABS warning light “” (for ABS
models)
If this warning light comes on or flashes
while riding, the ABS may be defective.
If this occurs, have a Yamaha dealer
check the system as soon as possible.
(See page 3-12.)
WARNING

EWA10081
If the ABS warning light comes on or
flashes while riding, the brake sys-
tem reverts to conventional braking.
Therefore, be careful not to cause
the wheels to lock during emergen-
cy braking. If the warning light
comes on or flashes while riding,
have a Yamaha dealer check the
brake system as soon as possible.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on or
remains on, have a Yamaha dealer
check the electrical circuit.
EAU38610
Immobilizer system indicator light
The electrical circuit of the indicatorlight can be checked by turning the key
to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
When the key is turned to “OFF” and 30
seconds have passed, the indicator
light will start flashing indicating the im-
mobilizer system is enabled. After 24
hours have passed, the indicator light
will stop flashing, however the immobi-
lizer system is still enabled.
NOTE:

This model is also equipped with a
self-diagnosis device for the immobiliz-
er system. If the immobilizer system is
defective, the indicator light will start
flashing a pattern and the odometer/
tripmeter will display a 2-digit code
when the key is turned to “ON”. When
this occurs, have a Yamaha dealer
check the self-diagnosis system. How-
ever, if the indicator light slowly flashes
five times, and then quickly flashes two
times repeatedly, error code 52 will be
displayed. This error could be caused
by signal interference. If this occurs, try
the following.
1. Use the code re-registering key to
start the engine.
NOTE:

Make sure there are no other immobi-
lizer keys close to the main switch, and
do not keep more than one immobilizer
key on the same key ring! Immobilizer
system keys may cause signal interfer-
ence, which may prevent the engine
from starting.
2. If the engine starts, turn it off, and
try starting the engine with the
standard keys.
3. If one or both of the standard keys
do not start the engine, take the
vehicle, the code re-registering
key and both standard keys to a
Yamaha dealer and have the stan-
dard keys re-registered.
ABS

PRE-OPERATION CHECKS
4-3
1
2
3
4
5
6
7
8
9

Throttle grip

Make sure that operation is smooth.

Check cable free play.

If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-15, 6-25
Control cables

Make sure that operation is smooth.

Lubricate if necessary.6-24
Drive chain

Check chain slack.

Adjust if necessary.

Check chain condition.

Lubricate if necessary.6-22, 6-24
Wheels and tires

Check for damage.

Check tire condition and tread depth.

Check air pressure.

Correct if necessary.6-15, 6-18
Brake and shift pedals

Make sure that operation is smooth.

Lubricate pedal pivoting points if necessary.6-25
Brake and clutch levers

Make sure that operation is smooth.

Lubricate lever pivoting points if necessary.6-25
Sidestand

Make sure that operation is smooth.

Lubricate pivot if necessary.6-26
Chassis fasteners

Make sure that all nuts, bolts and screws are properly tightened.

Tighten if necessary.—
Instruments, lights, signals
and switches

Check operation.

Correct if necessary.—
Sidestand switch

Check operation of ignition circuit cut-off system.

If system is defective, have Yamaha dealer check vehicle.3-19
ITEM CHECKS PAGE

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
1
2
3
4
5
6
7
8
9

EAU18680
NOTE:


Air filter

This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed air to avoid damaging it.

The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.

Replace the brake hoses every four years and if cracked or damaged.
25

*
Front and rear brake
switches

Check operation.
√√√√√ √
26

Moving parts and cables

Lubricate.
√√√√ √
27

*
Throttle grip housing
and cable

Check operation and free play.

Adjust the throttle cable free play if necessary.

Lubricate the throttle grip housing and cable.
√√√√ √
28

*
Air induction system

Check the air cut-off valve, reed valve, and hose for
damage.

Replace the entire air induction system if necessary.
√√√√ √
29

*
Muffler and exhaust pipe

Check the screw clamp for looseness.
√√√√√
30

*
Lights, signals and
switches

Check operation.

Adjust headlight beam.
√√√√√ √
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
2
3
4
5
67
8
9
NOTE:

If the specified clutch lever free play
could be obtained as described above,
tighten the locknut and skip the rest of
the procedure, otherwise proceed as
follows.
3. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loos-
en the clutch cable.
4. Loosen the locknut at the crank-
case.
5. To increase the clutch lever free
play, turn the adjusting nut in direc-
tion (a). To decrease the clutch le-ver free play, turn the adjusting nut
in direction (b).
6. Tighten the locknut at the clutch le-
ver and the crankcase.
EAU22270
Adjusting the rear brake light
switch
The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction (a). To
make the brake light come on later, turn
the adjusting nut in direction (b).
1. Locknut (crankcase)
2. Clutch lever free play adjusting nut
(crankcase)
12
(a)(b)

1. Rear brake light switch
2. Rear brake light switch adjusting nut
1
2 (a)(b)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
1
2
3
4
5
6
7
8
9

EAU24080
Replacing the tail/brake light
bulb
1. Remove the seat. (See
page 3-14.)
2. Remove the socket (together with
the bulb) by turning it counter-
clockwise.
3. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
4. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
5. Install the socket (together with the
bulb) by turning it clockwise.
6. Install the seat.
EAU24202
Replacing a turn signal light
bulb
1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
CAUTION:

ECA11190
Do not overtighten the screw, other-
wise the lens may break.
1. Socket
1

1. Screw
2. Turn signal light lens
12

1. Turn signal light bulb
1