Yamaha TDM900 Manual

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

TDM900 (R) 2003. For complete service information procedures it is necessary to use this Supple-

mentary Service Manual together with the following manual.

TDM900 (N) 2001 SERVICE MANUAL: 5PS1-AE1

TDM900 (R) 2003

SUPPLEMENTARY

SERVICE MANUAL

E2002 by Yamaha Motor Co., Ltd.

First Edition, September 2002

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTE:

WARNING

CAUTION:

EAS00002

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-

al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles

should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-

hicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-

cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and

will appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the motorcycle operator, a bystander or a person checking or repairing the mo-

torcycle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid

out with the individual steps in sequential order.

1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each

page indicate the current chapter.

Refer to “SYMBOLS”.

2Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) ap-

pears.

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

24 25

2321

19 2018

16 1715

1413

11 12

GEN

INFO SPEC

ENG

FI ELEC

COOL

CHK

ADJ

TRBL

SHTG

CHAS

EAS00008

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols 1to 9indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Cooling system

7Fuel injection system

8Electrical system

9Troubleshooting

Symbols 10 to 17 indicate the following.

10 Serviceable with engine mounted

11 Filling fluid

12 Lubricant

13 Special tool

14 Tightening torque

15 Wear limit, clearance

16 Engine speed

17 Electrical data

Symbols 18 to 23 in the exploded diagrams indi-

cate the types of lubricants and lubrication

points.

18 Engine oil

19 Gear oil

20 Molybdenum-disulfide oil

21 Wheel-bearing grease

22 Lithium-soap- based grease

23 Molybdenum-disulfide grease

Symbols 24 to 25 in the exploded diagrams indi-

cate the following.

24 Apply locking agent (LOCTITE)

25 Replace the part

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL

CHECKING THE SWITCHES 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC STARTING SYSTEM 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT DIAGRAM 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 5. . . . . . . . . .

TROUBLESHOOTING 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIGHTING SYSTEM 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT DIAGRAM 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING

FAULTY LIGHTING SYSTEM 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEADLIGHT DOES NOT COME ON 14. . . . . . . . . . . . . . . . . . . . . . . . . .

HEADLIGHT BULB BURNT OUT 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TDM900 (R) 2003 WIRING DIAGRAM (EUR)

TDM900 (R) 2003 WIRING DIAGRAM (OCE)

–1–

GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS/

CHASSIS SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Model code 5PS4 (EUR)

5PS5 (OCE)

SSS

ENGINE SPECIFICATIONS

Item Standard Limit

Throttle bodies

Model (manufacturer) quantity

Intake vacuum pressure

Throttle cable free play (at the flange

of the throttle grip)

ID mark

Throttle valve size

38EIS (MIKUNI) 2

33 X36 kPa

3 X5 mm

5PS1 10

#50

SSS

CHASSIS SPECIFICATIONS

Item Standard Limit

Front tire

Tire type

Size

Model (manufacturer)

Tire pressure (cold)

0 X90 kg

90 X203 kg

High-speed riding

Min. tire tread depth

Tubeless

120/70ZR 18 M/C (59W)

MEZ4 FRONT (METZELER)/

D220FSTJ (DUNLOP)

225 kPa (2.25 kgf/cm2, 2.25 bar)

SSS

1.6 mm

Rear tire

Tire type

Size

Model (manufacturer)

Tire pressure (cold)

0 X90 kg

90 X203 kg

High-speed riding

Min. tire tread depth

Tubeless

160/60ZR 17 M/C (69W)

MEZ4 (METZELER)/

D220STJ (DUNLOP)

250 kPa (2.5 kgf/cm2, 2.5 bar)

290 kPa (2.9 kgf/cm2, 2.9 bar)

250 kPa (2.5 kgf/cm2, 2.5 bar)

SSS

1.6 mm

–2–

1Main switch

2Horn switch

3Pass switch

4Dimmer switch

5Hazard switch

6Turn signal switch

7Clutch switch

8Engine stop switch

9Start switch

10 Front brake light switch

11 Neutral switch

12 Rear brake light switch

13 Fuses

14 Sidestand switch

CHECKING THE SWITCHES ELEC

EAS00731

ELECTRICAL

CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the termi-

nals. Refer to “CHECKING SWITCH CONTINUITY”.

Damage/wear !Repair or replace.

Improperly connected !Properly connect.

Incorrect continuity reading !Replace the switch.

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