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Yamaha_TDM900P_2002_Sevice Repair & Maintenece Manual
TOTAL 323 PAGES
CONTENTS
CHAPTER 1 GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER MODEL LABEL
FEATURES
OUTLINE FI SYSTEM ECU (Electronic Control Unit) THREE-WAY CATALYTIC CONVERTER SYSTEM AIR INDUCTION SYSTEM INSTRUMENT PANEL
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY REPLACEMENT PARTS GASKETS, OIL SEALS AND O-RINGS LOCK WASHERS/PLATES AND COTTER PINS BEARINGS AND OIL SEALS CIRCLIPS
CHECKING THE CONNECTIONS
SPECIAL TOOLS
CHAPTER 2
SPECIFICATIONS GENERAL SPECIFICATIONS ENGINE SPECIFICATIONS CHASSIS SPECIFICATIONS ELECTRICAL SPECIFICATIONS CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES
OIL FLOW DIAGRAMS COOLING SYSTEM DIAGRAMS CABLE ROUTING
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
SEAT
FRONT COWLINGS
FUEL TANK
REMOVING THE FUEL TANK
REMOVING THE FUEL PUMP
INSTALLING THE FUEL PUMP
INSTALLING THE FUEL HOSE
REAR COWLING
AIR FILTER CASE
ENGINE
ADJUSTING THE VALVE CLEARANCE SYNCHRONIZING THE THROTTLE BODIES CHECKING AND ADJUSTING THE EXHAUST GAS AT IDLE ADJUSTING THE EXHAUST GAS VOLUME CHECKING THE EXHAUST GAS AT IDLE ADJUSTING THE ENGINE IDLING SPEED ADJUSTING THE THROTTLE CABLE FREE PLAY CHECKING THE SPARK PLUGS CHECKING THE IGNITION TIMING MEASURING THE COMPRESSION PRESSURE CHECKING THE ENGINE OIL LEVEL CHANGING THE ENGINE OIL ADJUSTING THE CLUTCH CABLE FREE PLAY CHECKING THE AIR FILTER ELEMENT CHECKING THE FUEL AND VACUUM HOSES CHECKING THE CRANKCASE BREATHER HOSE CHECKING THE EXHAUST SYSTEM CHECKING THE COOLANT LEVEL CHECKING THE COOLING SYSTEM CHANGING THE COOLANT
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS
FRONT WHEEL REMOVING THE FRONT WHEEL CHECKING THE FRONT WHEEL CHECKING THE BRAKE DISCS ADJUSTING THE FRONT WHEEL STATIC BALANCE DISASSEMBLING THE FRONT WHEEL ASSEMBLING THE FRONT WHEEL INSTALLING THE FRONT WHEEL
REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET
REAR WHEEL REMOVING THE REAR WHEEL CHECKING THE REAR WHEEL CHECKING THE REAR WHEEL DRIVE HUB CHECKING AND REPLACING THE REAR WHEEL SPROCKET INSTALLING THE REAR WHEEL ADJUSTING THE REAR WHEEL STATIC BALANCE
FRONT AND REAR BRAKES
FRONT BRAKE PADS REAR BRAKE PADS REPLACING THE FRONT BRAKE PADS REPLACING THE REAR BRAKE PADS FRONT BRAKE MASTER CYLINDER REAR BRAKE MASTER CYLINDER DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER DISASSEMBLING THE REAR BRAKE MASTER CYLINDER CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS ASSEMBLYING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER ASSEMBLING THE REAR BRAKE MASTER CYLINDER FRONT BRAKE CALIPERS REAR BRAKE CALIPER DISASSEMBLING THE FRONT BRAKE CALIPERS DISASSEMBLING THE REAR BRAKE CALIPER CHECKING THE FRONT AND REAR BRAKE CALIPERS ASSEMBLING AND INSTALLING THE FRONT BRAKE
