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Yamaha TDM900 TDM900P 2001-2007 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: TDM900 Model Variant: TDM900P Production Years Covered: 2001, 2002, 2003, 2004, 2005, 2006, 2007 👋 Introduction Market Position Category: Sport Touring Motorcycle Target Audience: Riders seeking a versatile motorcycle for commuting, touring, and spirited riding Competitive Analysis Key Competitors: Honda VFR800, Triumph Sprint ST, Kawasaki GTR1000 (predecessor), Suzuki Bandit 1200S Key Features Engine Configuration: Parallel-twin, liquid-cooled, DOHC, 4-stroke Frame Type: Aluminum twin-spar frame Suspension Setup: Telescopic USD front forks, Monoshock rear suspension with linkage 📋 Manual Details Coverage Areas Manual Type: Full Service Repair Manual Language: English Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, tuning, and troubleshooting Fuel System: Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank, lines Ignition System: Ignition coils, spark plugs, CDI unit, wiring diagrams Transmission: Clutch operation, gearbox inspection, maintenance, and repair Cooling System: Radiator, cooling fan, thermostat, coolant circulation, hoses Exhaust System: Exhaust manifold, catalytic converter (if applicable), muffler, lambda sensor Electrical System: Wiring diagrams, battery, alternator, starter motor, lighting, fuses, relays, sensors Chassis And Suspension: Front fork (USD), rear shock absorber, linkage, swingarm, steering system Brakes: Front and rear brake calipers, master cylinders, brake lines, discs, ABS (if applicable) Wheels And Tires: Wheel bearings, tire pressure, mounting and balancing Bodywork And Fairings: Fairing removal and installation, panel alignment, seat, fuel tank mounting Troubleshooting: Diagnostic charts, common fault identification and rectification Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake bleeding Repair: Detailed step-by-step repair instructions for all major components Overhaul: Complete engine and gearbox overhaul procedures Diagnosis: Troubleshooting guides and fault code interpretation Adjustment: Carburetor (if applicable to earlier models or specific markets, though TDM900 is EFI), throttle cable, clutch cable, suspension settings Technical Depth Depth: Comprehensive, covering from basic rider maintenance to full engine rebuilds and electrical diagnostics 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for easy navigation Print Quality Quality: Professional, likely sourced from original manufacturer's documentation Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Completeness Scope: Extremely thorough, intended for professional mechanics and advanced DIY enthusiasts. ⚙️ Engine Specifications Primary Engine Engine Type: 897cc, liquid-cooled, 4-stroke, DOHC, parallel-twin Bore X Stroke: 92.0 mm x 67.5 mm Compression Ratio: 10.0:1 Valve Train: DOHC, 4 valves per cylinder Carburetion Or Injection: Electronic Fuel Injection (EFI) Performance Horsepower: Approx. 90 HP @ 8,500 RPM (varies slightly by region/spec) Torque: Approx. 88 Nm (65 lb-ft) @ 6,000 RPM (varies slightly by region/spec) Fuel System Fuel Tank Capacity: 20 Liters (5.3 US gallons) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Final Drive: Chain drive Features Clutch Type: Wet, multiple disc 📐 Dimensions Exterior Length: Approx. 2,185 mm (86.0 in) Width: Approx. 770 mm (30.3 in) Height: Approx. 1,240 mm (48.8 in) Wheelbase: Approx. 1,485 mm (58.5 in) Weights Dry Weight: Approx. 194 kg (427.7 lbs) Wet Weight: Approx. 211 kg (465.2 lbs) 🛡️ Safety Features Ratings ABS Availability: Optional on some models/markets Active Features Braking System: Dual 298mm discs front, Single 245mm disc rear (ABS optional) 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, digital speedometer, multi-function display (odometer, trip meters, fuel gauge, clock) Driver Assistance ABS: Optional anti-lock braking system available on select models Connectivity Charging Port: No factory integrated USB or power port, aftermarket options available 🔧 Maintenance Service Intervals Oil Change Interval: Every 10,000 km or 6 months (refer to manual for specifics) Spark Plug Replacement: Every 20,000 km (refer to manual for specifics) Air Filter Cleaning: Every 10,000 km or as needed based on conditions Valve Clearance Check: Every 40,000 km (refer to manual for specifics) Fluid Specifications Engine Oil Type: Yamalube 4 (or equivalent) 10W-40 API SG or higher, JASO MA Engine Oil Capacity: 3.00 L without filter change; 3.20 L with filter change (refer to manual) Coolant Type: Permanent type antifreeze (ethylene glycol based), 50% solution with de-ionized water Brake Fluid Type: DOT 4 Transmission Oil Type: Refer to manual for specific gearbox oil (often 75W-90 or similar gear oil) Known Issues Common Wear Item: Clutch plates (depending on riding style), swingarm bearings Potential Issue: Stalling at low RPMs (can be EFI related, check for air leaks, TPS adjustment) Maintenance Tip: Regular chain lubrication and adjustment is critical for driveability and longevity 📚 Vehicle History Brand Heritage Manufacturer: Yamaha Motor Company, Japan Model Evolution Predecessor: TDM850 Key Updates For Tdm900: Fuel injection, revised frame, improved suspension, updated styling, lighter overall weight compared to TDM850 Production Manufacturing Location: Japan 🏆 Awards & Recognition Recognitions Industry Acclaim: Consistently praised for its blend of sportiness and touring comfort, often cited as a benchmark in the sport-touring segment Ratings Engine Reliability: Generally considered very reliable with proper maintenance
