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 Supplementary 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.
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 manual. 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.
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. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. 2 Each chapter is divided into sections.
EAS00008 1 2 GEN INFO SYMBOLS SPEC 3 4 CHK ADJ CHAS 5 6 COOL ENG 7 8 FI ELEC 10 9 TRBL SHTG 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system 8 Electrical system 9 Troubleshooting Symbols 10 to 17 indicate the following.
CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ELECTRICAL CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS/ CHASSIS SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code Standard Limit SSS SSS 5PS4 (EUR) 5PS5 (OCE) ENGINE SPECIFICATIONS Item Throttle bodies Model (manufacturer) quantity Intake vacuum pressure Throttle cable free play (at the flange of the throttle grip) ID mark Throttle valve size Standard 38EIS (MIKUNI) 33 X 36 kPa 3 X 5 mm 2 Limit SSS SSS SSS SSS SSS 5PS1 10 #50 CHASSIS SPECIFICATIONS Item Front tire Tire type Size Mod
CHECKING THE SWITCHES ELEC EAS00731 ELECTRICAL CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear ! Repair or replace. Improperly connected ! Properly connect. Incorrect continuity reading ! Replace the switch.
ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM –3– ELEC
ELECTRIC STARTING SYSTEM 4 5 7 8 9 12 13 14 49 59 60 61 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– ELEC
ELECTRIC STARTING SYSTEM ELEC 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). S The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).
ELECTRIC STARTING SYSTEM EAS00757 ELEC EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. (Manual No.: 5PS1-AE1) The starter motor fails to turn. Check: 1. main and ignition fuses 2. battery 3. starter motor 4. starting circuit cut-off relay 5. diode 6. starter relay 7. main switch 8. engine stop switch 9. neutral switch 10. sidestand switch 11. clutch switch 12. start switch 13.
ELECTRIC STARTING SYSTEM EAS00759 ELEC Tester positive probe ! sky blue 1 Tester negative probe ! black/yellow 2 4. Starting circuit cut-off relay S Disconnect the starting circuit cut-off relay from the wire harness. S Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cut-off relay terminals as shown.
ELECTRIC STARTING SYSTEM EAS00761 ELEC EAS00750 6. Starter relay 8. Engine stop switch S Disconnect the starter relay from the coupler. S Connect the pocket tester (Ω 1) and battery (12 V) to the starter relay terminals as shown. S Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the engine stop switch OK? YES Battery positive terminal ! red/white 1 Battery negative terminal ! blue/white 2 NO Replace the right handlebar switch.
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? YES NO Replace the right handlebar switch. EAS00766 13. Wiring S Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. S Is the starting system’s wiring properly connected and without defects? YES The starting system circuit is OK. NO Properly connect or repair the starting system’s wiring.
LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM –10– ELEC
LIGHTING SYSTEM 4 5 9 23 37 40 45 46 55 56 62 63 64 67 70 Main fuse Battery Main switch ECU 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– ELEC
LIGHTING SYSTEM EAS00781 ELEC EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. (Manual No.: 5PS1-AE1) Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary light or meter light. Check: 1. main, signaling system and headlight fuses 2. battery 3. main switch 4. headlight relay 5. dimmer switch 6. pass switch 7.
LIGHTING SYSTEM EAS00787 S Dose the headlight relay have continuity between red/yellow and green/blue? YES 7. Wiring S Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. S Is the lighting system’s wiring properly connected and without defects? NO Replace the headlight relay. YES Check the condition of each of the lighting system’s circuits. Refer to “CHECKING THE LIGHTING SYSTEM”. EAS00784 5. Dimmer switch S Check the dimmer switch for continuity. Refer to “CHECKING THE SWITCHES”.
FAULTY LIGHTING SYSTEM 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 S Wrong headlight bulb S Faulty battery S Faulty rectifier/regulator S Improperly grounded circuit S Faulty main switch S Faulty dimmer switch S Faulty headlight relay S Headlig
WIRING DIAGRAM (EUR) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 Crankshaft position sensor A.
WIRING DIAGRAM (OCE) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 Crankshaft position sensor A.
TDM900 (R) 2003 WIRING DIAGRAM (EUR) D Gy G/W C B A E G/W L/Y Gy 1 Br Lg Dg L/B L/R L/R L/B Dg Lg Br Y/L R/G R/G Y/L P/W Y Y P/W R/B G/B G/B R/B Br/B R/W R/W Br/B L B B/W W W B/W B/L B/L R/L L L R/L B/L Br/W Br/W B/L WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS 1 WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS 3 G Ch Y B R R R R R W 2 Y Ch G L 4 G/W W W W W R 3 HEADLIGHT SUB-WIRE HARNESS 2 WIRE HARNESS 6 W R - SUB-WIRE HARNESS 1
TDM900 (R) 2003 WIRING DIAGRAM (OCE) WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS 2 R L/W G/R WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS 1 WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS SUB-WIRE HARNESS 3 R/B L/W R/L B/W B/R L/W L/Y R/W L/G L/Y Sb B/Y Lg Br Dg Y L/B Br/W R/Y Br Ch L/Y B B/Y Br R/Y Br/W L/B Y Dg Br B/Y B L/Y Ch