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FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for theTDM900 (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

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NOTE:

WARNING

CAUTION:

EAS00002

NOTICEThis manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealersand 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 vehiclesshould have a basic understanding of mechanics and the techniques to repair these types of vehicles.Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-hicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers andwill appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT INFORMATIONParticularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander or a person checking or repairing the mo-torcycle.

A CAUTION indicates special precautions that must be taken to avoid damageto the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

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12

4

58

3

EAS00007

HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures are laidout with the individual steps in sequential order.

1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of eachpage indicate the current chapter.

Refer to SYMBOLS.2 Each chapter is divided into sections. The current section title is shown at the 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 eachremoval and disassembly section.

5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates adisassembly step.

6 Symbols indicate parts to be lubricated or replaced.Refer to SYMBOLS.

7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names ofparts, notes in jobs, etc.

8 Jobs requiring more information (such as special tools and technical data) are described sequen-tially.

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1

3

5

7

9

2

4

8

6

16 1715

1413

11 12

10

GEN

INFO SPEC

ENG

FI ELEC

COOL

CHK

ADJ

TRBL

SHTG

CHAS

EAS00008

SYMBOLSThe following symbols are not relevant to everyvehicle.Symbols 1 to 9 indicate the subject of eachchapter.

1 General information2 Specifications3 Periodic checks and adjustments4 Chassis5 Engine6 Cooling system7 Fuel injection system8 Electrical system9 Troubleshooting

Symbols 10 to 17 indicate the following.

10 Serviceable with engine mounted11 Filling fluid12 Lubricant13 Special tool14 Tightening torque15 Wear limit, clearance

16 Engine speed17 Electrical data

Symbols 18 to 23 in the exploded diagrams indi-cate the types of lubricants and lubricationpoints.

18 Engine oil

19 Gear oil20 Molybdenum-disulfide oil21 Wheel-bearing grease22 Lithium-soap- based grease23 Molybdenum-disulfide grease

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CONTENTS

SPECIFICATIONSGENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICALCHECKING THE SWITCHES 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTINGFAULTY 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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GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS/CHASSIS SPECIFICATIONS SPEC

SPECIFICATIONSGENERAL SPECIFICATIONS

Item Standard Limit

Model code 5PS4 (EUR)5PS5 (OCE)

ENGINE SPECIFICATIONS

Item Standard Limit

Throttle bodiesModel (manufacturer)quantityIntake vacuum pressureThrottle cable free play (at the flangeof the throttle grip)ID markThrottle valve size

38EIS (MIKUNI)23336 kPa35 mm

5PS1 10#50

CHASSIS SPECIFICATIONS

Item Standard Limit

Front tire

Tire typeSizeModel (manufacturer)

Tire pressure (cold)090 kg90203 kgHigh-speed riding

Min. tire tread depth

Tubeless120/70ZR 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)

1.6 mmRear tireTire typeSizeModel (manufacturer)

Tubeless160/60ZR 17 M/C (69W)MEZ4 (METZELER)/D220STJ (DUNLOP)

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ELECTRIC STARTING SYSTEM ELEC

EAS00755

ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM

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4 Main fuse5 Battery7 Starter relay8 Starter motor9 Main switch12 Starting circuit cut-off relay13 Sidestand switch

14 Neutral switch49 Clutch switch59 Engine stop switch60 Start switch61 Ignition fuse

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EAS00739

2. Battery

Check the condition of the battery.Refer to CHECKING AND CHARGINGTHE BATTERY in chapter 3. (Manual No.:5PS1-AE1)

YES NO

Clean the batteryterminals.

Recharge or re-place the battery.

Minimum open-circuit voltage

12.8 V or more at 20C

Is the battery OK?

3. Starter motor

Connect the positive battery terminal and

starter motor lead with a jumper lead .

A wire that is used as a jumper lead

WARNING

1

2 3

EAS00758


The starter motor fails to turn.

