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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
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