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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
EAS00008
GEN
INFO
SYMBOLS
SPEC
CHK
ADJ
CHAS
COOL
ENG
7
FI
ELEC
10
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
Limit
SSS
SSS
SSS
SSS
SSS
5PS1 10
#50
CHASSIS SPECIFICATIONS
Item
Front tire
Tire type
Size
Tire pressure (cold)
0 X 90 kg
90 X 203 kg
High-speed riding
Min. tire tread depth
Rear tire
Tire type
Size
Tire pressure (cold)
0 X 90 kg
90 X 203 kg
High-speed riding
Min. tire tread depth
Standard
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
Limit
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

CIRCUIT DIAGRAM
3
ELEC

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
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
Diode (starting circuit cut-off relay)
Clutch switch
Sidestand switch
Neutral switch
Start switch
Starter relay
Starter motor
Diode (starting circuit cut-off relay)

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?
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
YES
S Does the starter motor turn?
Replace the fuse(s).
YES
NO
Repair or replace the
starter motor.
6

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

sky blue 1
blue/yellow 3
Battery positive terminal ! red/black 1

Battery negative terminal !
black/yellow 2
Continuity

blue/green 4
blue/yellow 3
Tester positive prove ! blue/white 3

Tester negative prove ! black 4

black/yellow 2
sky blue 1
blue/yellow 3
sky blue 1
blue/yellow 3
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.
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 testers 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

EAS00761
ELEC
EAS00750
6. Starter relay
8. Engine stop switch
S Disconnect the starter relay from the coupler.

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

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.
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.

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.

S Is the main switch OK?
YES
EAS00763
11. Clutch switch
NO
S Check the clutch switch for continuity.

S Is the clutch switch OK?
Replace the main

switch.
YES
NO
Replace the clutch
switch.
8

EAS00764
12. Start switch

S Check the start switch for continuity.
S Is the start switch OK?
YES
NO
Replace the right
handlebar switch.
EAS00766
13. Wiring
S Check the entire starting systems wiring.
Refer to CIRCUIT DIAGRAM.
S Is the starting systems wiring properly connected and without defects?
YES
The starting system
circuit is OK.
NO
Properly connect or
repair the starting
systems 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.
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.
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

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 systems wiring.
Refer to CIRCUIT DIAGRAM.
S Is the lighting systems wiring properly connected and without defects?
NO
Replace the headlight relay.
YES
Check the condition
of each of the lighting
systems circuits.
Refer to CHECKING THE LIGHTING
SYSTEM.
EAS00784
5. Dimmer switch
S Check the dimmer switch for continuity.
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.
S Is the pass switch OK?
YES
NO
The pass switch is
faulty. Replace the
left
handlebar
switch.
13
ELEC
NO
Properly connect or
repair the lighting
systems 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
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
Engine stop switch
Start switch
Ignition fuse
62
63
64
65
66
67
68
69
70
Headlight fuse
Hazard fuse
Radiator fan motor fuse
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
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
Engine stop switch
Start switch
Ignition fuse
Headlight fuse
62
63
64
65
66
67
Radiator fan motor fuse