NOTE:

1. Main and ignition fuses

Check the main and ignition fuses for conti-nuity

EAS00738

EAS00757

TROUBLESHOOTING

Check:1. main and ignition fuses2. battery3. starter motor4. starting circuit cut-off relay5. diode6. starter relay7. main switch8. engine stop switch9. neutral switch

10. sidestand switch11. clutch switch

12. start switch13. wiring connections

(of the entire starting system)

Before troubleshooting, remove the followingpart(s):

1. seat

2. fuel tank3. air filter case4. side cowlingsTroubleshoot with the following specialtool(s).

Pocket tester90890-03132

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4. Starting circuit cut-off relay

Disconnect the starting circuit cut-off relayfrom the wire harness.

Connect the pocket tester (1) and bat-tery (12 V) to the starting circuit cut-off relayterminals as shown.

YES NO

Replace the startingcircuit cut-off relay.

Does the starting circuit cut-off relay havecontinuity between blue/ white and black?

EAS00759

Continuity

Tester positive probesky blue

Tester negative probe

blue/yellow

No conti-nuity

1

2

1

3

Tester positive probesky blue

Tester negative probeblack/yellow

Battery positive terminalred/blackBattery negative terminal

black/yellow

1

2

Tester positive proveblue/whiteTester negative proveblack

3

4

5. Starting circuit cut-off relay (diode)

Disconnect the starting circuit cut-off relayfrom the wire harness.

Tester positive probeblue/green

Tester negative probeblue/yellow

4

3

Tester positive probeblack/yellow

Tester negative probesky blue

2

1

Tester positive probeblue/yellow

Tester negative probesky blue

3

1

Tester positive probe

blue/yellowTester negative probe

blue/green

3

4

NOTE:

EAS00760


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6. Starter relay

Disconnect the starter relay from the cou-pler.

Connect the pocket tester (1) and bat-tery (12 V) to the starter relay terminals asshown.

YES NO

Replace the starterrelay.

Does the starter relay have continuity be-tween red and black?

EAS00761

Battery positive terminalred/whiteBattery negative terminal

blue/white

1

2

Tester positive proberedTester negative probeblack

3

4

EAS00749

7. Main switch

Check the main switch for continuity.Refer to CHECKING THE SWITCHES.

Is the main switch OK?

EAS00750

8. Engine stop switch

Check the engine stop switch for continuity.Refer to CHECKING THE SWITCHES.

Is the engine stop switch OK?

YES NO

Replace the righthandlebar switch.

EAS00751

9. Neutral switch

Check the neutral switch for continuity.

Refer to CHECKING THE SWITCHES. Is the neutral switch OK?

YES NO

Replace the neutralswitch.

EAS00752

10. Sidestand switch

Check the sidestand switch for continuity.Refer to CHECKING THE SWITCHES.

Is the sidestand switch OK?

YES NO

Replace the side-stand switch.

EAS00763


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12. Start switch

Check the start switch for continuity.Refer to CHECKING THE SWITCHES.

Is the start switch OK?

YES NO

Replace the righthandlebar switch.

EAS00764

13. Wiring

Check the entire starting systems wiring.Refer to CIRCUIT DIAGRAM.

Is the starting systems wiring properly con-nected and without defects?

YES NO

Properly connect orrepair the startingsystems wiring.

EAS00766

The starting systemcircuit is OK.

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LIGHTING SYSTEM ELEC

EAS00780

LIGHTING SYSTEMCIRCUIT DIAGRAM

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4 Main fuse5 Battery9 Main switch23 ECU37 High beam indicator light40 Meter light45 Pass switch

46 Dimmer switch55 Headlight

56 Headlight relay62 Headlight fuse63 Hazard light fuse64 Signaling system fuse

67 Tail/ brake light70 Auxiliary light

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YES NO

2. Battery

Check the condition of the battery.Refer to CHECKING AND CHARGINGTHE BATTERY in chapter 3. (Manual No.:5PS1-AE1)

Clean the batteryterminals.

Recharge or re-place the battery.

EAS00739

Minimum open-circuit voltage

12.8 V or more at 20C

Is the battery OK?

YES NO

3. Main switch

Check the main switch for continuity.Refer to CHECKING THE SWITCHES.

Is the main switch OK?

Replace the mainswitch.

EAS00749

4. Headlight relay

Disconnect the headlight relay from the wireharness.

