Yamaha Tdm900r5ps1ae2 5PS 03 Service Manual Suppl User 5e01a1e2 7fd1 4893 99e4 A12bd89ed6fe

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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.

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:

Failure to follow WARNING instructions could result in severe injury or death to
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.
A NOTE provides key information to make procedures easier or clearer.

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.
2
1

3
4

5

6

7

8

EAS00008

1

2

GEN
INFO

SYMBOLS

SPEC

3

4

CHK
ADJ

CHAS

5

6

COOL

ENG
7

8

FI

ELEC
10

9

TRBL
SHTG
11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

The following symbols are not relevant to every
vehicle.
Symbols 1 to 9 indicate the subject of each
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
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

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)

GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS/
CHASSIS SPECIFICATIONS

SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code

Standard

Limit
SSS
SSS

5PS4 (EUR)
5PS5 (OCE)

ENGINE SPECIFICATIONS
Item
Throttle bodies
Model (manufacturer)
quantity
Intake vacuum pressure
Throttle cable free play (at the flange
of the throttle grip)
ID mark
Throttle valve size

Standard
38EIS (MIKUNI)
33 X 36 kPa
3 X 5 mm

2

Limit
SSS
SSS
SSS
SSS
SSS

5PS1 10
#50

CHASSIS SPECIFICATIONS
Item
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

Standard

Limit

Tubeless
120/70ZR 18 M/C (59W)
MEZ4 FRONT (METZELER)/
D220FSTJ (DUNLOP)

SSS
SSS
SSS

225 kPa (2.25 kgf/cm2, 2.25 bar)
225 kPa (2.25 kgf/cm2, 2.25 bar)
225 kPa (2.25 kgf/cm2, 2.25 bar)
SSS

SSS
SSS
SSS
1.6 mm

Tubeless
160/60ZR 17 M/C (69W)
MEZ4 (METZELER)/
D220STJ (DUNLOP)

SSS
SSS
SSS

250 kPa (2.5 kgf/cm2, 2.5 bar)
290 kPa (2.9 kgf/cm2, 2.9 bar)
250 kPa (2.5 kgf/cm2, 2.5 bar)
SSS

SSS
SSS
SSS
1.6 mm

–1–

CHECKING THE SWITCHES

ELEC

EAS00731

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
2
3
4
5

Main switch
Horn switch
Pass switch
Dimmer switch
Hazard switch

6
7
8
9
10

Turn signal switch
Clutch switch
Engine stop switch
Start switch
Front brake light switch

–2–

11
12
13
14

Neutral switch
Rear brake light switch
Fuses
Sidestand switch

ELECTRIC STARTING SYSTEM
EAS00755

ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM

–3–

ELEC

ELECTRIC STARTING SYSTEM
4
5
7
8
9
12
13
14
49
59
60
61

Main fuse
Battery
Starter relay
Starter motor
Main switch
Starting circuit cut-off relay
Sidestand switch
Neutral switch
Clutch switch
Engine stop switch
Start switch
Ignition fuse

–4–

ELEC

ELECTRIC STARTING SYSTEM

ELEC

EAS00756

STARTING CIRCUIT CUT-OFF SYSTEM
OPERATION
If the engine stop switch is set to “ ” and the
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.
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE SIDESTAND IS UP AND
THE CLUTCH LEVER IS PULLED TO
THE HANDLEBAR
1
2
3
4
5
6
7
8
9
10
11
12
13
14

–5–

Battery
Main fuse
Main switch
Ignition fuse
Engine stop switch
Starting circuit cut-off relay
Diode (starting circuit cut-off relay)
Clutch switch
Sidestand switch
Neutral switch
Start switch
Starter relay
Starter motor
Diode (starting circuit cut-off relay)

ELECTRIC STARTING SYSTEM
EAS00757

ELEC

EAS00739

TROUBLESHOOTING

2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3. (Manual No.:
5PS1-AE1)

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)

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 replace the battery.

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).

EAS00758

3. Starter motor
S Connect the positive battery terminal 1 and
starter motor lead 2 with a jumper lead 3 .

Pocket tester
90890-03132
EAS00738

1. Main and ignition fuses

WARNING

S Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3. (Manual No.: 5PS1-AE1)
S Are the main and ignition fuses OK?
YES

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.

NO

S Does the starter motor turn?

Replace the fuse(s).

