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Yamaha · Modern chain-drive motorcycle (2000-)

TDM 900

Library entry covers 2002-2013

40 factory 27 guideline

Published source

Yamaha TDM900 Owner's Manual 5PS-28199-E6 (UK, English), periodic maintenance and lubrication chart pp.6-2 to 6-4, NOTE p.6-4

Factory owner's handbook. Covers TDM900; UK owner's manual 5PS-28199-E6, English (model year not printed on the chart pages supplied). Chart columns 1000/10000/20000/30000/40000 km plus annual check (km only, no mile figures printed); from 50000 km repeat the intervals starting from 10000 km; annual checks every year except if a kilometer-based maintenance is performed instead. Liquid-cooled fuel-injected parallel twin, chain final drive.

Open the source

67 items for a 2006 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2006 Yamaha TDM 900

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 500 mi

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 621 mi

1 item

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Factory

Manual: Drive chain (check chain slack, alignment and condition; adjust and lubricate chain with a special O-ring chain lubricant thoroughly). Factory: Every 1000 km and after washing the motorcycle or riding in the rain, printed as text; not a dealer item (p.6-3)

Every 3,000 mi or 12 months

3 items

Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline

Every 6,000 mi or 12 months

5 items

Inspect coolant hoses and clamps

Engine

Guideline
Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 6,214 mi or 12 months

18 items

Change engine oil

Engine

Factory

Manual: Engine oil (change; check oil level and vehicle for oil leakage). Factory: Marked every column incl. 1000 km initial (1000/10000/20000/30000/40000 km); annual check; not a dealer item (p.6-3)
Chassis fasteners (make sure all nuts, bolts and screws are properly tightened)

Engine

Factory

Factory: Marked 10000-40000 km; not at 1000 km; annual check; dealer item (p.6-3)
Lights, signals and switches (check operation, adjust headlight beam)

Engine

Factory

Factory: Every column incl. 1000 km initial; annual check; dealer item (p.6-4)
Shift pedal pivot shaft (lubricate with lithium-soap-based grease)

Engine

Factory

Factory: Marked 10000-40000 km; not at 1000 km; annual check; not a dealer item (p.6-3)
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle grip housing and cable (check operation and free play, adjust throttle cable free play if necessary, lubricate throttle grip housing and cable). Factory: Marked 10000-40000 km; not at 1000 km; annual check; dealer item (p.6-4)
Replace fuel lines

Fuel and air

Factory

Manual: Fuel line (check fuel hoses for cracks or damage). Factory: Marked 10000-40000 km; not at 1000 km; annual check; dealer item (p.6-2)
Synchronize throttle bodies

Fuel and air

Factory

Manual: Fuel injection (adjust engine idling speed and synchronization). Factory: Every column incl. 1000 km initial; annual check; dealer item (p.6-3)
Clutch lever pivot shaft (lubricate with lithium-soap-based grease)

Primary and gearbox

Factory

Factory: Marked 10000-40000 km; not at 1000 km; annual check; not a dealer item (p.6-3)
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Sidestand (check operation, lubricate). Factory: Marked 10000-40000 km; not at 1000 km; annual check; not a dealer item (p.6-3)
Sidestand switch (check operation)

Rear suspension and frame

Factory

Factory: Every column incl. 1000 km initial; annual check; dealer item (p.6-3)
Brake lever pivot shaft (lubricate with silicone grease)

Brakes

Factory

Factory: Marked 10000-40000 km; not at 1000 km; annual check; not a dealer item (p.6-3)
Brake pedal pivot shaft (lubricate with silicone grease)

Brakes

Factory

Factory: Marked 10000-40000 km; not at 1000 km; annual check; not a dealer item (p.6-3)
Check brake pads and discs

Brakes

Factory

Manual: Front brake (check operation, fluid level and vehicle for fluid leakage; replace brake pads whenever worn to the limit). Factory: Check every column incl. 1000 km initial; annual check; pads replaced whenever worn to the limit; dealer item (p.6-2)
Front and rear brake switches (check operation)

Brakes

Factory

Factory: Every column incl. 1000 km initial; annual check; dealer item (p.6-4)
Rear brake (check operation, fluid level and vehicle for fluid leakage; replace brake pads whenever worn to the limit)

Brakes

Factory

Factory: Hydraulic rear brake. Check every column incl. 1000 km initial; annual check; pads replaced whenever worn to the limit; dealer item (p.6-2)
Air induction system (check the air cut-off valve, reed valve and hose for damage; replace the entire air induction system if necessary)

