Page 1
Page 2
Page 3
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 Supplementary Service Manual together with the following manual.
TDM900 (N) 2001 SERVICE MANUAL: 5PS1-AE1
TDM900 (R) 2003
SUPPLEMENTARY
SERVICE MANUAL
E2002 by Yamaha Motor Co., Ltd.
First Edition, September 2002
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Page 4
EAS00002
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE: A NOTE provides key information to make procedures easier or clearer.
Failure to follow WARNING instructions could result in severe injury or death
the motorcycle operator, a bystander or a person checking or repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
to
Page 5
EAS00007
HOW TO 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.
1
The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter.
Refer to “SYMBOLS”.
2
Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) appears.
3
Sub-section titles appear in smaller print than the section title.
4
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
5
Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6
Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7
A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8
Jobs requiring more information (such as special tools and technical data) are described sequentially.
12
4
5
6
7
3
8
Page 6
1
GEN
INFO
3
CHK
ADJ
5
ENG
7
2
SPEC
4
CHAS
6
COOL
8
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols
chapter.
1
General information
2
Specifications
3
Periodic checks and adjustments
4
Chassis
5
Engine
6
Cooling system
7
Fuel injection system
8
Electrical system
9
Troubleshooting
1
to 9 indicate the subject of each
FI ELEC
9
10
TRBL
SHTG
11 12
1413
16 1715
19 2018
Symbols 10 to 17 indicate the following.
10
Serviceable with engine mounted
11
Filling fluid
12
Lubricant
13
Special tool
14
Tightening torque
15
Wear limit, clearance
16
Engine speed
17
Electrical data
Symbols
18
to 23 in the exploded diagrams indicate the types of lubricants and lubrication
points.
18
Engine oil
19
Gear oil
20
Molybdenum-disulfide oil
21
Wheel-bearing grease
22
Lithium-soap- based grease
23
Molybdenum-disulfide grease
Symbols 24 to 25 in the exploded diagrams indicate the following.
24
Apply locking agent (LOCTITE)
25
Replace the part
22
24 25
2321
Page 7
CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL
CHECKING THE SWITCHES 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC STARTING SYSTEM 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 5. . . . . . . . . .
TROUBLESHOOTING 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING
FAULTY LIGHTING SYSTEM 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT DOES NOT COME ON 14. . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BULB BURNT OUT 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TDM900 (R) 2003 WIRING DIAGRAM (EUR)
TDM900 (R) 2003 WIRING DIAGRAM (OCE)
Page 8
Page 9
GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS/
CHASSIS SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
SPEC
Model code 5PS4 (EUR)
5PS5 (OCE)
ENGINE SPECIFICATIONS
Item Standard Limit
Throttle bodies
Model (manufacturer) quantity
Intake vacuum pressure
Throttle cable free play (at the flange
of the throttle grip)
ID mark
Throttle valve size
38EIS (MIKUNI) 2
33 X 36 kPa
3 X 5 mm
5PS1 10
#50
CHASSIS SPECIFICATIONS
Item Standard Limit
Front tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 X 90 kg
90 X 203 kg
High-speed riding
Min. tire tread depth
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 X 90 kg
90 X 203 kg
High-speed riding
Min. tire tread depth
Tubeless
120/ 70ZR 18 M/ C (59W)
MEZ4 FRONT (METZELER)/
D220FSTJ (DUNLOP)
225 kPa (2.25 kgf/ cm
225 kPa (2.25 kgf/ cm
225 kPa (2.25 kgf/ cm
SSS
Tubeless
160/ 60ZR 17 M/ C (69W)
MEZ4 (METZELER)/
D220STJ (DUNLOP)
250 kPa (2.5 kgf/ cm
290 kPa (2.9 kgf/ cm
250 kPa (2.5 kgf/ cm
SSS
2
, 2.25 bar)
2
, 2.25 bar)
2
, 2.25 bar)
2
, 2.5 bar)
2
, 2.9 bar)
2
, 2.5 bar)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
1.6 mm
SSS
SSS
SSS
SSS
SSS
SSS
1.6 mm
–1–
Page 10
CHECKING THE SWITCHES
EAS00731
ELEC
ELECTRICAL
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/ wear ! Repair or replace.
Improperly connected ! Properly connect.
Incorrect continuity reading ! Replace the switch.
