2006 YAMAHA TDM 900 brake

INSTRUMENT AND CONTROL FUNCTIONS
3-12
1
2
3
4
5
6
7
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9

EAU26792
ABS (for ABS models)
The Yamaha ABS (Anti-lock Brake
System) features a dual electronic con-
trol system, which acts on the front and
rear brakes independently. The ABS is
monitored by an ECU (Electronic Con-
trol Unit), which will have recourse to
manual braking if a malfunction occurs.
WARNING

EWA10090

The ABS performs best on long
braking distances.

On certain (rough or gravel)
roads, the braking distance may
be longer with than without the
ABS. Therefore, always keep a
sufficient distance to the vehi-
cle ahead to match the riding
speed.
NOTE:


When the ABS is activated, the
brakes are operated in the usual
way. A pulsating action may be felt
at the brake lever or brake pedal,
but this does not indicate a mal-
function.

This ABS has a test mode whichallows the owner to experience the
pulsating at the brake lever or
brake pedal when the ABS is oper-
ating. However, special tools are
required, so please consult your
Yamaha dealer when performing
this test.
EAU13090
Fuel tank cap
To open the fuel tank cap
Open the fuel tank cap lock cover, in-
sert the key into the lock, and then turn
it 1/8 turn clockwise. The lock will be re-
leased and the fuel tank cap can be
opened.
To close the fuel tank cap
1. Push the fuel tank cap into position
with the key inserted in the lock.
2. Turn the key counterclockwise to
the original position, remove it, and
then close the lock cover.

1. Fuel tank cap lock cover
2. Unlock.
1
2

PRE-OPERATION CHECKS
4-2
2
3
45
6
7
8
9

EAU15603
Pre-operation check list
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.3-13
Engine oil

Check oil level in engine.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.6-7
Coolant

Check coolant level in reservoir.

If necessary, add recommended coolant to specified level.

Check cooling system for leakage.6-10
Front brake

Check operation.

If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check brake pads for wear.

Replace if necessary.

Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.6-20
Rear brake

Check operation.

If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check brake pads for wear.

Replace if necessary.

Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.6-20
Clutch

Check operation.

Lubricate cable if necessary.

Check lever free play.

Adjust if necessary.6-18

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
6-2
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EAU17705
Periodic maintenance and lubrication chart
NOTE:


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.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1000 km)
ANNUAL
CHECK
1 10203040
1*
Fuel line


Check fuel hoses for cracks or damage.
√√√√ √
2*
Spark plugs

Check condition.

Clean and regap.
√√

Replace.
√√
3*
Valves

Check valve clearance.

Adjust.Every 40000 km
4
Air filter element

Replace.
√
5
Clutch

Check operation.

Adjust.
√√√√√
6*
Front brake

Check operation, fluid level and vehicle for fluid leak-
age.
√√√√√ √

Replace brake pads. Whenever worn to the limit
7*
Rear brake

Check operation, fluid level and vehicle for fluid leak-
age.
√√√√√ √

Replace brake pads. Whenever worn to the limit
8*
Brake hoses

Check for cracks or damage.
√√√√ √

Replace. Every 4 years
9*
Wheels

Check runout and for damage.
√√√√

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
6-12
1
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3
4
5
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7
8
9against frost and corrosion.


If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
WARNING

EWA10380
Never attempt to remove the radiator
cap when the engine is hot.
NOTE:


The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.

If the engine overheats, see page
6-35 for further instructions.
EAU27053
Replacing the air filter element
The air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the seat. (See
page 3-14.)
2. Remove cowlings A and B as well
as panels A and B. (See
page 6-5.)
3. Remove the fuel tank bolts.
NOTE:

For TDM900, skip steps 4 and 11.4. Remove the rear brake fluid reser-
voir holder by removing the bolt.
For TDM900A
5. Lift the fuel tank away from the air
filter case. (Do not disconnect the
fuel hoses!)
6. Remove the air filter case cover by
removing the screws.
1. Bolt
1(×2)

1. Rear brake fluid reservoir holder
2. Rear brake fluid reservoir
3. Bolt
12
3

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
2
3
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5
67
8
9
7. Pull the air filter element out.
8. Insert a new air filter element into
the air filter case.
CAUTION:

ECA10480

Make sure that the air filter ele-
ment is properly seated in the
air filter case.

The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
9. Install the air filter case cover by in-
stalling the screws.
10. Place the fuel tank in the original
position and install the bolts.
WARNING

EWA11330

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.

Make sure that the fuel hoses
are properly connected and
routed, and not pinched.

Be sure to place the fuel tank
breather hose and the fuel tankoverflow hose in the original po-
sition.
11. Install the rear brake fluid reservoir
holder by installing the bolt.
1. Air filter case cover
2. Screw
1. Air filter element
1 2
2 21

1. Fuel tank breather/overflow hose
2. Fuel hose
1. Original position (paint mark)
12
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
2
3
4
5
67
8
9
WARNING

EWA10470

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.

The replacement of all wheel
and brake related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
WARNING

EWA10900

The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motorcy-
cle cannot be guaranteed.

After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.

Always make sure that the valvecaps are securely installed to
prevent air pressure leakage.

Use only the tire valves and
valve cores listed below to
avoid tire deflation during a ride.
WARNING

EWA10600
This motorcycle is fitted with su-
per-high-speed tires. Note the fol-
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
123

Front tire:
Size:
120/70 ZR18M/C (59W)
Manufacturer/model:
TDM900 METZELER/MEZ4
FRONT
TDM900A DUNLOP/D220FSTJ
Tire air valve:
TR412
Valve core:
#9100 (original)
Rear tire:
Size:
160/60 ZR17M/C (69W)
Manufacturer/model:
TDM900 METZELER/MEZ4
TDM900A DUNLOP/D220STJ
Tire air valve:
TR412
Valve core:
#9100 (original)