Wheels and tires

Factory

Factory: Marked 10000-40000 km; not at 1000 km; annual check; dealer item (p.6-4)
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tires (check tread depth and for damage, replace if necessary, check and correct air pressure). Factory: Marked 10000-40000 km; not at 1000 km; annual check; dealer item (p.6-3)
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Moving parts and cables (lubricate). Factory: Marked 10000-40000 km; not at 1000 km; annual check; not a dealer item (p.6-4)

Every 6,214 mi

9 items

Muffler and exhaust pipe (check the screw clamp for looseness)

Engine

Factory

Factory: Every column incl. 1000 km initial; no annual check; dealer item (p.6-4)
Rear suspension relay arm and connecting arm pivoting points (check operation)

Ignition and electrics

Factory

Factory: Marked 10000-40000 km; no annual check; dealer item (p.6-3)
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch (check operation, adjust). Factory: Every column incl. 1000 km initial; no annual check; not a dealer item (p.6-2)
Check steering head bearing adjustment

Front end

Factory

Manual: Steering bearings (check bearing play and steering for roughness). Factory: Every column incl. 1000 km initial; no annual check; dealer item (p.6-3)
Front fork (check operation and for oil leakage)

Front end

Factory

Factory: Marked 10000-40000 km; no annual check; no fork oil change interval printed; dealer item (p.6-3)
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Shock absorber assembly (check operation and shock absorber for oil leakage). Factory: Marked 10000-40000 km; no annual check; dealer item (p.6-3)
Swingarm (check operation and for excessive play)

Rear suspension and frame

Factory

Factory: Marked 10000-40000 km; no annual check; dealer item (p.6-3)
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings (check bearing for looseness or damage). Factory: Marked 10000-40000 km; no annual check; dealer item (p.6-3)
Wheels (check runout and for damage)

Wheels and tires

Factory

Factory: Marked 10000-40000 km; no annual check; dealer item (p.6-2)

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 12,427 mi

5 items

Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plugs (check condition, clean and regap). Factory: Marked at 10000 and 30000 km, alternating with replace; with the repeat-from-10000 km rule every 20000 km offset by 10000 km; no annual check; dealer item (p.6-2)
Replace oil filter

Engine

Factory

Manual: Engine oil filter element (replace). Factory: Marked at 1000, 20000 and 40000 km (not 10000 or 30000 km); no annual check; not a dealer item (p.6-4)
Replace spark plugs

Engine

Factory

Manual: Spark plugs (replace). Factory: Marked at 20000 and 40000 km; no annual check; dealer item (p.6-2)
Repack / replace steering head bearings

Front end

Factory

Manual: Steering bearings (lubricate with lithium-soap-based grease). Factory: Every 20000 km, printed as text; dealer item (p.6-3)
Clean and grease rear suspension linkage

Rear suspension and frame

Factory

Manual: Rear suspension relay arm and connecting arm pivoting points (lubricate with lithium-soap-based grease). Factory: Marked at 20000 and 40000 km; no annual check; dealer item (p.6-3)

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 15,000 mi or 4 years

1 item

Check valve clearances (shim adjusted)

Engine

Guideline

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

1 item

Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 24,000 mi or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 24,855 mi

2 items

Check and adjust valve clearances

Engine

Factory

Manual: Valves (check valve clearance, adjust). Factory: Every 40000 km, printed as text; dealer item (p.6-2)
Replace air filter element

Fuel and air

Factory

Manual: Air filter element (replace). Factory: Marked at 40000 km only; no annual check; not a dealer item. NOTE: disposable oil-coated paper element, must not be cleaned with compressed air; replace more frequently when riding in unusually wet or dusty areas (pp.6-2, 6-4)

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 31,069 mi

1 item

Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Swingarm (lubricate with lithium-soap-based grease). Factory: Every 50000 km, printed as text; dealer item (p.6-3)

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

4 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Brake master cylinder and caliper internal components (replace)

Brakes

Factory

Factory: From the NOTE under the chart: every two years replace the internal components of the brake master cylinders and calipers; not a chart row (p.6-4)
Replace brake fluid

Brakes

Factory

Manual: Brake fluid (change). Factory: From the hydraulic brake service NOTE under the chart: every two years change the brake fluid; regularly check and correct fluid level; not a chart row (p.6-4)

Every 3 years

1 item

Replace coolant

Engine

Factory

Manual: Cooling system (change). Factory: Change every 3 years, printed as text; check coolant level and vehicle for coolant leakage marked 10000-40000 km and annually; dealer item (p.6-4)

Every 4 years

2 items

Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hoses (replace). Factory: Every 4 years, printed as text (NOTE also: and if cracked or damaged); check for cracks or damage marked 10000-40000 km and annually; dealer item (pp.6-2, 6-4)
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.