Connect the pocket tester (1) and bat-tery (12 V) to the headlight relay terminal asshown.

Check the headlight relay for continuity


NOTE:

1. Main, signaling system and headlightfuses

Check the main, signaling system and head-light fuses for continuity.Refer to CHECKING THE FUSES in chap-ter 3. (Manual No.: 5PS1-AE1)

Are the main, parking lighting and headlightfuses OK?

EAS00781

TROUBLESHOOTING

Any of the following fail to light: headlight,high beam indicator light, taillight, auxilia-ry light or meter light.

Check:1. main, signaling system and headlight fuses

2. battery3. main switch4. headlight relay5. dimmer switch6. pass switch7. wiring connections

(of the entire lighting system)

Before troubleshooting, remove the followingpart(s):

1. fuel tank2. front cowling3. rear cowlingTroubleshoot with the following specialtool(s).

Pocket tester90890-03132

EAS00738

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EAS00784

YES NO

5. Dimmer switch

Check the dimmer switch for continuity.Refer to CHECKING THE SWITCHES.

Is the dimmer switch OK?

The dimmer switch isfaulty. Replace the

left handlebarswitch.

EAS00786

YES NO

6. Pass switch

Check the pass switch for continuity.Refer to CHECKING THE SWITCHES.

Is the pass switch OK?

EAS00787

YES NO

7. Wiring

Check the entire lighting systems wiring.Refer to CIRCUIT DIAGRAM.

Is the lighting systems wiring properly con-nected and without defects?

Properly connect orrepair the lightingsystems wiring.

Check the conditionof each of the lightingsystems circuits.Refer to CHECK-ING THE LIGHTINGSYSTEM.

YES NO

Dose the headlight relay have continuity be-tween red/ yellow and green/blue?

Replace the head-light relay.

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FAULTY LIGHTING SYSTEMTRBLSHTG

EAS00866

TROUBLESHOOTINGFAULTY LIGHTING SYSTEMHEADLIGHT DOES NOT COME ONWrong headlight bulbToo many electrical accessoriesHard charging Incorrect connection

Improperly grounded circuitPoor contacts (main or dimmer switch)Headlight relayBurnt-out headlight bulb

HEADLIGHT BULB BURNT OUTWrong headlight bulbFaulty batteryFaulty rectifier/ regulator

Improperly grounded circuitFaulty main switchFaulty dimmer switchFaulty headlight relayHeadlight bulb life expired

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62 Headlight fuse63 Hazard fuse

64 Signaling system fuse65 Radiator fan motor fuse66 Rear brake light switch67 Tail/ brake light68 Radiator fan relay69 Radiator fan motor70 Auxiliary light

COLOR CODE

B Black. . . . . . .Br Brown. . . . . .Ch Chocolate. . . . .Dg Dark green. . . . .G Green. . . . . .

Gy Gray. . . . .L Blue. . . . . . .Lg Light green. . . . . .O Orange. . . . . .P Pink. . . . . . .R Red. . . . . . .Sb Sky blue. . . . . .W White. . . . . .Y Yellow. . . . . . .

B/L Black/Blue. . . . .B/W Black/White. . . .B/Y Black/Yellow. . . .Br/B Brown/Black. . . .Br/G Brown/Green. . .Br/L Brown/Blue. . . .Br/R Brown/Red. . . .Br/W Brown/White. . .

G/B Green/Black. . . .G/R Green/Red. . . .G/W Green/White. . . .G/Y Green/Yellow. . . .Gy/G Gray/Green. . .Gy/R Gray/Red. . .L/B Blue/Black

1 Crankshaft position sensor2 A.C magneto

3 Rectifier/regulator4 Main fuse5 Battery6 Fuel injection system fuse7 Starter relay8 Starter motor9 Main switch10 Alarm11 Buck up fuse12 Starting circuit cut-off relay13 Sidestand switch14 Neutral switch15 Cylinder identification sensor16 Throttle position sensor17 Intake air pressure sensor18 Atmospheric pressure sensor19 Intake air temperature sensor