YES

NO
Repair or replace the
starter motor.

–6–

ELECTRIC STARTING SYSTEM
EAS00759

ELEC

Tester positive probe !
sky blue 1
Tester negative probe !
black/yellow 2

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 battery (12 V) to the starting circuit cut-off relay
terminals as shown.

Tester positive probe !
sky blue 1
Tester negative probe !
blue/yellow 3

Battery positive terminal ! red/black 1
Battery negative terminal !
black/yellow 2

Continuity

Tester positive probe !
blue/green 4
Tester negative probe !
blue/yellow 3

Tester positive prove ! blue/white 3
Tester negative prove ! black 4

Tester positive probe !
black/yellow 2
Tester negative probe !
sky blue 1
Tester positive probe !
blue/yellow 3
Tester negative probe !
sky blue 1
Tester positive probe !
blue/yellow 3
Tester negative probe !
blue/green 4

S Does the starting circuit cut-off relay have
continuity between blue/white and black?
YES

No continuity

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.

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
Replace the starting
circuit cut-off relay.

–7–

ELECTRIC STARTING SYSTEM
EAS00761

ELEC

EAS00750

6. Starter relay

8. Engine stop switch

S Disconnect the starter relay from the coupler.
S Connect the pocket tester (Ω
1) and battery (12 V) to the starter relay terminals as
shown.

S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the engine stop switch OK?
YES

Battery positive terminal ! red/white 1
Battery negative terminal !
blue/white 2

NO
Replace the right
handlebar switch.

Tester positive probe ! red 3
Tester negative probe ! black 4

EAS00751

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.

S Does the starter relay have continuity between red and black?
YES

EAS00752

10. Sidestand switch

NO

S Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the sidestand switch OK?

Replace the starter
relay.

YES

NO

EAS00749

7. Main switch

Replace the sidestand switch.

S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
YES

EAS00763

11. Clutch switch

NO

S Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the clutch switch OK?

Replace the main
switch.

YES

NO
Replace the clutch
switch.

–8–

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 connected and without defects?
YES
The starting system
circuit is OK.

NO
Properly connect or
repair the starting
system’s wiring.

–9–

ELEC

LIGHTING SYSTEM
EAS00780

LIGHTING SYSTEM
CIRCUIT DIAGRAM

–10–

ELEC

LIGHTING SYSTEM
4
5
9
23
37
40
45
46
55
56
62
63
64
67
70

Main fuse
Battery
Main switch
ECU
High beam indicator light
Meter light
Pass switch
Dimmer switch
Headlight
Headlight relay
Headlight fuse
Hazard light fuse
Signaling system fuse
Tail/ brake light
Auxiliary light

–11–

ELEC

LIGHTING SYSTEM
EAS00781

ELEC

EAS00739

TROUBLESHOOTING

2. Battery
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3. (Manual No.:
5PS1-AE1)

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)

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 replace the battery.

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).

EAS00749

3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
YES

Pocket tester
90890-03132

NO
Replace the main
switch.

EAS00738

1. Main, signaling system and headlight
fuses

4. Headlight relay

S Check the main, signaling system and headlight 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?

S Disconnect the headlight relay from the wire
harness.
S Connect the pocket tester (Ω
1) and battery (12 V) to the headlight relay terminal as
shown.
S Check the headlight relay for continuity.

YES

Battery positive terminal ! red/yellow 1
Battery negative terminal !
yellow/black 2

NO
Replace the fuse(s).

Tester positive probe ! red/yellow 3
Tester negative probe ! blue/black 4

–12–

LIGHTING SYSTEM
EAS00787

S Dose the headlight relay have continuity between red/yellow and green/blue?
YES

7. Wiring
S Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
S Is the lighting system’s wiring properly connected and without defects?

NO
Replace the headlight relay.

YES
Check the condition
of each of the lighting
system’s circuits.
Refer to “CHECKING THE LIGHTING
SYSTEM”.

EAS00784

5. Dimmer switch
S Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the dimmer switch OK?
YES

NO
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

ELEC

NO
The pass switch is
faulty. Replace the
left
handlebar
switch.

–13–

NO
Properly connect or
repair the lighting
system’s wiring.

