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Yamaha TDM900 TDM900P 2001-2007 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: TDM900 / TDM900P Model Code: TDM900 / TDM900P Year Range: 2001-2007 👋 Introduction Market Position Motorcycle Segment: Sport Touring / Adventure Touring Competitive Analysis Key Competitors Era: Honda VFR800, Kawasaki GTR1000, Suzuki Bandit 1200S, Ducati ST2/ST4 Key Features Engine Configuration: Parallel-twin, liquid-cooled, DOHC, 4-valve per cylinder Chassis Design: Aluminum deltabox frame, adjustable suspension, comfortable ergonomics Target Audience: Riders seeking a capable and comfortable motorcycle for long-distance touring and spirited riding Manual Value Proposition Cost Saving Aspect: Inexpensive way to maintain and repair the vehicle Content Quality: Detailed illustrations, diagrams, wiring schematics, and specifications 📋 Manual Details Coverage Areas Overall Coverage: Complete Service and Repair Page Count Estimated Page Count: N/A (Digital PDF - typically hundreds of pages equivalent) Manual Type Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, disassembly, inspection, assembly, tuning Engine Electrical: Ignition system, charging system, starting system, sensors, ECU diagnostics Emission Control: System components, diagnostics, adjustment Fuel System: Carburetor/injection system, fuel pump, filters, lines, tank inspection and service Suspension System: Front forks (damping, seals, oil), rear shock absorber, linkage inspection and service Clutch System: Clutch operation, adjustment, replacement of plates and springs Transmission: Manual transaxle system, gear inspection, lubrication, shift mechanism Drivetrain: Driveshaft and axle, final drive inspection and service Steering System: Handlebar, steering stem bearings, linkage inspection and service Brake System: Front and rear brake calipers, master cylinders, lines, discs, pads, bleeding procedures Body Interior Exterior: Fairings, panels, seat, tank, lighting, aesthetic components Body Electrical: Wiring schematics, lighting, instrumentation, switches, relays, battery service Restraint System: N/A (Motorcycle - typically refers to seatbelts or airbags in cars) Procedures Included Maintenance: Routine checks, oil changes, filter replacements, lubrication, adjustments Troubleshooting: Systematic diagnosis of common and uncommon problems Repair: Detailed step-by-step instructions for component repair and replacement Rebuild: Engine and major component rebuild procedures Technical Depth Depth: Comprehensive; suitable for novice DIYers to professional mechanics 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Fully Printable Zoom Functionality: Yes (Zoom IN/OUT) Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Delivery Method Delivery: Instant Download Software Requirements Reader Requirement: Adobe PDF Reader Unzipping Requirement: WinZip or equivalent Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve parallel-twin Displacement: 897cc Bore X Stroke: 92.0 mm x 67.5 mm Compression Ratio: 9.2:1 Performance Horsepower Approx: 98 HP @ 9000 rpm (European Spec) Torque Approx: 88 Nm @ 6500 rpm (European Spec) Fuel System Fuel Delivery: Fuel Injection (for most European/US models), Carburetor (early models may vary) Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/2 Ignition Ignition System: TCI (Transistor Controlled Ignition) Cooling System Cooling Type: Liquid-cooled Lubrication Oil Type Spec: Yamalube 4 10W-40 or equivalent API SG, Jaso MA Oil Capacity With Filter: Approx. 3.7 Liters (3.9 US qt) 🔧 Transmission Standard Transmission Type: Constant mesh 5-speed Optional Optional Transmission: N/A Features Clutch Type: Wet, multi-disc Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: Approx. 2210 mm (87.0 in) Width: Approx. 800 mm (31.5 in) Height: Approx. 1315 mm (51.8 in) Wheelbase: Approx. 1470 mm (57.9 in) Weights Dry Weight: Approx. 205 kg (452 lbs) Wet Weight Approx: Approx. 