Yamaha TDM900 (P R S) 2002-2004 Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 93015

Etiquetas: 2002 2003 2004 Misc Motorcycle Motorcycles TDM900 P TDM900 R TDM900 S Yamaha

Variantes de producto

Descripción

The TDM900, produced between 2002 and 2004, is a versatile sport-touring motorcycle known for its robust parallel-twin engine and capable chassis. Designed for riders seeking a balance of performance for spirited riding and comfort for longer journeys, the TDM900 features a liquid-cooled, 897 cc DOHC engine with electronic fuel injection and controlled throttle. Its design philosophy emphasizes reliability and a comfortable riding position, making it suitable for a wide range of road conditions. Available in variants P, R, and S, this model represents a commitment to engineering quality and practical motorcycle design. This comprehensive service repair manual provides in-depth guidance for the maintenance, troubleshooting, and repair of the TDM900. It covers all essential systems, including the engine, transmission, chassis, brakes, and electrical components, with detailed procedures for routine maintenance, major repairs, and component overhauls. The manual includes crucial technical specifications, torque values, diagnostic charts for common issues, and information on special tools. This resource is designed to assist owners, mechanics, and technicians in keeping their TDM900 motorcycles in optimal condition, ensuring longevity and performance.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

TDM900

Model Variants:

P, R, S

Model Years:

2002, 2003, 2004

👋 Introduction

Market Position

Segment:

Sport-touring / Adventure-sport motorcycle

Target Audience:

Riders seeking a versatile motorcycle for commuting, touring, and spirited riding

Competitive Analysis

Key Competitors:

Honda VFR800, Triumph Tiger 955i, Suzuki V-Strom 650/1000 (depending on era)

Key Features

Engine Type:

Parallel-twin, liquid-cooled, DOHC, 4-stroke

Design Philosophy:

Robust engine, comfortable ergonomics, capable chassis for varied road conditions

📋 Manual Details

Coverage Areas

Overall Coverage:

Comprehensive service, maintenance, and repair

Page Count

Estimated Pages:

Likely 300-500 pages (typical for this model and depth)

Manual Type

Type:

Service Repair Manual

Language

Language:

English (standard for Yamaha service manuals)

Format

Format:

Digital (PDF) or Printed

📖 Manual Coverage

Systems Covered

Engine:

Internal components, lubrication, cooling, fuel injection, ignition, exhaust, starting system

Transmission:

Clutch, gearbox, drive chain, shifting mechanism

Chassis:

Frame, suspension (front fork, rear shock), steering, wheels, tires

Brakes:

Front and rear brake systems (calipers, master cylinders, lines, discs), ABS (if applicable to specific variants)

Electrical:

Wiring diagrams, battery, charging system, lighting, instrumentation, ECUs, sensors, ignition coils

Fuel System:

Fuel tank, fuel pump, injectors, throttle body, evaporative emission control

Bodywork And Trim:

Fairings, seat, fuel tank cover, fenders, controls

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug servicing, chain adjustment, brake fluid changes, coolant checks

Troubleshooting:

Diagnostic charts for common problems and symptoms

Major Repairs:

Engine disassembly and reassembly, transmission overhaul, suspension component replacement, electrical system diagnostics and repair

Component Overhaul:

Carburetor (if applicable to earlier TDM models, though 900 is FI), fuel injection system, suspension forks, rear shock absorber

Special Tools:

Identification and usage of Yamaha-specific special tools

Technical Depth

Depth:

In-depth technical specifications, torque values, diagnostic procedures, and component tolerances for full rebuilds

📊 Manual Specifications

File Format

Digital Format:

PDF (Searchable text, printable pages, often high resolution for diagrams)

Print Quality

Print Quality:

High-resolution diagrams and schematics for clarity

Binding Type

Binding Type:

Comb-bound or perfect-bound (for printed versions) for durability

Paper Type

Paper Type:

Durable, often coated paper to withstand shop use (for printed versions)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, 4-valve parallel-twin

Displacement:

897 cc (Cubic Centimeters)

Bore X Stroke:

92.0 mm x 67.5 mm

Compression Ratio:

9.6:1

Performance

Horsepower:

Approx. 89.0 bhp @ 7,500 rpm (claimed)

Torque:

