Yamaha TDM900(R) 5PS1-AE2 - Manuals

Page 3 - FOREWORD

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 TD...

Page 4 - WARNING; NOTICE; Designs and specifications are subject to change without notice.; IMPORTANT INFORMATION

NOTE: WARNING CAUTION: EAS00002 NOTICE This 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 maintenanc...

Page 5 - HOW TO USE THIS MANUAL; Sub-section titles appear in smaller print than the section title.

1 2 4 5 7 8 6 3 EAS00007 HOW TO USE THIS MANUAL This 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 Th...

Page 6 - SYMBOLS

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 everyvehicle.Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic check...

Page 7 - CONTENTS; SPECIFICATIONS

CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SPECIFICATIONS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS SPECIFICATIONS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Page 9 - SPEC; GENERAL SPECIFICATIONS; Model code; ENGINE SPECIFICATIONS; Throttle bodies; CHASSIS SPECIFICATIONS; Front tire

–1– GENERAL SPECIFICATIONS / ENGINE SPECIFICATIONS / CHASSIS SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5PS4 (EUR)5PS5 (OCE) SSS SSS ENGINE SPECIFICATIONS Item Standard Limit Throttle bodies Model (manufacturer) quantity Intake vacuum pressureThrottle ca...

Page 10 - ELEC; CHECKING THE SWITCHES; Improperly connected

–2– 1 Main switch 2 Horn switch 3 Pass switch 4 Dimmer switch 5 Hazard switch 6 Turn 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 ...

Page 11 - ELECTRIC STARTING SYSTEM; CIRCUIT DIAGRAM

–3– ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM

Page 13 - If the engine stop switch is set to “

–5– ELECTRIC STARTING SYSTEM ELEC EAS00756 STARTING CIRCUIT CUT-OFF SYSTEMOPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches areclosed), the starter motor can only operate if atleast one of the following conditions is met: S The transmission is in neu...

Page 14 - Minimum open-circuit voltage; The starter motor fails to turn.

–6– EAS00739 2. Battery S Check the condition of the battery.Refer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3. (Manual No.:5PS1-AE1) YES NO S Clean the batteryterminals. 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. S...

Page 17 - Is the start switch OK?

–9– ELECTRIC STARTING 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 righthandlebar switch. EAS00764 13. Wiring S Check the entire starting system’s wiring.Refer to “CIRCUIT DIAGRAM”. S Is the starti...

Page 18 - LIGHTING SYSTEM

–10– LIGHTING SYSTEM ELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM

Page 22 - TRBL; FAULTY LIGHTING SYSTEM; HEADLIGHT DOES NOT COME ON

–14– FAULTY LIGHTING SYSTEM TRBL SHTG 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 B...

Page 23 - COLOR CODE

62 Headlight fuse 63 Hazard fuse 64 Signaling system fuse 65 Radiator fan motor fuse 66 Rear brake light switch 67 Tail / 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 ...

Yamaha TDM900(R) 5PS1-AE2 - Manuals

Manuals:

Manual Yamaha TDM900(R) 5PS1-AE2

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Yamaha Manuals