CALIPERS ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER
FRONT FORK
REMOVING THE FRONT FORK LEGS DISASSEMBLING THE FRONT FORK LEGS CHECKING THE FRONT FORK LEGS ASSEMBLING THE FRONT FORK LEGS INSTALLING THE FRONT FORK LEGS
HANDLEBAR
REMOVING THE HANDLEBAR CHECKING THE HANDLEBAR INSTALLING THE HANDLEBAR
STEERING HEAD
REMOVING THE LOWER BRACKET CHECKING THE STEERING HEAD INSTALLING THE STEERING HEAD
REAR SHOCK ABSORBER ASSEMBLY
HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER DISPOSING OF A REAR SHOCK ABSORBER AND
GAS CYLINDER REMOVING THE REAR CHOCK ABSORBER ASSEMBLY CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND
GAS CYLINDER INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY
SWINGARM AND DRIVE CHAIN
REMOVING THE SWINGARM REMOVING THE DRIVE CHAIN CHECKING THE SWINGARM DISASSEMBLING THE SWINGARM CHECKING THE CONNECTING ARM AND RELAY ARMS ASSEMBLING THE SWINGARM CHECKING THE DRIVE CHAIN INSTALLING THE SWINGARM CHAPTER 5
ENGINE
EXHAUST PIPES DRIVE SPROCKET LEADS AND HOSES ENGINE INSTALLING THE ENGINE
CAMSHAFT
CYLINDER HEAD COVER CAMSHAFTS REMOVING THE CAMSHAFTS CHECKING THE CAMSHAFTS CHECKING THE CAMSHAFT SPROCKETS AND TIMING
CHAIN GUIDES CHECKING THE TIMING CHAIN TENSIONER INSTALLING THE CAMSHAFTS
CYLINDER HEAD
REMOVING THE CYLINDER HEAD CHECKING THE CYLINDER HEAD INSTALLING THE CYLINDER HEAD
VALVES AND VALVE SPRINGS
REMOVING THE VALVES CHECKING THE VALVES AND VALVE GUIDES CHECKING THE VALVE SEATS CHECKING THE VALVE SPRINGS CHECKING THE VALVE LIFTERS INSTALLING THE VALVES
CYLINDER AND PISTONS
REMOVING THE CYLINDER AND PISTONS CHECKING THE CYLINDER AND PISTONS CHECKING THE PISTON RINGS CHECKING THE PISTON PINS INSTALLING THE PISTONS AND CYLINDER
CLUTCH
CLUTCH COVER PULL LEVER SHAFT CLUTCH REMOVING THE CLUTCH CHECKING THE FRICTION PLATES
SIFT SHAFT
GENERATOR ROTOR COVER SHIFT SHAFT AND STOPPER LEVER CHECKING THE SHIFT SHAFT CHECKING THE STOPPER LEVER INSTALLING THE SHIFT SHAFT
STARTER CLUTCH AND GENERATOR
STATOR COIL ASSEMBLY STARTER CLUTCH AND GENERATOR ROTOR REMOVING THE GENERATOR REMOVING THE STARTER CLUTCH CHECKING THE STARTER CLUTCH CHECKING THE GENERATOR SHAFT INSTALLING THE STARTER CLUTCH INSTALLING THE GENERATOR
OIL PAN AND OIL PUMP
OIL PUMP COVER AND OIL PUMP DRIVEN GEAR OIL PUMP OIL HOSE AND OIL TANK OIL PAN CHECKING THE OIL PUMP REMOVING THE OIL PAN CHECKING THE RELIEF VALVE CHECKING THE OIL DELIVERY PIPES CHECKING THE OIL STRAINER CHECKING THE OIL NOZZLES ASSEMBLING THE OIL PUMP INSTALLING THE OIL PUMP INSTALLING THE OIL STRAINER INSTALLING THE OIL PAN
CRANKSHAFT
