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Manual Yamaha TDM900(R) 5PS1-AE2

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  • Yamaha TDM900(R) 5PS1-AE2 - page 1

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  • Yamaha TDM900(R) 5PS1-AE2 - page 2

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  • Yamaha TDM900(R) 5PS1-AE2 - page 3

    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 SUPPLEMENT AR Y SERVICE MANUAL E 2 ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 4

    NOTE: W ARNING CAUTION: EAS00002 NOTICE This manual was produced by the Y amaha Motor Company , Ltd. primarily for use by Y amaha 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 Y amaha vehicles should hav ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 5

    1 2 4 5 7 8 6 3 EAS00007 HOW T O 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 abbre ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 6

    22 1 3 5 7 9 2 4 8 6 24 25 23 21 19 20 18 16 17 15 14 13 11 12 10 GEN INFO SPEC ENG FI ELEC COOL CHK ADJ TRBL SHTG CHAS EAS00008 SYMBOLS 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 ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 7

    CONTENTS SPECIFICA TIONS GENERAL SPECIFICA TIONS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SPECIFICA TIONS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS SPECIFICA TIONS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL CHECKING THE SWITCHES ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 8

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  • Yamaha TDM900(R) 5PS1-AE2 - page 9

    –1– GENERAL SPECIFICA TIONS / ENGINE SPECIFICA TIONS / CHASSIS SPECIFICA TIONS SPEC SPECIFICA TIONS GENERAL SPECIFICA TIONS Item Standard Limit Model code 5PS4 (EUR) 5PS5 (OCE) SSS SSS ENGINE SPECIFICA TIONS Item Standard Limit Throttle bodies Model (manufacturer) quantity Intake vacuum pressure Throttle cable free play (at the flange of the th ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 10

    –2– 1 Main switch 2 Horn switch 3 Pass switch 4 Dimmer switch 5 Hazard switch 6 T urn signal switch 7 Clutch switch 8 Engine stop switch 9 Start 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 d ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 11

    –3– ELECTRIC ST ARTING SYSTEM ELEC EAS00755 ELECTRIC ST ARTING SYSTEM CIRCUIT DIAGRAM ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 12

    –4– ELECTRIC ST ARTING 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 ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 13

    –5– ELECTRIC ST ARTING SYSTEM ELEC EAS00756 ST ARTING CIRCUIT CUT -OFF SYSTEM OPERA TION 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 clo ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 14

    –6– EAS00739 2. Battery S Check the condition of the battery . Refer to “CHECKING AND CHARGING THE BA TTERY” in chapter 3. (Manual No.: 5PS1-AE1) YES NO S Clean the battery terminals. S Recharge or re- place the battery . Minimum open-circuit voltage 12.8 V or more at 20 _ C S Is the battery OK? YES NO 3. Starter motor S Connect the positiv ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 15

    –7– 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 bat- tery (12 V) to the starting circuit cut-off relay terminals as shown. YES NO Replace the starting circuit cut-off relay . S Does the starting circuit cut-off relay have continuity between blu ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 16

    –8– 6. Starter relay S Disconnect the starter relay from the cou- pler . S Connect the pocket tester ( Ω 1) and bat- tery (12 V) to the starter relay terminals as shown. YES NO Replace the starter relay . S Does the starter relay have continuity be- tween red and black? EAS00761 Battery positive terminal ! red / white Battery negative termina ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 17

    –9– ELECTRIC ST ARTING SYSTEM ELEC 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. EAS00764 13. Wiring S Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. S Is the starting system’s wiring properly c ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 18

    –10– LIGHTING SYSTEM ELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 19

    –1 1– LIGHTING SYSTEM ELEC 4 Main fuse 5 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 T ail / brake light 70 Auxiliary light ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 20

    –12– YES NO 2. Battery S Check the condition of the battery . Refer to “CHECKING AND CHARGING THE BA TTERY” in chapter 3. (Manual No.: 5PS1-AE1) S Clean the battery terminals. S Recharge or re- place the battery . EAS00739 Minimum open-circuit voltage 12.8 V or more at 20 _ C S Is the battery OK? YES NO 3. Main switch S Check the main switc ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 21