Radiator fan relay
Radiator fan motor
Auxiliary light
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
G/W L/Y
Gy
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
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
G/W
R
R
R
Y Ch G L
HEADLIGHT
SUB-WIRE HARNESS 2
WIRE HARNESS
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
28
R/B
205
B - R
W W W
7
B
29
R/W
L/W
L/W R/B
L/W
Lg
B B 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
R/L
B/Y
Lg
R/L
12
OFF
P
L/Y
R/G
R/W
B/Y
Sb
L/Y
L/G
R/L
29
R/L
B/W
25
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
L/W
Br/L
L/Y B Br/R
28
R/B
R/L R/B
R/L
R/L
B/Y
R
Br/R L/B L/Y
24
Gy/R
R/B R/B A R/B
R/W
ON
R/L
A
L/Y
10
B/L B B/L
Y B/L
16
L/G
15
B
B
R/L B
23
R/W
Br/R
26
Br/R R/W
Br Br/R
R/W
G/R
17
L
P/W P/W B P/W
B/L P/W L
27
Y/G
R/W
Br/B E Br/B
R/W
R/W
Y/B
B/L
Br/B R/W
G/Y
Gy/G
L W/B
Y/L
L/G B
P/W
Br/W
B/L
B B
L A L
W L/Y
Y B Y
B/L
Br/B
Y
W/B
13
B/L
B/L
Br/L
B/L
Sb
18
B/L P
W/Y
B/L
14
61
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
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
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
32
Lg
33
63
Br/R
Br/G
Lg
34
Br/G
Lg
Br R/G G
D
Y/L
Y/L
Br
Br/G
R/G
64
Br/L
Dg Y L/B Br/W R/Y
56
Br
43
R/Y
L/B
65
R/Y
Br
Br/W
Ch L/Y B B/Y Br
B/Y L/Y
Y/B
44
66
L/B
L/R
Y/B
45
46
47
R/Y Br/W L/B Y Dg
48
OFF
OFF
HI
OFF
ON
ON
LO
ON
Br Y
B B
B/Y
B/Y L/Y
38
Ch
39
B/Y
40
L D L
49
R/W Br
Dg
L/Y
B/W
Br
L/B
B L/R
B
Y L/R
Y L/R B
-
G/Y
B L
L/B
Dg
Ch
W Y/L B/W Dg - Lg Br R/G
Br
G/Y
50
- - - - G L Ch Y
Y
D
Ch
D Ch
68
L/B
Dg
Ch
Dg
Ch
B W
D Dg
W B
Dg
67
51
G/Y L
55
69
B
D
B
52
53
54
Ch -
Dg -
Ch -
Dg -
B
L
L/B
70
L
37
Br B/Y B L/Y Ch
L/Y
B/Y L/Y
Br
R/W
36
L/R
L/R
B/W B/W C B/W
R/Y R/Y
R/Y
L/B
Br
35
G
Br/W
Br
Y/L
C
C D
Br R/G G
42
Br/W
- Ch
- Dg
- Ch
- Dg
41
B
TDM900 (R) 2003 WIRING DIAGRAM (OCE)
WIRE HARNESS
HEADLIGHT
SUB-WIRE HARNESS 2
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

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TDM900 (R) 2003

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The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

Failure to follow WARNING instructions could result in severe injury or death to

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HOW TO USE THIS MANUAL

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The following symbols are not relevant to every

TDM900 (R) 2003 WIRING DIAGRAM (EUR)

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GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS/

225 kPa (2.25 kgf/cm2, 2.25 bar)

250 kPa (2.5 kgf/cm2, 2.5 bar)

CHECKING THE SWITCHES

Turn signal switch

ELECTRIC STARTING SYSTEM

ELECTRIC STARTING SYSTEM

ELECTRIC STARTING SYSTEM

ELECTRIC STARTING SYSTEM

STARTING CIRCUIT CUT-OFF SYSTEM

ELECTRIC STARTING SYSTEM

The starter motor fails to turn.

Minimum open-circuit voltage

1. Main and ignition fuses

S Check the main and ignition fuses for continuity.

S A wire that is used as a jumper lead

S Does the starter motor turn?

Replace the fuse(s).

ELECTRIC STARTING SYSTEM

Tester positive probe !

4. Starting circuit cut-off relay

Tester positive probe !

Battery positive terminal ! red/black 1

Tester positive probe !

Tester positive prove ! blue/white 3

Tester positive probe !

S Does the starting circuit cut-off relay have

5. Starting circuit cut-off relay (diode)

ELECTRIC STARTING SYSTEM

8. Engine stop switch

S Disconnect the starter relay from the coupler.

S Check the engine stop switch for continuity.

Battery positive terminal ! red/white 1

Tester positive probe ! red 3

10. Sidestand switch

S Check the sidestand switch for continuity.

Replace the starter

Replace the sidestand switch.

S Check the main switch for continuity.

11. Clutch switch

S Check the clutch switch for continuity.

Replace the main

ELECTRIC STARTING SYSTEM

12. Start switch

Any of the following fail to light: headlight,

Minimum open-circuit voltage

1. Main, signaling system and headlight

S Disconnect the headlight relay from the wire