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

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Taper: Motorcycle

Distributeur:

UGS: 89451

Mots clés: 2002 2003 2004 Marine Motorcycle Sterndrive TDM900 P TDM900 R TDM900 S Yamaha

Variantes de produits

Description

This manual covers the TDM900, produced for the 2002, 2003, and 2004 model years. As a sport-touring motorcycle, the TDM900 is engineered for comfortable long-distance travel with a dynamic performance edge, building on the legacy of the TDM850 with an 897cc parallel-twin engine featuring electronic fuel injection. Its robust construction and versatile design make it suitable for a variety of riding conditions, embodying a reputation for reliability and performance. This comprehensive service and repair manual provides detailed information for maintaining and repairing your TDM900. It covers all essential systems, including the engine, transmission, chassis, brakes, and electrical components, with step-by-step instructions for maintenance, diagnostics, and repair procedures. This resource is invaluable for owners and technicians seeking to ensure optimal performance and longevity of the motorcycle, offering factory-level technical depth with abundant illustrations and torque specifications.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

TDM900

Model Codes:

P, R, S

Years Covered:

2002, 2003, 2004

👋 Introduction

Market Position

Market Segment:

Sport Touring / Adventure Motorcycle

Competitive Analysis

Key Competitors:

Honda VFR800, Kawasaki GTR1000, BMW R1100/1150RT (during its production era)

Key Features

Vehicle Philosophy:

Designed for comfortable long-distance touring with a sporty edge, combining power, versatility, and reliability

📋 Manual Details

Coverage Areas

Manual Coverage:

Complete service and repair

Page Count

Page Count:

Not specified (assumed comprehensive for full service)

Manual Type

Manual Type:

Official Factory Service Manual / Repair Manual

Language

Language:

English

Format

File Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, diagnostics, tuning, lubrication, cooling, fuel injection system, ignition system

Transmission:

Clutch operation, gearbox inspection and repair, shift mechanism

Chassis:

Frame inspection and repair, suspension (front forks, rear shock absorber), steering system

Brakes:

Hydraulic system, caliper service, master cylinder, disc inspection, bleeding procedures

Electrical:

Wiring diagrams, lighting system, ignition system, starting system, charging system, sensors, ECU diagnostics

Fuel System:

Fuel pump, injectors, fuel pressure regulation, evaporative emission control system

Bodywork:

Fairing removal and installation, seat, fuel tank, body panels

Cooling System:

Radiator service, fan operation, thermostat, coolant flow diagnostics.

Exhaust System:

Component identification, inspection, and potential repair guidelines.

Wheel And Tire:

Tire pressure, wear inspection, wheel bearing service, spoke tensioning (if applicable to specific models, though TDM900 uses cast wheels).

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustment, tire pressure, brake pad replacement

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting for common and complex issues

Repair:

Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly

Diagnostics:

Fault code interpretation, sensor testing, electrical system analysis

Engine Rebuild:

Detailed instructions for engine disassembly, internal component inspection, measurement, and reassembly.

Suspension Rebuild:

Instructions for fork seal replacement, fork oil change, and rear shock absorber servicing.

Torque Specifications:

All critical fastener torque values are provided for engine, chassis, and bodywork components.

Technical Depth

Depth:

Factory-level, from basic adjustments to complete engine rebuilds and complex electrical diagnostics

Wiring Schematics:

Comprehensive wiring diagrams included for all electrical systems.

Diagrams Illustrations:

Abundant step-by-step illustrations and exploded diagrams for clarity.

Special Tools:

Lists and descriptions of any specialized tools required for specific procedures.

📊 Manual Specifications

File Format

File Format:

Print Quality

Printability:

Full printable, allowing users to print specific pages or the entire document

Binding Type

Binding Type:

Digital (PDF), no physical binding

Paper Type

Paper Type:

N/A (digital format)

Zoom Capabilities

Zoom Features:

Yes, allows zooming in on diagrams and text for clarity

Searchability

Search Functionality:

Typically searchable PDF for quick information retrieval

⚙️ Engine Specifications

Primary Engine

Engine Type:

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

Displacement:

897 cc

Bore X Stroke:

98.0 mm x 59.0 mm

Compression Ratio:

9.6:1

Performance

Horsepower:

Approx. 90 hp @ 8,000 rpm

Torque:

Approx. 8.9 kg-m (87 Nm) @ 6,000 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (Mikuni DFI)

Fuel Type:

Unleaded gasoline (95 RON or higher recommended)

Ignition

Ignition System:

Digital TCI (Transistor Controlled Ignition)

Lubrication

Oil Capacity:

Approx. 3.8 liters (4.0 US qt) with filter change

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multiple disc, cable-actuated

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Length:

2,150 mm (84.6 in)

Width:

780 mm (30.7 in)

Height:

1,305 mm (51.4 in)

Weights

Dry Weight:

Approx. 205 kg (452 lbs)

Wet Weight:

Approx. 228 kg (503 lbs) (fully fueled)

Fuel Tank Capacity:

20 liters (5.3 US gal)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A for motorcycles in this era

Active Features

Braking System:

Dual front disc brakes (298mm), single rear disc brake (245mm). ABS optional on some models (S variant).

Lighting:

Halogen headlights, LED taillight

💡 Technology Features

Infotainment

Infotainment System:

Basic analog/digital instrumentation. No integrated infotainment system.

Driver Assistance

ABS Availability:

Optional Anti-lock Braking System (ABS) available on the 'S' model variant.

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 10,000 km (6,000 miles) or annually

Valve Clearance Check:

Every 20,000 km (12,000 miles)

Spark Plug Replacement:

Every 10,000 km (6,000 miles)

Fluid Specifications

Engine Oil Type:

Yamalube 4 (or equivalent) API SG or higher, SAE 10W-40

Coolant Type:

Ethylene glycol based antifreeze coolant (50% solution)

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Clutch plates, chain and sprockets, brake pads, fork seals (typical for high mileage)

Potential Electrical Issues:

Occasional voltage regulator/rectifier failures reported by some owners, though not a widespread epidemic.

📚 Vehicle History

Brand Heritage

Brand Focus:

Yamaha is a renowned Japanese manufacturer with a strong legacy in motorcycles, known for innovation and performance across various segments.

Model Evolution

Predecessor:

The TDM900 builds upon the TDM850 platform, offering increased displacement, improved fuel injection, and revised styling for enhanced touring capabilities.

Production

Manufacturing Origin:

Japan