1 Main switch
2 Horn switch
3 Pass switch
4 Dimmer switch
5 Hazard switch
6 Turn signal switch
7 Clutch switch
8 Engine stop switch
9 Start switch
10 Front brake light switch
–2–
11 Neutral switch
12 Rear brake light switch
13 Fuses
14 Sidestand switch
Page 11
ELECTRIC STARTING SYSTEM
EAS00755
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
ELEC
–3–
Page 12
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 Engine stop switch
60 Start switch
61 Ignition fuse
ELECTRIC STARTING SYSTEM
ELEC
–4–
Page 13
ELECTRIC STARTING SYSTEM
EAS00756
STARTING CIRCUIT CUT-OFF SYSTEM
OPERATION
If the engine stop switch is set to “
main switch is set to “ON” (both switches are
closed), the starter motor can only operate if at
least one of the following conditions is met:
S The transmission is in neutral (the neutral
switch is closed).
S The clutch lever is pulled to the handlebar
(the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).
The starting circuit cut-off relay prevents the
starter motor from operating when neither of
these conditions has been met. In this instance,
the starting circuit cut-off relay is open so current cannot reach the starter motor. When at
least one of the above conditions has been met
the starting circuit cut-off relay is closed and the
engine can be started by pressing the starter
switch.
ELEC
” and the
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE SIDESTAND IS UP AND
THE CLUTCH LEVER IS PULLED TO
THE HANDLEBAR
Battery
1
Main fuse
2
Main switch
3
Ignition fuse
4
Engine stop switch
5
Starting circuit cut-off relay
6
Diode (starting circuit cut-off relay)
7
Clutch switch
8
Sidestand switch
9
10
Neutral switch
11
Start switch
12
Starter relay
13
Starter motor
14
Diode (starting circuit cut-off relay)
–5–
Page 14
ELECTRIC STARTING SYSTEM
ELEC
EAS00757
TROUBLESHOOTING
The starter motor fails to turn.
Check:
1. main and ignition fuses
2. battery
3. starter motor
4. starting circuit cut-off relay
5. diode
6. starter relay
7. main switch
8. engine stop switch
9. neutral switch
10. sidestand switch
11. clutch switch
12. start switch
13. wiring connections
(of the entire starting system)
NOTE:
S Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. air filter case
4. side cowlings
S Troubleshoot with the following special
tool(s).
EAS00739
2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3. (Manual No.:
5PS1-AE1)
Minimum open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
YES NO
S Clean the battery
terminals.
S Recharge or re-
place the battery.
EAS00758
3. Starter motor
S Connect the positive battery terminal and
starter motor lead with a jumper lead .
2 3
1
Pocket tester
90890-03132
EAS00738
1. Main and ignition fuses
S Check the main and ignition fuses for conti-
nuity.
Refer to “CHECKING THE FUSES” in chapter 3. (Manual No.: 5PS1-AE1)
S Are the main and ignition fuses OK?
YES
NO
Replace the fuse(s).
WARNING
S A wire that is used as a jumper lead
must have at least the same capacity or
more as that of the battery lead, otherwise the jumper lead may burn.
S This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
S Does the starter motor turn?
YES
Repair or replace the
starter motor.
NO
–6–
Page 15
ELECTRIC STARTING SYSTEM
ELEC
EAS00759
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.
Battery positive terminal ! red/ black
Battery negative terminal !
black/ yellow
Tester positive prove ! blue/ white
Tester negative prove ! black
3
4
Tester positive probe !
sky blue
1
Tester negative probe !
black/ yellow
2
Tester positive probe !
sky blue
Tester negative probe !
1
2
Tester positive probe !
blue/ yellow
blue/ green
1
Continuity
3
4
Tester negative probe !
blue/ yellow
3
Tester positive probe !
black/ yellow
2
Tester negative probe !
sky blue
1
Tester positive probe !
blue/ yellow
Tester negative probe !
sky blue
3
No continuity
1
S Does the starting circuit cut-off relay have
continuity between blue/ white and black?
YES NO
Replace the starting
circuit cut-off relay.
EAS00760
5. Starting circuit cut-off relay (diode)
S Disconnect the starting circuit cut-off relay
from the wire harness.
S Connect the pocket tester (Ω 1) to the
starting circuit cut-off relay terminals as
shown.
S Measure the starting circuit cut-off relay for
continuity as follows.
Tester positive probe !
blue/ yellow
3
Tester negative probe !
blue/ green
4
NOTE:
When you switch the tester’s positive and
negative probes, the readings in the above
chart will be reversed.
S Are the testing readings correct?
YES NO
–7–
Replace the starting
circuit cut-off relay.
