Yamaha_TDM900P_2002_Sevice Repair 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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