FAULTY LIGHTING SYSTEM
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

–14–

TRBL
SHTG

WIRING DIAGRAM (EUR)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61

Crankshaft position sensor
A.C magneto
Rectifier/ regulator
Main fuse
Battery
Fuel injection system fuse
Starter relay
Starter motor
Main switch
Alarm
Buck up fuse
Starting circuit cut-off relay
Sidestand switch
Neutral switch
Cylinder identification sensor
Throttle position sensor
Intake air pressure sensor
Atmospheric pressure sensor
Intake air temperature sensor
Coolant temperature sensor
Lean angle cut-off relay
O2 sensor
ECU
Injector (#1)
Injector (#2)
Al system solenoid
Intake solenoid
Ignition coil
Spark plug
Fuel pump
Speed sensor
Meter assembly
Oil level warning light
Neutral indicator light
Multi-function meter
Engine trouble warning light
Hi beam indicator light
Left turn signal indicator light
Right turn signal indicator light
Meter light
Oil level switch
Turn signal relay
Left handlebar switch
Horn switch
Pass switch
Dimmer switch
Hazard switch
Turn signal switch
Clutch switch
Horn
Rear turn signal light (left)
Rear turn signal light (right)
Front turn signal light (left)
Front turn signal light (right)
Headlight
Headlight relay
Right handlebar switch
Front brake light switch
Engine stop switch
Start switch
Ignition fuse

62
63
64
65
66
67
68
69
70

Headlight fuse
Hazard fuse
Signaling system fuse
Radiator fan motor fuse
Rear brake light switch
Tail/ brake light
Radiator fan relay
Radiator fan motor
Auxiliary light

COLOR CODE
B .......
Br . . . . . .
Ch . . . . .
Dg . . . . .
G ......
Gy . . . . .
L .......
Lg . . . . . .
O ......
P .......
R.......
Sb . . . . . .
W ......
Y .......
B/ L . . . . .
B/ W . . . .
B/ Y . . . .
Br/ B . . . .
Br/ G . . .
Br/ L . . . .
Br/ R . . . .
Br/ W . . .
G/B . . . .
G/R . . . .
G/W . . . .
G/Y . . . .
Gy/ G . . .
Gy/ R . . .
L/B . . . . .
L/G . . . .
L/R . . . .
L/W . . . .
L/Y . . . . .
P/ W . . . .
R/ B . . . .
R/ G . . . .
R/ L . . . .
R/ W . . . .
R/ Y . . . .
W/ B . . . .
W/ Y . . . .
Y/ B . . . .
Y/ G . . . .
Y/ L . . . . .

Black
Brown
Chocolate
Dark green
Green
Gray
Blue
Light green
Orange
Pink
Red
Sky blue
White
Yellow
Black/ Blue
Black/ White
Black/ Yellow
Brown/ Black
Brown/ Green
Brown/ Blue
Brown/ Red
Brown/ White
Green / Black
Green / Red
Green / White
Green / Yellow
Gray / Green
Gray / Red
Blue/ Black
Blue/ Green
Blue/ Red
Blue/ White
Blue/ Yellow
Pink/ White
Red/ Black
Red/ Green
Red/ Blue
Red/ White
Red/ Yellow
White/ Black
White/ Yellow
Yellow/ Black
Yellow/ Green
Yellow/ Blue

WIRING DIAGRAM (OCE)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61

Crankshaft position sensor
A.C magneto
Rectifier/ regulator
Main fuse
Battery
Fuel injection system fuse
Starter relay
Starter motor
Main switch
Buck up fuse
Starting circuit cut-off relay
Sidestand switch
Neutral switch
Cylinder identification sensor
Throttle position sensor
Intake air pressure sensor
Atmospheric pressure sensor
Intake air temperature sensor
Coolant temperature sensor
Lean angle cut-off switch
O2 sensor
ECU
Injector (#1)
Injector (#2)
Al system solenoid
Intake solenoid
Ignition coil
Spark plug
Fuel pump
Speed sensor
Meter assembly
Oil level warning light
Neutral indicator light
Multi function meter
Engine trouble warning light
Hi beam indicator light
Left turn signal indicator light
Right turn signal indicator light
Meter light
Oil level switch
Turn signal relay
Left handlebar switch
Horn switch
Pass switch
Dimmer switch
Turn signal switch
Clutch switch
Horn
Rear turn signal light (left)
Rear turn signal light (right)
Front turn signal light (left)
Front turn signal light (right)
Headlight
Headlight relay
Right handlebar switch
Front brake light switch
Engine stop switch
Start switch
Ignition fuse
Headlight fuse
Signaling system fuse