    –13– LIGHTING SYSTEM ELEC EAS00784 YES NO 5. Dimmer switch S Check the dimmer switch for continuity . Refer to “CHECKING THE SWITCHES”. S Is the dimmer switch OK? The dimmer switch is faulty . Replace the left handlebar switch. EAS00786 YES NO 6. Pass switch S Check the pass switch for continuity . Refer to “CHECKING THE SWITCHES”. S Is ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 22

    –14– F AUL TY LIGHTING SYSTEM TRBL SHTG EAS00866 TROUBLESHOOTING F AUL TY LIGHTING SYSTEM HEADLIGHT DOES NOT COME ON S Wrong headlight bulb S T oo 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 BU ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 23

    62 Headlight fuse 63 Hazard fuse 64 Signaling system fuse 65 Radiator fan motor fuse 66 Rear brake light switch 67 T ail / brake light 68 Radiator fan relay 69 Radiator fan motor 70 Auxiliary light COLOR CODE B Black . . . . . . . Br Brown . . . . . . Ch Chocolate . . . . . Dg Dark green . . . . . G Green . . . . . . Gy Gray . . . . . L Blue . . . ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 24

    62 Radiator fan motor fuse 63 Radiator fan relay 64 Radiator fan motor 65 Auxiliary light 66 Rear brake light switch 67 T ail / brake light COLOR CODE B Black . . . . . . . Br Brown . . . . . . Ch Chocolate . . . . . Dg Dark green . . . . . G Green . . . . . . Gy Gray . . . . . L Blue . . . . . . . Lg Light green . . . . . . O Orange . . . . . . P ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 25

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  • Yamaha TDM900(R) 5PS1-AE2 - page 26

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  • Yamaha TDM900(R) 5PS1-AE2 - page 27

    R B Dg Lg Br B Y Ch G L ON OFF P R L/Y OFF ON OFF ON HI LO OFF ON R N L Y L B YB B B B B B B B B B B/Y L/Y OFF RUN OFF ON B L Gy G/W G/W L/Y L/W R/W L/B L/R Dg Lg Br BY C h G L L/B L/R Y/L B/W R/G L/B Br/R B R/W G/Y Br/R L/Y W W W W Gy G/W R/W R/G L/G L W/B B/L B/L Y L L L Gy/G B/L B/L Y/G P B/L L B/L B R/L L/Y R/W B/Y B L/W G/Y G/W W/B B/L Br/B R/ ...

  • Yamaha TDM900(R) 5PS1-AE2 - page 28

    R L/W R/L R/B L/W G/R B/R B/W L/W R/W L/Y L/Y L/G Sb B/Y Lg R/Y L/B Ch B/Y Br L/Y Br/W YD g 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 HARNESS 2 SUB-WIRE HARNESS 1 SUB-WIRE HARNESS 3 Br Br TDM900 (R) 2003 WIRING DIAGRAM (OCE) ...

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Documents that we receive from a manufacturer of a Yamaha TDM900(R) 5PS1-AE2 can be divided into several groups. They are, among others:
- Yamaha technical drawings
- TDM900(R) 5PS1-AE2 manuals
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All of them are important, but the most important information from the point of view of use of the device are in the user manual Yamaha TDM900(R) 5PS1-AE2.

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals Yamaha TDM900(R) 5PS1-AE2, service manual, brief instructions and user manuals Yamaha TDM900(R) 5PS1-AE2. Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product Yamaha TDM900(R) 5PS1-AE2.

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A complete manual for the device Yamaha TDM900(R) 5PS1-AE2, how should it look like?
A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Yamaha TDM900(R) 5PS1-AE2 by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Yamaha TDM900(R) 5PS1-AE2.

A complete Yamaha manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual Yamaha TDM900(R) 5PS1-AE2 - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the Yamaha TDM900(R) 5PS1-AE2, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the Yamaha TDM900(R) 5PS1-AE2, that we can find in the current document
3. Tips how to use the basic functions of the device Yamaha TDM900(R) 5PS1-AE2 - which should help us in our first steps of using Yamaha TDM900(R) 5PS1-AE2
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with Yamaha TDM900(R) 5PS1-AE2
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of Yamaha TDM900(R) 5PS1-AE2 in a specific country, if it was not possible to solve the problem on our own.

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