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Yamaha TDM900 R Supplementary Service Manual
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Yamaha TDM900 R Supplementary Service Manual

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  • Page 3 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 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 4: Important Information

    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.

  • Page 5: How To Use This Manual

    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. 1 The manual is divided into chapters.
  • Page 6 EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system COOL 7 Fuel injection system 8 Electrical system...

  • Page 7: Table Of Contents

    CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS ........ENGINE SPECIFICATIONS .

  • Page 9: Specifications

    GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS/ SPEC CHASSIS SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5PS4 (EUR) 5PS5 (OCE) ENGINE SPECIFICATIONS Item Standard Limit Throttle bodies Model (manufacturer) quantity 38EIS (MIKUNI) 33 X 36 kPa Intake vacuum pressure 3 X 5 mm Throttle cable free play (at the flange of the throttle grip) ID mark...

  • Page 10: Electrical

    ELEC CHECKING THE SWITCHES 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.

  • Page 11: Electric Starting System

    ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM –3–...
  • Page 12 ELEC ELECTRIC STARTING SYSTEM Main fuse Battery Starter relay Starter motor Main switch Starting circuit cut-off relay Sidestand switch Neutral switch Clutch switch Engine stop switch Start switch Ignition fuse –4–...

  • Page 13: Starting Circuit Cut-Off System Operation

    ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: S The transmission is in neutral (the neutral switch is closed).

  • Page 14: Troubleshooting

    ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. (Manual No.: 1. main and ignition fuses 5PS1-AE1) 2.
  • Page 15 ELEC ELECTRIC STARTING SYSTEM EAS00759 Tester positive probe ! 4. Starting circuit cut-off relay sky blue S Disconnect the starting circuit cut-off relay Tester negative probe ! from the wire harness. black/yellow S Connect the pocket tester (Ω 1) and bat- Tester positive probe ! tery (12 V) to the starting circuit cut-off relay sky blue...
  • Page 16 ELEC ELECTRIC STARTING SYSTEM EAS00761 EAS00750 6. Starter relay 8. Engine stop switch S Disconnect the starter relay from the cou- S Check the engine stop switch for continuity. pler. Refer to “CHECKING THE SWITCHES”. S Connect the pocket tester (Ω S Is the engine stop switch OK? 1) and bat- tery (12 V) to the starter relay terminals as...
  • Page 17 ELEC ELECTRIC STARTING SYSTEM EAS00764 12. Start switch S Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the start switch OK? Replace the right handlebar switch. EAS00766 13. Wiring S Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”.

  • Page 18: Lighting System

    ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM –10–...
  • Page 19 ELEC LIGHTING SYSTEM Main fuse Battery Main switch High beam indicator light Meter light Pass switch Dimmer switch Headlight Headlight relay Headlight fuse Hazard light fuse Signaling system fuse Tail / brake light Auxiliary light –11–...

  • Page 20: Troubleshooting

    ELEC LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Any of the following fail to light: headlight, Refer to “CHECKING AND CHARGING high beam indicator light, taillight, auxilia- THE BATTERY” in chapter 3. (Manual No.: ry light or meter light.
  • Page 21 ELEC LIGHTING SYSTEM EAS00787 S Dose the headlight relay have continuity be- 7. Wiring tween red/yellow and green/blue? S Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. S Is the lighting system’s wiring properly con- nected and without defects? Replace the head- light relay.

  • Page 22: Faulty Lighting System

    TRBL FAULTY LIGHTING SYSTEM SHTG EAS00866 TROUBLESHOOTING FAULTY LIGHTING SYSTEM HEADLIGHT DOES NOT COME ON S Wrong headlight bulb S Too many electrical accessories S Hard charging S Incorrect connection S Improperly grounded circuit S Poor contacts (main or dimmer switch) S Headlight relay S Burnt-out headlight bulb HEADLIGHT BULB BURNT OUT...
  • Page 23 WIRING DIAGRAM (EUR) Crankshaft position sensor Headlight fuse A.C magneto Hazard fuse Rectifier/ regulator Signaling system fuse Main fuse Radiator fan motor fuse Battery Rear brake light switch Fuel injection system fuse Tail / brake light Starter relay Radiator fan relay Starter motor Radiator fan motor Main switch...
  • Page 24 WIRING DIAGRAM (OCE) Crankshaft position sensor Radiator fan motor fuse A.C magneto Radiator fan relay Rectifier/ regulator Radiator fan motor Main fuse Auxiliary light Battery Rear brake light switch Fuel injection system fuse Tail / brake light Starter relay Starter motor Main switch Buck up fuse COLOR CODE...

  • Page 27: Tdm900 (R) 2003 Wiring Diagram (Eur)

    TDM900 (R) 2003 WIRING DIAGRAM (EUR) Gy G/W L/B L/R Dg Lg Br Br/B Br/B B Y Ch G L B/L Br/W Br/W Br/B Gy/R HEADLIGHT HEADLIGHT WIRE WIRE SUB-WIRE WIRE SUB-WIRE WIRE SUB-WIRE - - - WIRE HARNESS SUB-WIRE Gy/G Br/W Br/R...

  • Page 28: Tdm900 (R) 2003 Wiring Diagram (Oce)

    TDM900 (R) 2003 WIRING DIAGRAM (OCE) HEADLIGHT WIRE HEADLIGHT SUB-WIRE WIRE SUB-WIRE SUB-WIRE WIRE WIRE WIRE HARNESS SUB-WIRE HARNESS HARNESS HARNESS 2 HARNESS HARNESS SUB-WIRE HARNESS 2 HARNESS 1 HARNESS 1 HARNESS 3 R/B L/W B/Y Lg Br/W B/Y Br Br/W Y Dg...

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2003 tdm900 r2003 tdm900

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