Page 16
ELECTRIC STARTING SYSTEM
ELEC
EAS00761
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.
Battery positive terminal ! red/ white
Battery negative terminal !
blue/ white
Tester positive probe ! red
Tester negative probe ! black
3
4
S Does the starter relay have continuity be-
tween red and black?
YES NO
Replace the starter
relay.
EAS00750
8. Engine stop switch
S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the engine stop switch OK?
YES NO
1
Replace the right
2
EAS00751
handlebar switch.
9. Neutral switch
S Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the neutral switch OK?
YES NO
Replace the neutral
switch.
EAS00752
10. Sidestand switch
S Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the sidestand switch OK?
EAS00749
7. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
YES NO
Replace the main
switch.
YES NO
Replace the sidestand switch.
EAS00763
11. Clutch switch
S Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the clutch switch OK?
YES NO
Replace the clutch
switch.
–8–
Page 17
ELECTRIC STARTING SYSTEM
EAS00764
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.
EAS00766
13. Wiring
S Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the starting system’s wiring properly con-
nected and without defects?
ELEC
YES NO
The starting system
circuit is OK.
Properly connect or
repair the starting
system’s wiring.
–9–
Page 18
EAS00780
LIGHTING SYSTEM
CIRCUIT DIAGRAM
LIGHTING SYSTEM
ELEC
–10–
Page 19
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
63 Hazard light fuse
64 Signaling system fuse
67 Tail/brake light
70 Auxiliary light
LIGHTING SYSTEM
ELEC
–11–
Page 20
LIGHTING SYSTEM
ELEC
EAS00781
TROUBLESHOOTING
Any of the following fail to light: headlight,
high beam indicator light, taillight, auxiliary light or meter light.
Check:
1. main, signaling system and headlight fuses
2. battery
3. main switch
4. headlight relay
5. dimmer switch
6. pass switch
7. wiring connections
(of the entire lighting system)
NOTE:
S Before troubleshooting, remove the following
part(s):
1. fuel tank
2. front cowling
3. rear cowling
S Troubleshoot with the following special
tool(s).
EAS00739
2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3. (Manual No.:
5PS1-AE1)
Minimum open-circuit voltage
12.8 V or more at 20_C
S Is the battery OK?
YES NO
S Clean the battery
terminals.
S Recharge or re-
place the battery.
EAS00749
3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
Pocket tester
90890-03132
EAS00738
1. Main, signaling system and headlight
fuses
S Check the main, signaling system and head-
light fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3. (Manual No.: 5PS1-AE1)
S Are the main, parking lighting and headlight
fuses OK?
YES NO
Replace the fuse(s).
YES NO
Replace the main
switch.
4. Headlight relay
S Disconnect the headlight relay from the wire
harness.
S Connect the pocket tester (Ω 1) and bat-
tery (12 V) to the headlight relay terminal as
shown.
S Check the headlight relay for continuity.
Battery positive terminal ! red/ yellow
Battery negative terminal !
yellow/ black
Tester positive probe ! red/ yellow
Tester negative probe ! blue/ black
3
4
1
2
–12–
Page 21
LIGHTING SYSTEM
ELEC
S Dose the headlight relay have continuity be-
tween red/ yellow and green/blue?
YES NO
Replace the headlight relay.
EAS00784
5. Dimmer switch
S Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the dimmer switch OK?
YES NO
EAS00787
7. Wiring
S Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the lighting system’s wiring properly con-
nected and without defects?
YES NO
Check the condition
of each of the lighting
system’s circuits.
Properly connect or
repair the lighting
system’s wiring.
Refer to “CHECKING THE LIGHTING
SYSTEM”.
The dimmer switch is
faulty. Replace the
left handlebar
switch.
EAS00786
6. Pass switch
S Check the pass switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the pass switch OK?
YES NO
The pass switch is
faulty. Replace the
left handlebar
switch.
