Yamaha TDM900 Supplementary Service Manual Download Page 3

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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

2002 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.

Summary of Contents for TDM900

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Page 3: ...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...

Page 4: ...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 wh...

Page 5: ...e top of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s ap pears 3 Sub section titles appear in smaller print than the section title 4 To help identify par...

Page 6: ...rical system 9 Troubleshooting 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...

Page 7: ...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 SY...

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Page 9: ...IFICATIONS Item Standard Limit Front tire Tire type Size Model manufacturer Tire pressure cold 0 X 90 kg 90 X 203 kg High speed riding Min tire tread depth Tubeless 120 70ZR 18 M C 59W MEZ4 FRONT METZ...

Page 10: ...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 fo...

Page 11: ...3 ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM...

Page 12: ...YSTEM ELEC 4 Main fuse 5 Battery 7 Starter relay 8 Starter motor 9 Main switch 12 Starting circuit cut off relay 13 Sidestand switch 14 Neutral switch 49 Clutch switch 59 Engine stop switch 60 Start s...

Page 13: ...m operating when neither of these conditions has been met In this instance the starting circuit cut off relay is open so cur rent cannot reach the starter motor When at least one of the above conditio...

Page 14: ...ammable is in the vicinity SDoes the starter motor turn WARNING 1 2 3 EAS00758 ELECTRIC STARTING SYSTEM ELEC The starter motor fails to turn NOTE YES NO 1 Main and ignition fuses SCheck the main and i...

Page 15: ...lue white Tester negative prove black 3 4 5 Starting circuit cut off relay diode SDisconnect the starting circuit cut off relay from the wire harness SConnect the pocket tester 1 to the starting circu...

Page 16: ...O Replace the main switch EAS00750 8 Engine stop switch SCheck the engine stop switch for continuity Refer to CHECKING THE SWITCHES SIs the engine stop switch OK YES NO Replace the right handlebar swi...

Page 17: ...e start switch OK YES NO Replace the right handlebar switch EAS00764 13 Wiring SCheck the entire starting system s wiring Refer to CIRCUIT DIAGRAM SIs the starting system s wiring properly con nected...

Page 18: ...10 LIGHTING SYSTEM ELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM...

Page 19: ...Battery 9 Main switch 23 ECU 37 High beam indicator light 40 Meter light 45 Pass switch 46 Dimmer switch 55 Headlight 56 Headlight relay 62 Headlight fuse 63 Hazard light fuse 64 Signaling system fuse...

Page 20: ...ative terminal yellow black 1 2 Tester positive probe red yellow Tester negative probe blue black 3 4 LIGHTING SYSTEM ELEC NOTE YES NO 1 Main signaling system and headlight fuses SCheck the main signa...

Page 21: ...s the pass switch OK The pass switch is faulty Replace the left handlebar switch EAS00787 YES NO 7 Wiring SCheck the entire lighting system s wiring Refer to CIRCUIT DIAGRAM SIs the lighting system s...

Page 22: ...es SHard charging SIncorrect connection SImproperly grounded circuit SPoor contacts main or dimmer switch SHeadlight relay SBurnt out headlight bulb HEADLIGHT BULB BURNT OUT SWrong headlight bulb SFau...

Page 23: ...0 Alarm 11 Buck up fuse 12 Starting circuit cut off relay 13 Sidestand switch 14 Neutral switch 15 Cylinder identification sensor 16 Throttle position sensor 17 Intake air pressure sensor 18 Atmospher...

Page 24: ...destand switch 13 Neutral switch 14 Cylinder identification sensor 15 Throttle position sensor 16 Intake air pressure sensor 17 Atmospheric pressure sensor 18 Intake air temperature sensor 19 Coolant...

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Page 27: ...Y R R B B R R R B W B W WIRE HARNESS HEADLIGHT SUB WIRE HARNESS 2 WIRE HARNESS WIRE HARNESS WIRE HARNESS WIRE HARNESS HEADLIGHT SUB WIRE HARNESS 1 L Y B L Y B B L R L R G Y G Y R W R W L W B R B R B B...

Page 28: ...Y Br L Y Br W Y Dg B R Y L B Ch B Y Br L Y Br W Y Dg B WIRE HARNESS HEADLIGHT SUB WIRE HARNESS 2 WIRE HARNESS WIRE HARNESS WIRE HARNESS WIRE HARNESS HEADLIGHT SUB WIRE HARNESS 1 SUB WIRE HARNESS2 SUB...

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