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Yamaha TDM900 TDM900P 2001-2007 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TDM900
Model Variant:
TDM900P
Production Years Covered:
2001, 2002, 2003, 2004, 2005, 2006, 2007
👋 Introduction
Market Position
Category:
Sport Touring Motorcycle
Target Audience:
Riders seeking a versatile motorcycle for commuting, touring, and spirited riding
Competitive Analysis
Key Competitors:
Honda VFR800, Triumph Sprint ST, Kawasaki GTR1000 (predecessor), Suzuki Bandit 1200S
Key Features
Engine Configuration:
Parallel-twin, liquid-cooled, DOHC, 4-stroke
Frame Type:
Aluminum twin-spar frame
Suspension Setup:
Telescopic USD front forks, Monoshock rear suspension with linkage
📋 Manual Details
Coverage Areas
Manual Type:
Full Service Repair Manual
Language:
English
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, assembly, tuning, and troubleshooting
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank, lines
Ignition System:
Ignition coils, spark plugs, CDI unit, wiring diagrams
Transmission:
Clutch operation, gearbox inspection, maintenance, and repair
Cooling System:
Radiator, cooling fan, thermostat, coolant circulation, hoses
Exhaust System:
Exhaust manifold, catalytic converter (if applicable), muffler, lambda sensor
Electrical System:
Wiring diagrams, battery, alternator, starter motor, lighting, fuses, relays, sensors
Chassis And Suspension:
Front fork (USD), rear shock absorber, linkage, swingarm, steering system
Brakes:
Front and rear brake calipers, master cylinders, brake lines, discs, ABS (if applicable)
Wheels And Tires:
Wheel bearings, tire pressure, mounting and balancing
Bodywork And Fairings:
Fairing removal and installation, panel alignment, seat, fuel tank mounting
Troubleshooting:
Diagnostic charts, common fault identification and rectification
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake bleeding
Repair:
Detailed step-by-step repair instructions for all major components
Overhaul:
Complete engine and gearbox overhaul procedures
Diagnosis:
Troubleshooting guides and fault code interpretation
Adjustment:
Carburetor (if applicable to earlier models or specific markets, though TDM900 is EFI), throttle cable, clutch cable, suspension settings
Technical Depth
Depth:
Comprehensive, covering from basic rider maintenance to full engine rebuilds and electrical diagnostics
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF for easy navigation
Print Quality
Quality:
Professional, likely sourced from original manufacturer's documentation
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
Completeness
Scope:
Extremely thorough, intended for professional mechanics and advanced DIY enthusiasts.
⚙️ Engine Specifications
Primary Engine
Engine Type:
897cc, liquid-cooled, 4-stroke, DOHC, parallel-twin
Bore X Stroke:
92.0 mm x 67.5 mm
Compression Ratio:
10.0:1
Valve Train:
DOHC, 4 valves per cylinder
Carburetion Or Injection:
Electronic Fuel Injection (EFI)
Performance
Horsepower:
Approx. 90 HP @ 8,500 RPM (varies slightly by region/spec)
Torque:
Approx. 88 Nm (65 lb-ft) @ 6,000 RPM (varies slightly by region/spec)
Fuel System
Fuel Tank Capacity:
20 Liters (5.3 US gallons)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Final Drive:
Chain drive
Features
Clutch Type:
Wet, multiple disc
📐 Dimensions
Exterior
Length:
Approx. 2,185 mm (86.0 in)
Width:
Approx. 770 mm (30.3 in)
Height:
Approx. 1,240 mm (48.8 in)
Wheelbase:
Approx. 1,485 mm (58.5 in)
Weights
Dry Weight:
Approx. 194 kg (427.7 lbs)
Wet Weight:
Approx. 211 kg (465.2 lbs)
🛡️ Safety Features
Ratings
ABS Availability:
Optional on some models/markets
Active Features
Braking System:
Dual 298mm discs front, Single 245mm disc rear (ABS optional)
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, digital speedometer, multi-function display (odometer, trip meters, fuel gauge, clock)
Driver Assistance
ABS:
Optional anti-lock braking system available on select models
Connectivity
Charging Port:
No factory integrated USB or power port, aftermarket options available
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km or 6 months (refer to manual for specifics)
Spark Plug Replacement:
Every 20,000 km (refer to manual for specifics)
Air Filter Cleaning:
Every 10,000 km or as needed based on conditions
Valve Clearance Check:
Every 40,000 km (refer to manual for specifics)
Fluid Specifications
Engine Oil Type:
Yamalube 4 (or equivalent) 10W-40 API SG or higher, JASO MA
Engine Oil Capacity:
3.00 L without filter change; 3.20 L with filter change (refer to manual)
Coolant Type:
Permanent type antifreeze (ethylene glycol based), 50% solution with de-ionized water
Brake Fluid Type:
DOT 4
Transmission Oil Type:
Refer to manual for specific gearbox oil (often 75W-90 or similar gear oil)
Known Issues
Common Wear Item:
Clutch plates (depending on riding style), swingarm bearings
Potential Issue:
Stalling at low RPMs (can be EFI related, check for air leaks, TPS adjustment)
Maintenance Tip:
Regular chain lubrication and adjustment is critical for driveability and longevity
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Company, Japan
Model Evolution
Predecessor:
TDM850
Key Updates For Tdm900:
Fuel injection, revised frame, improved suspension, updated styling, lighter overall weight compared to TDM850
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Consistently praised for its blend of sportiness and touring comfort, often cited as a benchmark in the sport-touring segment
Ratings
Engine Reliability:
Generally considered very reliable with proper maintenance
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