Yamaha 2002 TDM900P Manuals

Manuals and User Guides for Yamaha 2002 TDM900P. We have 1 Yamaha 2002 TDM900P manual available for free PDF download: Service Manual

Yamaha 2002 TDM900P Service Manual

Yamaha 2002 TDM900P Service Manual (475 pages)

Brand: Yamaha | Category: Motorcycle | Size: 17.39 MB

Table of Contents

Table of Contents

7
- Important Manual Information
  4
- How to Use this Manual
  5
- Chassis
  6
- Cooling System
  6
- Electrical System
  6
- Engine
  6
- Fuel Injection System
  6
- Periodic Checks and Adjustments
  6
- Specifications
  6
- Troubleshooting
  6
  - Table of Contents
    7
  - Gen Info
    10
- Chapter 1 General Information
  12
- Motorcycle Identification
  12
  - Vehicle Identification Number
    12
  - Model Label
    12
- Features
  13
  - Outline
    13
  - Fi System
    14
  - ECU (Electronic Control Unit)
    16
  - Three-Way Catalytic Converter System
    28
  - Air Induction System
    30
  - Instrument Panel
    32
- Important Information
  34
  - Preparation for Removal and Disassembly
    34
  - Replacement Parts
    34
  - Gaskets, Oil Seals and O-Rings
    34
  - Lock Washers/Plates and Cotter Pins
    35
  - Bearings and Oil Seals
    35
  - Circlips
    35
- Checking the Connections
  36
- Special Tools
  37
Specifications Spec

41
- Spec
  41
  - Specifications Spec
    41
- Chapter 2 Specifications
  43
- General Specifications
  43
- Engine Specifications
  44
- Chassis Specifications
  53
- Electrical Specifications
  57
- Conversion Table
  60
- General Tightening Torque Specifications
  60
- Tightening Torques
  61
  - Engine Tightening Torques
    61
  - Chassis Tightening Torques
    64
- Lubrication Points and Lubricant Types
  66
  - Engine Lubrication Points and Lubricant Types
    66
  - Chassis Lubrication Points and Lubricant Types
    67
- Oil Flow Diagrams
  68
- Cooling System Diagrams
  73
- Cable Routing
  76
Chk Adj

88
- Chapter 3 Periodic Checks and Adjustments
  90
- Introduction
  90
- Periodic Maintenance and Lubrication Intervals
  90
- Seat
  92
- Front Cowlings
  93
- Fuel Tank
  94
  - Removing the Fuel Tank
    95
  - Removing the Fuel Pump
    95
  - Installing the Fuel Pump
    96
  - Installing the Fuel Hose
    96
- Rear Cowling
  97
- Air Filter Case
  98
- Engine
  99
- Chassis
  132
  - Adjusting the Front Brake
    132
  - Adjusting the Rear Brake
    133
  - Checking the Brake Fluid Level
    134
  - Checking the Front and Rear Brake Pads
    135
  - Adjusting the Rear Brake Light Switch
    136
  - Checking the Front and Rear Brake Hoses
    136
  - Bleeding the Hydraulic Brake System
    137
  - Adjusting the Shift Pedal
    138
  - Adjusting the Drive Chain Slack
    139
  - Lubricating the Drive Chain
    140
  - Checking and Adjusting the Steering Head
    141
  - Checking the Front Fork
    144
  - Adjusting the Front Fork Legs
    144
  - Adjusting the Rear Shock Absorber Assembly
    146
  - Checking the Tires
    148
  - Checking the Wheels
    150
  - Checking and Lubricating the Cables
    151
  - Lubricating the Levers and Pedals
    151
  - Lubricating the Sidestand
    151
  - Lubricating the Rear Suspension
    151
- Electrical System
  152
  - Checking and Charging the Battery
    152
  - Checking the Fuses
    157
  - Replacing the Headlight Bulbs
    159
  - Adjusting the Headlight Beams
    160
Chassis Chas

