Yamaha 2003 TDM900, Supplementary Service Manual

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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 First Edition September 2002 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

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 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 S...

Page 5: ...he 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 parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number i...

Page 6: ...trical 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 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 beari...

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 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 ...

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Page 9: ...CIFICATIONS 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 METZELER D220FSTJ DUNLOP 225 kPa 2 25 kgf cm2 2 25 bar 225 kPa 2 25 kgf cm2 2 25 bar 225 kPa 2 25 kgf cm2 2 25 bar SSS SSS SSS SSS SSS SSS SSS 1 6 mm Rear tire Tire type Size Model manufacturer Tire pres...

Page 10: ...l 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 ...

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

Page 12: ...SYSTEM 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 switch 61 Ignition fuse ...

Page 13: ...om 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 conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the starter switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH L...

Page 14: ...lammable 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 ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 Manual No 5PS1 AE1 SAre the main and ignition fuses OK Replace the fuse s EAS00738 EAS00757 TROUBLESHOOTING Check 1 main and ig...

Page 15: ...blue 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 Ω 1 to the starting circuit cut off relay terminals as shown SMeasure the starting circuit cut off relay for continuity as follows Tester positive probe blue green Tester negative probe blue yellow 4 3 Tester positive prob...

Page 16: ... NO 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 switch EAS00751 9 Neutral switch SCheck the neutral switch for continuity Refer to CHECKING THE SWITCHES SIs the neutral switch OK YES NO Replace the neutral switch EAS00752 10 Sidestand switch SCheck ...

Page 17: ...he 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 and without defects YES NO Properly connect or repair the starting system s wiring EAS00766 The starting system circuit is OK ...

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 67 Tail brake light 70 Auxiliary light ...

Page 20: ...egative 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 signaling system and head light fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 Manual No 5PS1 AE1 SAre the main parking lighting and headlight fuses OK Replace the fuse s EAS00781 TROUBLE...

Page 21: ...Is 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 wiring properly con nected and without defects Properly connect or repair the lighting system s wiring Check the condition of each of the lighting system s circuits Refer to CHECK ING THE LIGHTING SY...

Page 22: ...ies 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 SFaulty battery SFaulty rectifier regulator SImproperly grounded circuit SFaulty main switch SFaulty dimmer switch SFaulty headlight relay SHeadlight bulb life expired ...

Page 23: ...10 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 Atmospheric pressure sensor 19 Intake air temperature sensor 20 Coolant temperature sensor 21 Lean angle cut off relay 22 O2 sensor 23 ECU 24 Injector 1 25 Injector 2 26 Al system solenoid 27 Intake solenoid ...

Page 24: ...idestand 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 temperature sensor 20 Lean angle cut off switch 21 O2 sensor 22 ECU 23 Injector 1 24 Injector 2 25 Al system solenoid 26 Intake solenoid 27 Ignition coil 28 Spark plug 29 Fuel pump 30 Speed sensor 31...

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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 Br Br B B L B B R G Br Lg Dg B W Y L W Y Ch L G B L P W L B R W Br B B L Br W R L R B R L G B Br Y B B 187 187 Ch B Ch B 1 2 3 4 6 5 7 8 R W L W 11 12 9 10 61 62 58 59 60 57 14 13 15 16 17 18 19 23 24...

Page 28: ...B 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 WIRE HARNESS1 SUB WIRE HARNESS3 Br Br TDM900 R 2003 WIRING DIAGRAM OCE ...