–13–
Page 22
EAS00866
TROUBLESHOOTING
FAULTY LIGHTING SYSTEM
HEADLIGHT DOES NOT COME ON
S Wrong headlight bulb
S Too many electrical accessories
S Hard charging
S Incorrect connection
S Improperly grounded circuit
S Poor contacts (main or dimmer switch)
S Headlight relay
S Burnt-out headlight bulb
HEADLIGHT BULB BURNT OUT
S Wrong headlight bulb
S Faulty battery
S Faulty rectifier/ regulator
S Improperly grounded circuit
S Faulty main switch
S Faulty dimmer switch
S Faulty headlight relay
S Headlight bulb life expired
FAULTY LIGHTING SYSTEM
TRBL
SHTG
–14–
Page 23
WIRING DIAGRAM (EUR)
1 Crankshaft position sensor
2 A.C magneto
3 Rectifier/ regulator
4 Main fuse
5 Battery
6 Fuel injection system fuse
7 Starter relay
8 Starter motor
9 Main switch
10 Alarm
11 Buck up fuse
12 Starting circuit cut-off relay
13 Sidestand switch
14 Neutral switch
15 Cylinder identification sensor
16 Throttle position sensor
17 Intake air pressure sensor
18 Atmospheric pressure sensor
19 Intake air temperature sensor
20 Coolant temperature sensor
21 Lean angle cut-off relay
22 O
sensor
2
23 ECU
24 Injector (#1)
25 Injector (#2)
26 Al system solenoid
27 Intake solenoid
28 Ignition coil
29 Spark plug
30 Fuel pump
31 Speed sensor
32 Meter assembly
33 Oil level warning light
34 Neutral indicator light
35 Multi-function meter
36 Engine trouble warning light
37 Hi beam indicator light
38 Left turn signal indicator light
39 Right turn signal indicator light
40 Meter light
41 Oil level switch
42 Turn signal relay
43 Left handlebar switch
44 Horn switch
45 Pass switch
46 Dimmer switch
47 Hazard switch
48 Turn signal switch
49 Clutch switch
50 Horn
51 Rear turn signal light (left)
52 Rear turn signal light (right)
53 Front turn signal light (left)
54 Front turn signal light (right)
55 Headlight
56 Headlight relay
57 Right handlebar switch
58 Front brake light switch
59 Engine stop switch
60 Start switch
61 Ignition fuse
62 Headlight fuse
63 Hazard fuse
64 Signaling system fuse
65 Radiator fan motor fuse
66 Rear brake light switch
67 Tail/brake light
68 Radiator fan relay
69 Radiator fan motor
70 Auxiliary light
COLOR CODE
B Black. . . . . . .
Br Brown. . . . . .
Ch Chocolate. . . . .
Dg Dark green. . . . .
G Green. . . . . .
Gy Gray. . . . .
L Blue. . . . . . .
Lg Light green. . . . . .
O Orange. . . . . .
P Pink. . . . . . .
R Red. . . . . . .
Sb Sky blue. . . . . .
W White. . . . . .
Y Yellow. . . . . . .
B/ L Black/ Blue. . . . .
B/ W Black/ White. . . .
B/ Y Black/ Yellow. . . .
Br/ B Brown/ Black. . . .
Br/ G Brown/ Green. . .
Br/ L Brown /Blue. . . .
Br/ R Brown /Red. . . .
Br/ W Brown/ White. . .
G/ B Green/ Black. . . .
G/ R Green/ Red. . . .
G/ W Green / White. . . .
G/ Y Green/ Yellow. . . .
Gy/ G Gray/ Green. . .
Gy/ R Gray / Red. . .
L/ B Blue/ Black. . . . .
L/ G Blue/ Green. . . .
L/ R Blue /Red. . . .
L/ W Blue/ White. . . .
L/ Y Blue/ Yellow. . . . .
P/ W Pink/ White. . . .
R/ B Red / Black. . . .
R/ G Red/ Green. . . .
R/ L Red /Blue. . . .
R/ W Red/ White. . . .
R/ Y Red / Yellow. . . .
W/ B White/ Black. . . .
W/ Y White/ Yellow. . . .
Y/ B Yellow/ Black. . . .
Y/ G Yellow/ Green. . . .
Y/ L Yellow/ Blue. . . . .