163
- Chas
  163
  - Chassis Chas
    163
  - Front Wheel and Brake Discs
    165
- Chapter 4
  166
- Front Wheel
  166
- Removing the Front Wheel
  167
- Checking the Front Wheel
  168
- Checking the Brake Discs
  169
- Adjusting the Front Wheel Static Balance
  170
- Disassembling the Front Wheel
  171
- Assembling the Front Wheel
  172
- Installing the Front Wheel
  172
- Rear Wheel, Brake Disc and Rear Wheel Sprocket
  173
  - Rear Wheel
    173
  - Removing the Rear Wheel
    176
  - Checking the Rear Wheel
    176
  - Checking the Rear Wheel Drive Hub
    177
  - Checking and Replacing the Rear Wheel Sprocket
    177
  - Installing the Rear Wheel
    178
  - Adjusting the Rear Wheel Static Balance
    179
- Front and Rear Brakes
  180
- Front Fork
  208
  - Removing the Front Fork Legs
    211
  - Disassembling the Front Fork Legs
    212
  - Checking the Front Fork Legs
    213
  - Assembling the Front Fork Legs
    214
  - Installing the Front Fork Legs
    218
- Handlebar
  219
  - Removing the Handlebar
    221
  - Checking the Handlebar
    222
  - Installing the Handlebar
    223
- Steering Head
  227
  - Removing the Lower Bracket
    227
  - Checking the Steering Head
    228
  - Installing the Steering Head
    229
- Rear Shock Absorber Assembly
  230
- Swingarm and Drive Chain
  236
  - Removing the Swingarm
    238
  - Removing the Drive Chain
    239
  - Checking the Swingarm
    239
  - Disassembling the Swingarm
    240
  - Assembling the Swingarm
    240
  - Checking the Drive Chain
    241
  - Installing the Swingarm
    243
Eng

246
- Chapter 5
  250
- Engine
  250
- Exhaust Pipes
  250
- Drive Sprocket
  251
- Engine
  252
- Leads and Hoses
  252
- Installing the Engine
  255
- Camshaft
  256
  - Cylinder Head Cover
    256
  - Camshafts
    257
  - Removing the Camshafts
    258
  - Checking the Camshafts
    260
  - Checking the Camshaft Sprockets and Timing Chain Guides
    262
  - Checking the Timing Chain Tensioner
    263
  - Installing the Camshafts
    264
- Cylinder Head
  268
  - Removing the Cylinder Head
    269
  - Checking the Cylinder Head
    269
  - Installing the Cylinder Head
    270
- Valves and Valve Springs
  271
  - Removing the Valves
    272
  - Checking the Valves and Valve Guides
    273
  - Checking the Valve Seats
    275
  - Checking the Valve Springs
    277
- Cylinder and Pistons
  281
  - Removing the Cylinder and Pistons
    282
  - Checking the Cylinder and Pistons
    283
  - Checking the Piston Rings
    285
  - Checking the Piston Pins
    286
  - Installing the Pistons and Cylinder
    287
- Clutch
  289
  - Clutch Cover
    289
  - Pull Lever Shaft
    290
  - Clutch
    290
  - Removing the Clutch
    293
  - Checking the Friction Plates
    293
  - Checking the Clutch Plates
    295
  - Checking the Clutch Springs
    295
  - Checking the Clutch Housing
    296
  - Checking the Clutch Boss
    296
  - Checking the Pressure Plate
    296
  - Checking the Pull Lever Shaft and Pull Rod
    297
  - Checking the Primary Drive
    297
  - Installing the Clutch
    298
  - Generator Rotor Cover
    300
  - Shift Shaft
    300
  - Shift Shaft and Stopper Lever
    301
- Starter Clutch and Generator
  303
  - Stator Coil Assembly
    303
  - Starter Clutch and Generator Rotor
    304
  - Removing the Generator
    305
  - Removing the Starter Clutch
    306
  - Checking the Starter Clutch
    306
  - Checking the Generator Shaft
    307
  - Installing the Starter Clutch
    308
  - Installing the Generator
    308
- Oil Pan and Oil Pump
  309
  - Oil Pump Cover and Oil Pump Driven Gear
    309
  - Oil Pump
    310
  - Oil Hose and Oil Tank
    312
  - Oil Pan
    313
  - Checking the Oil Pump
    314
  - Removing the Oil Pan
    314
  - Checking the Relief Valve
    315
  - Checking the Oil Delivery Pipes
    315
  - Checking the Oil Strainer
    315
  - Checking the Oil Nozzles
    315
  - Assembling the Oil Pump
    316
  - Installing the Oil Pump
    316
  - Installing the Oil Strainer
    317
  - Installing the Oil Pan
    317
- Crankshaft
  318
  - Balancer Shaft
    318
  - Crankshaft Assembly
    320
  - Connecting Rod
    321
  - Disassembling the Crankcase
    322
  - Removing the Crankshaft Assembly
    323
  - Removing the Connecting Rods
    323
  - Checking the Timing Chain and Timing Chain Guide
    323
  - Checking the Crankshaft and Connecting Rods
    324
  - Checking the Crankcase
    328
  - Checking the Bearings
    328
  - Checking the Circlips and Washers
    329
  - Installing the Connecting Rods
    329
  - Installing the Crankshaft
    331
  - Assembling the Crankcase
    332
- Transmission
  336
  - Transmission, Shift Drum Assembly, and Shift Forks
    336
  - Removing the Transmission
    341
  - Checking the Shift Forks
    341
  - Checking the Shift Drum Assembly
    342
  - Checking the Transmission
    342
  - Installing the Transmission
    343
- Cool
  346
6 Cool