20 Coolant temperature sensor21 Lean angle cut-off relay22 O2sensor23 ECU24 Injector (#1)25 Injector (#2)26 Al system solenoid27 Intake solenoid28 Ignition coil

29 Spark plug30 Fuel pump31 Speed sensor32 Meter assembly33 Oil level warning light34 Neutral indicator light35 Multi-function meter36 Engine trouble warning light37 Hi beam indicator light

38 Left turn signal indicator light39 Right turn signal indicator light40 Meter light41 Oil level switch

42 Turn signal relay43 Left handlebar switch

WIRING DIAGRAM (EUR)

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62 Radiator fan motor fuse63 Radiator fan relay

64 Radiator fan motor65 Auxiliary light66 Rear brake light switch67 Tail/ 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 Pink. . . . . . .R Red. . . . . . .Sb Sky blue. . . . . .W White. . . . . .Y Yellow. . . . . . .B/L Black/Blue. . . . .B/W Black/White. . . .B/Y Black/Yellow. . . .

Br/B Brown/Black. . . .Br/L Brown/Blue. . . .Br/R Brown/Red. . . .Br/W Brown/White. . .G/B Green/Black. . . .G/R Green/Red. . . .G/W Green/White. . . .G/Y Green/Yellow. . . .

Gy/G Gray/Green. . .Gy/R Gray/Red. . .L/B Blue/Black. . . . .L/G Blue/Green. . . .L/R Blue/Red. . . .L/W Blue/White. . . .L/Y Blue/Yellow

1 Crankshaft position sensor2 A.C magneto

3 Rectifier/regulator4 Main fuse5 Battery6 Fuel injection system fuse7 Starter relay8 Starter motor9 Main switch10 Buck up fuse11 Starting circuit cut-off relay12 Sidestand switch13 Neutral switch14 Cylinder identification sensor15 Throttle position sensor16 Intake air pressure sensor17 Atmospheric pressure sensor18 Intake air temperature sensor19 Coolant temperature sensor

20 Lean angle cut-off switch21 O2sensor22 ECU23 Injector (#1)24 Injector (#2)25 Al system solenoid26 Intake solenoid27 Ignition coil28 Spark plug

29 Fuel pump30 Speed sensor31 Meter assembly32 Oil level warning light33 Neutral indicator light34 Multi function meter35 Engine trouble warning light36 Hi beam indicator light37 Left turn signal indicator light

38 Right turn signal indicator light39 Meter light40 Oil level switch41 Turn signal relay

42 Left handlebar switch43 Horn switch

WIRING DIAGRAM (OCE)

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RB

DgLgBr

BYChGL

ON

OFF

P

R

L/Y

OFF

ON

OFF

ON

HI

LO

OFF

ON

R

N

L

YLB

Y B

BBB

BBB

BB

B

B/Y

L/Y

OFF

RUN

OFF

ON

B

L

Gy G/W G/W

L/Y

L/WR/W

L/B L/R Dg Lg Br

B Y C h G L

L/BL/R Y/L

B/W

R/G

L/BBr/R

B

R /W G /Y

Br/R

L/Y

WWW

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/LY/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/L