BALANCER SHAFT CRANKSHAFT ASSEMBLY CONNECTING ROD DISASSEMBLING THE CRANKCASE REMOVING THE CRANKSHAFT ASSEMBLY REMOVING THE CONNECTING RODS
CHECKING THE CRANKCASE CHECKING THE BEARINGS CHECKING THE CIRCLIPS AND WASHERS
CHAPTER 6
COOLING SYSTEM
RADIATOR CHECKING THE RADIATOR INSTALLING THE RADIATOR
THERMOSTATB THERMOSTAT ASSEMBLY CHECKING THE THERMOSTAT ASSEMBLING THE THERMOSTAT ASSEMBLY INSTALLING THE THERMOSTAT ASSEMBLY
WATER PUMP DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP ASSEMBLING THE WATER PUMP INSTALLING THE WATER PUMP
CHAPTER 7
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
CIRCUIT DIAGRAM
ECU‘S SELF-DIAGNOSTIC FUNCTION
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL
(FAIL-SAFE ACTION)
FAIL-SAFE ACTIONS TABLE
TROUBLESHOOTING CHART
DIAGNOSTIC MONITORING MODE
TROUBLESHOOTING DETAILS
THROTTLE BODY ASSEMBLY
CHECKING THE INJECTOR
CHECKING THE THROTTLE BODY
CHECKING THE PRESSURE REGULATOR
CHECKING THE FUEL PUMP AND PRESSURE REGULATOR
OPERATION
CHECKING THE THROTTLE BODY JOINTS
CHECKING THE SURGE TANK
CHECKING THE ACTUATOR
AIR INDUCTION SYSTEM
AIR INJECTION AIR CUT-OFF VALVE AIR INDUCTION SYSTEM DIAGRAMS AIR CUT-OFF VALVE AND REED VALVE CHECKING THE AIR INDUCTION SYSTEM
CHAPTER 8
ELECTRICAL
ELECTRICAL COMPONENTS
CHECKING SWITCH CONTINUITY
CHECKING THE SWITCHES
CHECKING THE BULBS AND BULB SOCKETS
TYPES OF BULBS CHECKING THE CONDITION OF THE BULBS CHECKING THE CONDITION OF THE BULB SOCKETS CHECKING THE LEDs
IGNITION SYSTEM
CIRCUIT DIAGRAM TROUBLESHOOTING
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION TROUBLESHOOTING
STARTER MOTOR
CHECKING THE STARTER MOTOR ASSEMBLING THE STARTER MOTOR
CHARGING SYSTEM
CIRCUIT DIAGRAM TROUBLESHOOTING
LIGHTING SYSTEM
CIRCUIT DIAGRAM TROUBLESHOOTING CHECKING THE LIGHTING SYSTEM
SIGNALING SYSTEM
CIRCUIT DIAGRAM TROUBLESHOOTING CHECKING THE SIGNAL SYSTEM
COOLING SYSTEM
CIRCUIT DIAGRAM TROUBLESHOOTING
CHAPTER 9
TROUBLESHOOTING
STARTING FAILURES
ENGINE FUEL SYSTEM ELECTRICAL SYSTEMS
INCORRECT ENGINE IDLING SPEED
ENGINE FUEL SYSTEM ELECTRICAL SYSTEMS
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
ENGINE FUEL SYSTEM
FAULTY GEAR SHIFTING
SHIFTING IS DIFFICULT SHIFT PEDAL DOES NOT MOVE JUMPS OUT OF GEAR
FAULTY CLUTCH
CLUTCH SLIPS CLUTCH DRAGS
OVERHEATING
ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEMS
OVER COOLING
COOLING SYSTEM
POOR BRAKING PERFORMANCE
FAULTY FRONT FORK LEGS
LEAKING OIL MALFUNCTION
UNSTABLE HANDLING
FAULTY LIGHTING OR SIGNALING SYSTEM
HEADLIGHT DOES NOT COME ON HEADLIGHT BULB BURNT OUT TAIL/BRAKE LIGHT DOES NOT COME ON TAIL/BRAKE LIGHT BULB BURNT OUT TURN SIGNAL DOES NOT COME ON TURN SIGNAL BLINKS SLOWLY TURN SIGNAL REMAINS LIT TURN SIGNAL BLINKS QUICKLY HORN DOES NOT SOUND
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