62
63
64
65
66
67

Radiator fan motor fuse
Radiator fan relay
Radiator fan motor
Auxiliary light
Rear brake light switch
Tail/ brake light

COLOR CODE
B .......
Br . . . . . .
Ch . . . . .
Dg . . . . .
G ......
Gy . . . . .
L .......
Lg . . . . . .
O ......
P .......
R.......
Sb . . . . . .
W ......
Y .......
B/ L . . . . .
B/ W . . . .
B/ Y . . . .
Br/ B . . . .
Br/ L . . . .
Br/ R . . . .
Br/ W . . .
G/B . . . .
G/R . . . .
G/W . . . .
G/Y . . . .
Gy/ G . . .
Gy/ R . . .
L/B . . . . .
L/G . . . .
L/R . . . .
L/W . . . .
L/Y . . . . .
P/ W . . . .
R/ B . . . .
R/ G . . . .
R/ L . . . .
R/ W . . . .
R/ Y . . . .
W/ Y . . . .
Y/ B . . . .
Y/ G . . . .
Y/ L . . . . .

Black
Brown
Chocolate
Dark green
Green
Gray
Blue
Light green
Orange
Pink
Red
Sky blue
White
Yellow
Black/ Blue
Black/ White
Black/ Yellow
Brown/ Black
Brown/ Blue
Brown/ Red
Brown/ White
Green / Black
Green / Red
Green / White
Green / Yellow
Gray / Green
Gray / Red
Blue/ Black
Blue/ Green
Blue/ Red
Blue/ White
Blue/ Yellow
Pink/ White
Red/ Black
Red/ Green
Red/ Blue
Red/ White
Red/ Yellow
White/ Yellow
Yellow/ Black
Yellow/ Green
Yellow/ Blue

TDM900 (R) 2003 WIRING DIAGRAM (EUR)
D

Gy G/W

C

B

A

E

G/W L/Y
Gy

1

Br Lg Dg L/B L/R

L/R L/B Dg Lg Br

Y/L R/G

R/G Y/L

P/W Y

Y P/W

R/B G/B

G/B R/B

Br/B R/W

R/W Br/B

L

B

B/W W

W B/W

B/L

B/L

R/L L

L R/L

B/L Br/W

Br/W B/L

WIRE
HARNESS

HEADLIGHT
SUB-WIRE
HARNESS 1

WIRE
HARNESS

SUB-WIRE
HARNESS 2

WIRE
HARNESS

WIRE
HARNESS

SUB-WIRE
HARNESS 3

G Ch Y B

R

R

R

R
R

W

2

Y Ch G L

4

G/W

W

W

W

W

R

3

HEADLIGHT
SUB-WIRE HARNESS 2

WIRE HARNESS

6

W

R

-

SUB-WIRE
HARNESS 1

L - Y/G P G/R R/L W/B G/W B/W - L/W B/Y B R/W Br/B G/Y - G/B R/B Gy/R O B/W
Gy/G W/Y - Br/W P/W Y Y/L Gy B/L - - - R/W L/Y - Br/R Y/B - B/W - - B/W