Page 24
WIRING DIAGRAM (OCE)
1 Crankshaft position sensor
2 A.C magneto
3 Rectifier/ regulator
4 Main fuse
5 Battery
6 Fuel injection system fuse
7 Starter relay
8 Starter motor
9 Main switch
10 Buck up fuse
11 Starting circuit cut-off relay
12 Sidestand switch
13 Neutral switch
14 Cylinder identification sensor
15 Throttle position sensor
16 Intake air pressure sensor
17 Atmospheric pressure sensor
18 Intake air temperature sensor
19 Coolant temperature sensor
20 Lean angle cut-off switch
21 O
sensor
2
22 ECU
23 Injector (#1)
24 Injector (#2)
25 Al system solenoid
26 Intake solenoid
27 Ignition coil
28 Spark plug
29 Fuel pump
30 Speed sensor
31 Meter assembly
32 Oil level warning light
33 Neutral indicator light
34 Multi function meter
35 Engine trouble warning light
36 Hi beam indicator light
37 Left turn signal indicator light
38 Right turn signal indicator light
39 Meter light
40 Oil level switch
41 Turn signal relay
42 Left handlebar switch
43 Horn switch
44 Pass switch
45 Dimmer switch
46 Turn signal switch
47 Clutch switch
48 Horn
49 Rear turn signal light (left)
50 Rear turn signal light (right)
51 Front turn signal light (left)
52 Front turn signal light (right)
53 Headlight
54 Headlight relay
55 Right handlebar switch
56 Front brake light switch
57 Engine stop switch
58 Start switch
59 Ignition fuse
60 Headlight fuse
61 Signaling system fuse
62 Radiator fan motor fuse
63 Radiator fan relay
64 Radiator fan motor
65 Auxiliary light
66 Rear brake light switch
67 Tail/brake light
COLOR CODE
B Black. . . . . . .
Br Brown. . . . . .
Ch Chocolate. . . . .
Dg Dark green. . . . .
G Green. . . . . .
Gy Gray. . . . .
L Blue. . . . . . .
Lg Light green. . . . . .
O Orange. . . . . .
P Pink. . . . . . .
R Red. . . . . . .
Sb Sky blue. . . . . .
W White. . . . . .
Y Yellow. . . . . . .
B/ L Black/ Blue. . . . .
B/ W Black/ White. . . .
B/ Y Black/ Yellow. . . .
Br/ B Brown/ Black. . . .
Br/ L Brown /Blue. . . .
Br/ R Brown /Red. . . .
Br/ W Brown/ White. . .
G/ B Green/ Black. . . .
G/ R Green/ Red. . . .
G/ W Green / White. . . .
G/ Y Green/ Yellow. . . .
Gy/ G Gray/ Green. . .
Gy/ R Gray / Red. . .
L/ B Blue/ Black. . . . .
L/ G Blue/ Green. . . .
L/ R Blue /Red. . . .
L/ W Blue/ White. . . .
L/ Y Blue/ Yellow. . . . .
P/ W Pink/ White. . . .
R/ B Red / Black. . . .
R/ G Red/ Green. . . .
R/ L Red /Blue. . . .
R/ W Red/ White. . . .
R/ Y Red / Yellow. . . .
W/ Y White/ Yellow. . . .
Y/ B Yellow/ Black. . . .
Y/ G Yellow/ Green. . . .
Y/ L Yellow/ Blue. . . . .
Page 25
Page 26
Page 27
TDM900 (R) 2003 WIRING DIAGRAM (EUR)
Gy
G/W
L/Y
G/W
1
2 3
WWW
R
ON
OFF
P
L/BBr/R
