2006 YAMAHA TDM 900 engine coolant

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

DESCRIPTION
2-2
2
3
4
5
6
7
8
9 TDM900A
12
3456
7 7 8 9 10 11 1212
3456

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
6 7 8 9 10

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)

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

EAU11911
Tachometer unit
The electric tachometer allows the rider
to monitor the engine speed and keep it
within the ideal power range.
When the key is turned to “ON”, the ta-
chometer needle will sweep once
across the r/min range and then return
to zero r/min in order to test the electri-
cal circuit.
CAUTION:

ECA10031
Do not operate the engine in the ta-
chometer red zone.
Red zone: 8000 r/min and above
This tachometer unit is equipped with a
clock.
To set the clock:
1. Push both the “SELECT” and “RE-
SET” buttons for at least two sec-
onds.
2. When the hour digits start flashing,
push the “RESET” button to set the
hours.
3. Push the “SELECT” button to
change the minutes.
4. When the minute digits start flash-
ing, push the “RESET” button to
set the minutes.
5. Push the “SELECT” button to start
the clock.
NOTE:


After setting the clock, be sure to
push the “SELECT” button before
turning the key to “OFF”, otherwise
the clock will not be set.

When the key is turned to “OFF”,
the clock display will remain on for
48 hours and then go off to prevent
the battery from discharging.
EAU12181
Coolant temperature gauge
With the key in the “ON” position, the
coolant temperature gauge indicates
the temperature of the coolant. When
the key is turned to “ON”, the coolant
temperature gauge needle will sweep
once across the temperature range and
then return to “C” in order to test the
electrical circuit. The coolant tempera-
ture varies with changes in the weather
and engine load. If the needle reaches
or enters the red zone, stop the vehicle
and let the engine cool. (See
page 6-35.)
1. Tachometer
2. Tachometer red zone
3. Clock
2
3
1

1. Coolant temperature gauge
2. Coolant temperature gauge red zone
12

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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
2
3
4
5
67
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, alignment and condition.

Adjust and lubricate chain with a special O-ring chain
lubricant thoroughly.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

*
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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
1
2
3
4
5
6
7
8
9
CAUTION:

ECA11620

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

Make sure that no foreign mate-
rial enters the crankcase.
9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
10. Turn the engine off, and thencheck the oil level and correct it if
necessary.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU38581
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:


The coolant level must be checked
on a cold engine since the level
varies with engine temperature.

Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.
NOTE:

The coolant should be between the
minimum and maximum level marks.
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
3.80 L (4.02 US qt) (3.34 Imp.qt)
With oil filter element replacement:
3.90 L (4.12 US qt) (3.43 Imp.qt)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
2
3
4
5
67
8
9 For TDM900
For TDM900A
3. If the coolant is at or below theminimum level mark, remove pan-
el B for TDM900 or panel A for
TDM900A (See page 6-5.), re-
move the reservoir cap, add cool-
ant to the maximum level mark,
and then install the reservoir cap
and the panel.
For TDM900For TDM900A
CAUTION:

ECA10470

If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.

If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool-
ing system will not be protected
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
1. Maximum level mark
2. Coolant reservoir cap
3. Minimum level mark
1 2
33 1
2

1. Coolant reservoir cap
1

1. Coolant reservoir cap
Coolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt) (0.22 Imp.qt)
1