Approx. 9.1 kg-m (66 ft-lb) @ 6,000 rpm (claimed)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual throttle valves (YCC-T, Yamaha Chip Controlled Throttle)

Ignition System:

Digital TCI (Transistor Controlled Ignition)

Exhaust System:

Catalytic converter (Euro 2 compliant)

Cooling System

Coolant Type:

Yamaha Genuine Coolant or equivalent (high-quality ethylene glycol-based antifreeze)

Coolant Capacity:

Approx. 1.8 L

Oil System

Oil Type:

Yamalube 4 (or equivalent) 10W-40 API SG or higher, JASO MA certified motorcycle oil

Oil Capacity W Filter:

Approx. 3.1 L

Oil Capacity Wo Filter:

Approx. 2.7 L

Spark Plugs

Spark Plug Type:

NGK CR9EK (or equivalent)

Spark Plug Gap:

0.7 - 0.8 mm

🔧 Transmission

Standard

Transmission Type:

5-speed sequential

Clutch Type:

Wet, multi-plate

Final Drive:

O-ring sealed chain drive

Features

Gear Ratios:

Not specified, but the manual will detail individual gear ratios and final drive ratio

Transmission Oil Type:

Yamalube 4 (or equivalent) 10W-40 API SG or higher, JASO MA certified motorcycle oil

📐 Dimensions

Exterior

Length:

Approx. 2,120 mm (83.5 in)

Width:

Approx. 800 mm (31.5 in)

Height:

Approx. 1,265 mm (49.8 in)

Wheelbase:

Approx. 1,490 mm (58.7 in)

Ground Clearance:

Approx. 150 mm (5.9 in)

Weights

Dry Weight:

Approx. 193 kg (425 lbs)

Wet Weight:

Approx. 213 kg (470 lbs) (with fluids and full tank)

Fuel Tank Capacity:

20 L (5.3 gal)

Wheels And Tires

Front Tire Size:

120/70ZR18M/C (59W)

Rear Tire Size:

170/60ZR17M/C (72W)

Front Brake Type:

Dual hydraulic disc

Rear Brake Type:

Hydraulic disc

Suspension

Front Suspension Type:

Telescopic fork

Front Fork Travel:

Approx. 150 mm (5.9 in)

Rear Suspension Type:

Monoshock, link-type suspension

Rear Shock Travel:

Approx. 130 mm (5.1 in)

🛡️ Safety Features

Ratings

Safety Features:

ABS available on some models (e.g., TDM900A), robust braking system, hazard lights

Active Features

Active Safety:

Responsive brakes, balanced chassis, good visibility

Passive Features

Passive Safety:

Integrated frame design, passenger grab rails

💡 Technology Features

Infotainment

Infotainment System:

N/A (Motorcycle focused, no complex infotainment)

Driver Assistance

Driver Assistance Systems:

Optional ABS (Anti-lock Braking System) on some variants (TDM900A)

Connectivity

Connectivity Features:

Engine Management

Engine Management System:

Yamaha's EFI with ECU control and diagnostic port for fault code retrieval

🔧 Maintenance

Service Intervals

First Service:

1,000 km or 6 months

Subsequent Services:

Every 6,000 km or 12 months (whichever comes first)

Valve Clearance Check:

Every 24,000 km or 24 months

Fluid Specifications

Engine Oil Viscosity:

10W-40

Brake Fluid Type:

DOT 4

Coolant Type:

Yamaha Genuine Coolant or equivalent (high-quality ethylene glycol-based antifreeze)

Known Issues

Common Wear Items:

Chain and sprockets, brake pads, tires, regulator/rectifier (less common on this model but a general Yamaha concern), fuel pump O-rings (over time)

Potential Faults To Check:

Voltage output from stator/alternator, fuel injection system diagnostics (idle issues, starting problems), front fork seal leaks

📚 Vehicle History

Brand Heritage

Brand Focus:

Yamaha's reputation for reliable engines and innovative motorcycle design

Model Evolution

Predecessor:

TDM850

Introduction Year:

TDM900 introduced in 2001 for the 2002 model year

Production

Manufacturing Location:

Japan

Production Period Covered:

2002-2004 (for this specific manual)

🏆 Awards & Recognition

Recognitions

Awards:

Not widely publicized for specific awards; generally well-regarded for its segment.