R/W L/W

R

28

R/B

R

205

B - R

W W W

R

O

R

7
B

R

R

29

R/W

5

L/W

L/W R/B

L/W

Lg

R

R

R

B

B B B

9

8

B

L/W G/R

R/B

B/W B/R L/W L/Y R/W L/G L/Y Sb

11

B B B

B

R/L

B/Y

Lg

R/L

12

10
OFF
P

B

B

B

B

B

B

L/Y

29

R/L

R/G

B

B

B

R/W

B/Y

Sb

L/Y

L/G

R/L

R/L

G

B

B/W

25

L/W
B

G/B G/B A G/B

G/Y

R/L

30

G B/W

R/L G/B

G/W
Br/R

W/B
B
Br/L
L/Y
Br/R
B

205

Gy/R

B

Br/L

L/Y B Br/R

R/L R/B

R/L

B/Y

R
Br/R L/B L/Y

Gy/R
R/B R/B A R/B

R/W

B

ON

24

28

R/B

R/L
A

O

L/Y

L

B/L B B/L

Y B/L

16

B

R

B

Br/L

B

L

L/G

15

B

B
B

B

B

L A L

P/W

R/L B
R/W

Br/R

26

Br/R R/W

Br Br/R
R/W

G/R

17
B/L P/W L

L

Y/G

P/W P/W B P/W

R/W

E

27

R/W

Br/B E Br/B

R/W

Y/B

B/L

Br/B R/W

G/Y

Gy/G

L W/B

B

Y/L

L/G B

B

L

23

P

B/L
B B

B

Y

Br/W

W L/Y

B

B

Y B Y

B/L

B

Br/B

L

Y
W/B

13

B

B/L

B/L

B/L

Sb

18
B/L P

L

W/Y

P

L

B/L

14
61

L

Br/L

Br/W
E
Br/W
Br/W

R/W

19

Br/W B/L
B/L E B/L

31

W/Y

B/W
B/W
B/W
B/W

B/L

62

W L/Y

Br/L

R/Y
R/W R/B

B/L

20

B

57

B/L

G/Y B R/W

R/W L/W G/Y

R/B B Br

Br B R/B

58

G/R
Y/G

G/R B/L

60

L

22

B/L

L W/Y

- - -

OFF

59

B/L

L Y/G B/L

ON

21

OFF
RUN

B/L

187

187

G/Y

Gy/G

Br

B

32

Lg

33

D

63
Br/R

Br/G

Lg

34

Br/G

Lg
Br R/G G
D

-

Y/L

Br R/G G

42

Br/W

Y/L
Br

Br/G

R/G

64
Br/L

R

Dg Y L/B Br/W R/Y

56

Br

43

R/Y

L/B

Br/W

W

Ch L/Y B B/Y Br

B/Y L/Y

C

L/B

65

R/Y

Br

44

66

D

L/B

L/R

Y/B

45

46

47

R/Y Br/W L/B Y Dg

48

OFF

OFF

HI

OFF

R

ON

ON

LO

ON

N

Br Y

B B

L/R

B/Y
B/Y L/Y

Y

38

B/Y L/Y

Ch

39
B/Y

Dg

L/Y

B/W

Br

L/B

Y

B L/R

40
L D L

49

D

R/W Br

B
Y L/R

Y L/R B
-

G/Y

B L

Y

Y

L/B

B

B

Dg

Y

Ch

W Y/L B/W Dg - Lg Br R/G

Br

G/Y

B

50

- - - - G L Ch Y

Y
D

Ch

D Ch

W

Y

68

Y

L/B

Dg
Ch

Dg

Ch

B W

D Dg

W B

Dg

67
51

G/Y L

55

B

L

L

69

B

B
D
B

B

B

52

53

54

Ch -

Dg -

Ch -

Dg -

B

B

B

B

B

B

B

B

B

B
L

B

L

L/B

70
L

37

Br B/Y B L/Y Ch

L/Y

L

Br

R/W

36

W

Y/B

L/R

B/W B/W C B/W

W

R/Y R/Y

Br

35

G
Br/W

Br

R/Y

Y/L
C

C D

- Ch

- Dg

- Ch

- Dg

B

B

B

B

41
B

TDM900 (R) 2003 WIRING DIAGRAM (OCE)

WIRE HARNESS

HEADLIGHT
SUB-WIRE HARNESS 2

R

L/W G/R

WIRE
HARNESS

HEADLIGHT
SUB-WIRE
HARNESS 1

WIRE
HARNESS

SUB-WIRE
HARNESS 2

WIRE
HARNESS

SUB-WIRE
HARNESS 1

WIRE
HARNESS

SUB-WIRE
HARNESS 3

R/B L/W R/L

B/W B/R L/W L/Y R/W L/G L/Y Sb

B/Y

Lg

Br

Dg Y L/B Br/W R/Y
Br

Ch L/Y B B/Y Br

R/Y Br/W L/B Y Dg
Br B/Y B L/Y Ch
Source Exif Data: 
File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.3
Linearized                      : No
Create Date                     : 2002:10:04 14:37:35
Producer                        : Acrobat Distiller 4.05 for Windows
Modify Date                     : 2006:04:19 02:02:16+02:00
Title                           : 5PS 03 Service Manual Suppl
Author                          : JBX
Page Count                      : 28
Page Mode                       : UseOutlines
Page Layout                     : SinglePage
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