Instruction/ maintenance manual of the product TDM900(R) 5PS1-AE2 Yamaha
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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.
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.
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 .
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.
CONTENTS SPECIFICA TIONS GENERAL SPECIFICA TIONS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SPECIFICA TIONS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS SPECIFICA TIONS 1 . . .
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–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 SPEC.
–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 switc.
–3– ELECTRIC ST ARTING SYSTEM ELEC EAS00755 ELECTRIC ST ARTING SYSTEM CIRCUIT DIAGRAM.
–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 E.
–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 close.
–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.
–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 .
–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.
–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.
–10– LIGHTING SYSTEM ELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM.
–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 .
–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.
–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.
–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 Inc.
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 . . . . . .
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 . .
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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.
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.
An important point after buying a device Yamaha TDM900(R) 5PS1-AE2 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Yamaha TDM900(R) 5PS1-AE2 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Yamaha TDM900(R) 5PS1-AE2 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Yamaha TDM900(R) 5PS1-AE2 you will learn all the available features of the product, as well as information on its operation. The information that you get Yamaha TDM900(R) 5PS1-AE2 will certainly help you make a decision on the purchase.
If you already are a holder of Yamaha TDM900(R) 5PS1-AE2, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Yamaha TDM900(R) 5PS1-AE2.
However, one of the most important roles played by the user manual is to help in solving problems with Yamaha TDM900(R) 5PS1-AE2. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Yamaha TDM900(R) 5PS1-AE2 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