230 kg (507 lbs) Capacities Fuel Tank Capacity: Approx. 20 Liters (5.3 US gal) 🛡️ Safety Features Ratings Safety Features Comment: N/A (Motorcycle - safety is primarily rider control and component integrity) Active Features Braking System: Dual 298mm discs with 4-piston calipers (front), 245mm disc with 2-piston caliper (rear); ABS optional on some models. Passive Features Frame Structure: Rigid aluminum deltabox frame for stable handling 💡 Technology Features Infotainment Infotainment System: N/A (Basic motorcycle instrumentation) Driver Assistance ABS: Optional on some European and UK models Connectivity Connectivity Features: N/A Lighting Headlight Type: Dual Halogen bulbs 🔧 Maintenance Service Intervals Oil Change Interval: Every 4,000-6,000 km (2,500-3,700 miles) or annually, whichever comes first Oil Filter Change Interval: Every oil change Spark Plug Inspection Replacement: Inspect at 10,000 km (6,200 miles), replace as needed Valve Clearance Check: Every 20,000 km (12,500 miles) Fluid Specifications Fork Oil Type: Yamaha Fork Oil G10 or equivalent SAE 10W suspension fluid Fork Oil Level: Refer to manual for specific height (e.g., 130mm) Brake Fluid Type: DOT 4 Known Issues Common Wear Items: Clutch plates, steering head bearings, wheel bearings, fork seals Electrical Notes: Corrosion in connectors, especially for lighting and ignition systems, can be an occasional issue, particularly in humid climates. Maintenance Resources Manual Utility: Essential for correct torque values, fluid capacities, and step-by-step procedures. 📚 Vehicle History Brand Heritage Yamaha Legacy: Yamaha Motor Corporation is a Japanese manufacturer of motorcycles, marine products, and other motorized products. Model Evolution Tdm Lineage: The TDM series began with the TDM850 in the early...
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Yamaha TDM900 TDM900P 2001-2007 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TDM900 / TDM900P
Model Code:
TDM900 / TDM900P
Year Range:
2001-2007
👋 Introduction
Market Position
Motorcycle Segment:
Sport Touring / Adventure Touring
Competitive Analysis
Key Competitors Era:
Honda VFR800, Kawasaki GTR1000, Suzuki Bandit 1200S, Ducati ST2/ST4
Key Features
Engine Configuration:
Parallel-twin, liquid-cooled, DOHC, 4-valve per cylinder
Chassis Design:
Aluminum deltabox frame, adjustable suspension, comfortable ergonomics
Target Audience:
Riders seeking a capable and comfortable motorcycle for long-distance touring and spirited riding
Manual Value Proposition
Cost Saving Aspect:
Inexpensive way to maintain and repair the vehicle
Content Quality:
Detailed illustrations, diagrams, wiring schematics, and specifications
📋 Manual Details
Coverage Areas
Overall Coverage:
Complete Service and Repair
Page Count
Estimated Page Count:
N/A (Digital PDF - typically hundreds of pages equivalent)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, disassembly, inspection, assembly, tuning
Engine Electrical:
Ignition system, charging system, starting system, sensors, ECU diagnostics
Emission Control:
System components, diagnostics, adjustment
Fuel System:
Carburetor/injection system, fuel pump, filters, lines, tank inspection and service
Suspension System:
Front forks (damping, seals, oil), rear shock absorber, linkage inspection and service
Clutch System:
Clutch operation, adjustment, replacement of plates and springs
Transmission:
Manual transaxle system, gear inspection, lubrication, shift mechanism
Drivetrain:
Driveshaft and axle, final drive inspection and service
Steering System:
Handlebar, steering stem bearings, linkage inspection and service
Brake System:
Front and rear brake calipers, master cylinders, lines, discs, pads, bleeding procedures
Body Interior Exterior:
Fairings, panels, seat, tank, lighting, aesthetic components
Body Electrical:
Wiring schematics, lighting, instrumentation, switches, relays, battery service
Restraint System:
N/A (Motorcycle - typically refers to seatbelts or airbags in cars)
Procedures Included