L/Y
Br/L L/Y
L/Y
B
Br/R
Br/R B
D C
Y/L
R/G
Y/L
G/R
L/W R/WL/Y L/YL/G
L
W/B
B/L
B/L
P/W
B/L P L
B/W
WIRE
HARNESS
L
B/L
Br/W
B/L
G/R
R/G
W
L Y B/L
17
18
W
HEADLIGHT
SUB-WIRE
HARNESS 1
Sb B/Y Lg
16
E
B/L B/L
B/W
L
B/L
L
P
B/L
19
20
B/L G/R
DgLgBr
L/B L/R
Gy
G/W
W
W
W
W
W
W
-
RB
R R R
B
9
R
Br/L
R
Br/L
B
61
Br/L
62
Br/L
R/W
R/Y
B
G/Y G/Y
BB
R/B R/B
R
BBB
BBB
10
BBB
BBB
B
B
B
B
B
B
B
B
BB
B
57
R/W R/W L/W
Br Br
4
R
R
R
R
B
B
B
BB
B
187
R
6
-
RR
R
7
5
8
B
BB
58
187
L/WR/W
R/W
L/W
R/W R/B B
59
OFF
RUN
L/W
R
11
R/G
60
OFF
ON
B
R/W
B/Y
BYChGL
WIRE HARNESS
12
Sb L/Y
L/G
B
Sb
14
L/G
13
BB
B
L/G
Dg Lg Br
L/BL/R
BYChGL
HEADLIGHT
SUB-WIRE HARNESS 2
RLgR/BL/W
R/L
R L/W R/LR/B B
L/Y
15
L/Y
W
B/L
W/B
L
B/L
B/RB/W
B
YY
P/W P/W R/B
B/L B/L
SUB-WIRE
WIRE
HARNESS
HARNESS 2
B
B/L B/L
B/L
B
Y Y
Y
A
L
L L
B
P/WP/W P/W
Br/W
E
Br/W
Br/W
-
--
Y/G
L
B/L
21
L
WIRE
HARNESS
Y/G
A
R/B
G/B
G/B
L
R/L
L
R/L
SUB-WIRE
HARNESS 1
R/L
L/Y
R/W
B/Y
B
L/W
G/Y
G/W
W/B
B/L Br/B
L
Y
P/W
P
Br/W
G/R
Y/G
R/W
Gy/G
22
B/L
Gy/G
Br/B
R/W
B/L Br/W
WIRE
HARNESS
B/W B/W
B/W B/W
E
23
B/L
Br/B
R/W
B/LBr/W
SUB-WIRE
HARNESS 3
O
Gy/R
R/B
G/B
Br/R
Y/B
G/Y
Y/L
W/Y
Gy/G
L
-
Y/G
W/Y
A
R/B R/B
A
G/B G/B
G/W
W/BR/L
G/R
P
- --- -
Br/W
P/W
Gy
Y/L
Y
24
25
Br/R
E
Br/B Br/B
--
B/L
R/L
A
R/L
R/L
R/L
26
27
B
B/YL/WB/W
G/YBr/B
R/W
Br/R
L/Y
R/L
R/B
R/L
G/B
R/W
Br/R
Br
R/W
Y/B
R/W
E
R/W
Gy/R
R/B
G/B
---
Br/R
R/W
R/W
Br/B
O
B/W
B/WB/WR/W
R/B
205
O
R/B
205
Gy/R
30
B/W
G
BR/L
L
W/Y
31
B/L
W
L/Y
B/L
W/YL
B/L
28
29
28
29
R/L
G
B
B/W
Br
L
R/W G/Y
B
L
G/Y
63
Br/R
64
Br/L
R
65
Br
Br
R/W
68
L
G/Y
L
B
69
L
B
Br/G
Br
L/R
D
L/R
L/R
L/R
B
70
B
Br
66
Br Y
BB
Y
L/R
YB
L/RY
YLB
YB
67
B
BBr
R/Y
56
L/B
R/Y Y/B
--
Y
55
B B
B
D
B
32
33
Br/G
-
Br/W
42
Br/G
R/YR/Y
Y/BL/B
L/B
D
L/B
B
L/B
L/B
43
44
OFF
ON
B/W
Br
Br
G/Y
50
R/YBr L/B Br/W
45 46
OFF
ON
HI
LO
YB
Y
D
Y
47 48
OFF
ON
Ch
51
-
Ch
B
B
-
Ch
B
Br/W
B/Y L/Y
R
N
L
B/Y
B/Y
L/Y
L/Y
B/Y
L/Y
B/Y
L/Y
YDg
L/Y
Ch
Br/W
R/Y L/B
B/YBr
Br/W
R/YL/B
B
B/Y Br
YDg
B
L/Y
Ch
49
Ch
Dg
D
Ch Ch
Dg
52
-
Dg
B
B
-
Dg
B
D
Dg Dg
Ch
Ch
B
B
-
B
Dg
53
-
Ch
54
-
Dg
B
B
B
-
Dg
B
G
Br
R/G
D
D
C
G
Br
R/G
R/G
W
C
W
D
L
LL
BW
W
BW
41
B
34
Br
G
W
35
36
37
Y
38
Ch
39
Dg
40
-
R/G
BrLgDg
B/W
Y/L
W
----
YChLG
Lg
Y/L
Lg
D
Lg
Y/L
C
Y/L
B/WB/W B/W
C
Page 28
TDM900 (R) 2003 WIRING DIAGRAM (OCE)
WIRE HARNESS
HEADLIGHT
SUB-WIRE HARNESS 2
R L/W R/LR/B L/W
B/RB/W
WIRE
HARNESS
G/R
L/W R/WL/Y L/YL/G
HEADLIGHT
SUB-WIRE
HARNESS 1
Sb B/Y Lg
WIRE
HARNESS
SUB-WIRE
HARNESS 2
WIRE
HARNESS
SUB-WIRE
HARNESS 1
WIRE
HARNESS
SUB-WIRE
HARNESS 3
Br
Br/W
YDg
R/YL/B
B
B/Y Br
L/Y
Br
Ch
Br/W
R/Y L/B
B/YBr
YDg
B
L/Y
Ch
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