347
- Chapter 6 Cooling System
  349
- Radiator
  349
  - Checking the Radiator
    350
  - Installing the Radiator
    351
- Thermostat
  352
  - Thermostat Assembly
    352
  - Checking the Thermostat
    354
  - Assembling the Thermostat Assembly
    355
  - Installing the Thermostat Assembly
    355
- Water Pump
  356
  - Installing the Water Pump
    360
Air Induction System

362
- Chapter 7 Fuel Injection System
  364
- Circuit Diagram
  365
- Ecu's Self-Diagnostic Function
  366
- Fail-Safe Actions Table
  367
- Substitute Characteristics Operation Control (Fail-Safe Action)
  367
- Troubleshooting Chart
  368
- Diagnostic Monitoring Mode
  369
- Troubleshooting Details
  374
- Throttle Body Assembly
  388
- Checking the Injector
  391
- Checking the Pressure Regulator
  391
- Checking the Throttle Body
  391
- Checking the Fuel Pump and Pressure Regulator Operation
  392
- Checking the Actuator
  393
- Checking the Surge Tank
  393
- Checking the Throttle Body Joints
  393
- Air Cut-Off Valve
  394
- Air Induction System
  394
- Air Injection
  394
- Air Induction System Diagrams
  395
- Air Cut-Off Valve and Reed Valve
  396
- Checking the Air Induction System
  397
- Elec
  398
Circuit Diagram

400
- Checking Switch Continuity
  403
- Checking the Bulbs and Bulb Sockets
  405
- Circuit Diagram
  409
- Troubleshooting
  410
  - Starter Motor
    420
  - Signaling System
    437
- Checking the Fuel Pump
  456
- Checking and Adjusting the Throttle Position Sensor
  457
- Trbl Shtg
  461
Trbl Shtg

462
- Chapter 9 Troubleshooting
  464
- Starting Failures
  464
  - Engine
    464
  - Fuel System
    464
  - Electrical Systems
    464
- Incorrect Engine Idling Speed
  465
  - Engine
    465
  - Fuel System
    465
  - Electrical Systems
    465
- Faulty Gear Shifting
  466
  - Shifting Is Difficult
    466
  - Shift Pedal Does Not Move
    466
  - Jumps out of Gear
    466
- Poor Medium-And-High-Speed Performance
  466
  - Engine
    466
  - Fuel System
    466
- Faulty Clutch
  467
  - Clutch Slips
    467
  - Clutch Drags
    467
- Overheating
  467
  - Engine
    467
  - Cooling System
    467
  - Fuel System
    467
  - Electrical Systems
    467
- Faulty Front Fork Legs
  468
  - Leaking Oil
    468
  - Malfunction
    468
- Overcooling
  468
  - Cooling System
    468
- Poor Braking Performance
  468
- Unstable Handling
  469
  - Faulty Lighting or Signaling System
    469

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