R/L

G/Y

Y/L

B/L

W/Y

W/Y

L

Br/R

G/B

R/B

Gy/R

O

L

Y

P/W

B/W B/WB/W B/W

P

Br/W

G/R

Y/G

R/W

Gy/G

B B/Y

RLgR/BL/W

S b L /Y

L/Y

L/G R/L

R

L/W

W

W

B

Br/L L/YB r/ R B

R/W

R/YR/W R/B B

Sb

BBr

Br/L

Br/L

R

R

Br

Br

L

B

B

Y

B B

L/B

L/R

L/RY

Br

Y

L

B

R/W

G/Y

R R R

RR

R

R

B

B

B

B

B

BB

W

W

W

B

L

R

Br/L

Br/L

L/G B

BB

Br/RBr Br/R R/W

BR/L

B/WG

205

205

B B B

B B B

B B

B

R L/W R/LR /B BG/R

B/RB/W L / W R / WL/Y L/YL/G S b B /Y L g

W L/Y

B/L

W/YL

B/L

B/LY/GL

W L/Y

B/L

Br

L

R /Y Y /B

R/Y

L/B

B/LG/R

W/BL

B/L

B /L P L

B/W

B/WB/WR/W

OGy/RR/BG/BG/YBr/B

Br/R

R/WBB/YL/WB/WG/WW/BR/LG/RPY/GL

L/YB/LGyY/LYP/WBr/WW/YGy/G

W

Y/L P/W P/W R/B

R/L

G/B

B/L B/LB/W

R/G

W L

R/B

R/L

G/B

L

Y Y

R

R

B

B

RR

R

BW

B W

WIRE HARNESS HEADLIGHT

SUB-WIRE HARN ESS 2WIRE HARNESS

WIRE HARNESS

WIRE HARNESS

WIRE HARNESS

HEADLIGHTSUB-WIREHARNESS 1

L Y B /L

Y B

- -

B

L/R

L/R

G/Y G/YR/W R/W L/WB

R/B R/BBr BrB B

L/B

B

R/GBrLgDgB/WY/LW

YChLG

B/LP/W L

B

R/WBr/B

B/LBr/W

R/L R/B

R/LG/B

Br YBB

187

187

Ch

B

Ch

B

1

2 3

4

6

5

7

8

R/W

L/W

11

12910

61

62

58

59

60

57

14

1315

16

17

18

19

23

24

25

21

22

31

27

30

29

29

28

28

26

20

Br/GBr/R

63

BrBr/L

64

65

68

70

67

55

56

44

43

50

45 46 47 48

42

49

51

66

69

-

-

-

- -

- - - - - Y/B- - - - --

-

-

L/R

L/RD

Br/W

E

B

B

Ch

Ch

B/Y

B/Y

L/Y

L/Y

Dg

B

Dg

B

52

-

-

-

Br/W

Br/G

B

Dg

Dg

Dg

B

Dg

B

54 41

40

39

38

37

36

34

35

3233

-

- - - -

-

-

B

B

W

Dg

Ch

B

Ch

B

53

-

-

B

Ch

B

D

L/B

L/B

D

Y

YB

Y

R/YBr L/B Br/W

Br/W

Br/G

B/Y L/Y

Br

D

W

W

C

G

G

D Y/L

Y/L

C

Lg

Lg

D

Br

Br

D

R/G

R/G

C

Dg DgD

L L L

Dg

Ch

Y

Br

R/G

G

W

Y/L

Lg

D

B/WB/W B/WC

Ch ChD

P/WP/W P/WB

B /L B /LB

B /L B /L

B/L G/R

Br/WE

Y YB

L LA

G /B G /BA

R /B R /BA

Br /B Br /BE

D C B

SUB-WIREHARNESS2

SUB-WIREHARNESS1

SUB-WIREHARNESS3

A

Br/B

B/L Br/W

R/W Br/B

B/LBr/W

R/W

E

Br/W

R/L

A

R/L

R/W

B

R/L

Gy/R

R/B

R/B

O

G

B/W

R/W

E

R/W

Br/R R/W

B/W

B

B

B

B

B

B

Y/B

R/YR/Y

Y/BL/B

B/Y

L/Y

R /Y L /B

ChB/YBr L/Y

Br/W Y Dg

B

R/YL/B

Ch B/Y BrL/Y

Br/WYDg

B

BrG/Y

G/Y

TDM900 (R) 2003 WIRING DIAGRAM (EUR)

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R L/W R/LR/B L /WG/R

B/RB/W L/W R/WL/Y L/YL/G Sb B/Y Lg

R/Y L/B

ChB/YBr L/Y

Br/W Y Dg

B

R/YL/B

Ch B /Y B rL/Y

Br/WYDg

B

WIRE HARNESSHEADLIGHTSUB-WIRE HARN ESS 2

WIRE HARNESS

WIRE HARNESS

WIRE HARNESS

WIRE HARNESS

HEADLIGHTSUB-WIREHARNESS 1

SUB-WIREHARNESS2

SUB-WIREHARNESS1

SUB-WIREHARNESS3

Br

Br

TDM900 (R) 2003 WIRING DIAGRAM (OCE)

Documents

5PS_2003_Serv