Maintenance:
Routine checks, oil changes, filter replacements, lubrication, adjustments
Troubleshooting:
Systematic diagnosis of common and uncommon problems
Repair:
Detailed step-by-step instructions for component repair and replacement
Rebuild:
Engine and major component rebuild procedures
Technical Depth
Depth:
Comprehensive; suitable for novice DIYers to professional mechanics
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Fully Printable
Zoom Functionality:
Yes (Zoom IN/OUT)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Delivery Method
Delivery:
Instant Download
Software Requirements
Reader Requirement:
Adobe PDF Reader
Unzipping Requirement:
WinZip or equivalent
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 4-valve parallel-twin
Displacement:
897cc
Bore X Stroke:
92.0 mm x 67.5 mm
Compression Ratio:
9.2:1
Performance
Horsepower Approx:
98 HP @ 9000 rpm (European Spec)
Torque Approx:
88 Nm @ 6500 rpm (European Spec)
Fuel System
Fuel Delivery:
Fuel Injection (for most European/US models), Carburetor (early models may vary)
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2
Ignition
Ignition System:
TCI (Transistor Controlled Ignition)
Cooling System
Cooling Type:
Liquid-cooled
Lubrication
Oil Type Spec:
Yamalube 4 10W-40 or equivalent API SG, Jaso MA
Oil Capacity With Filter:
Approx. 3.7 Liters (3.9 US qt)
🔧 Transmission
Standard
Transmission Type:
Constant mesh 5-speed
Optional
Optional Transmission:
N/A
Features
Clutch Type:
Wet, multi-disc
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
Approx. 2210 mm (87.0 in)
Width:
Approx. 800 mm (31.5 in)
Height:
Approx. 1315 mm (51.8 in)
Wheelbase:
Approx. 1470 mm (57.9 in)
Weights
Dry Weight:
Approx. 205 kg (452 lbs)
Wet Weight Approx:
Approx. 230 kg (507 lbs)
Capacities
Fuel Tank Capacity:
Approx. 20 Liters (5.3 US gal)
🛡️ Safety Features
Ratings
Safety Features Comment:
N/A (Motorcycle - safety is primarily rider control and component integrity)
Active Features
Braking System:
Dual 298mm discs with 4-piston calipers (front), 245mm disc with 2-piston caliper (rear); ABS optional on some models.
Passive Features
Frame Structure:
Rigid aluminum deltabox frame for stable handling
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic motorcycle instrumentation)
Driver Assistance
ABS:
Optional on some European and UK models
Connectivity
Connectivity Features:
N/A
Lighting
Headlight Type:
Dual Halogen bulbs
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 4,000-6,000 km (2,500-3,700 miles) or annually, whichever comes first
Oil Filter Change Interval:
Every oil change
Spark Plug Inspection Replacement:
Inspect at 10,000 km (6,200 miles), replace as needed
Valve Clearance Check:
Every 20,000 km (12,500 miles)
Fluid Specifications
Fork Oil Type:
Yamaha Fork Oil G10 or equivalent SAE 10W suspension fluid
Fork Oil Level:
Refer to manual for specific height (e.g., 130mm)
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Items:
Clutch plates, steering head bearings, wheel bearings, fork seals
Electrical Notes:
Corrosion in connectors, especially for lighting and ignition systems, can be an occasional issue, particularly in humid climates.
Maintenance Resources
Manual Utility:
Essential for correct torque values, fluid capacities, and step-by-step procedures.
📚 Vehicle History
Brand Heritage
Yamaha Legacy:
Yamaha Motor Corporation is a Japanese manufacturer of motorcycles, marine products, and other motorized products.
Model Evolution
Tdm Lineage:
The TDM series began with the TDM850 in the early 1990s, evolving into the TDM900 with fuel injection and updated styling for increased performance and touring capability.
Production
Production Start Year:
2001
Production End Year:
2007
Manufacturing Location:
Japan (Primary)
🏆 Awards & Recognition
Recognitions
Industry Awards:
None specifically listed, but received acclaim for its blend of performance and comfort in the sport-touring segment.
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