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 Supple-
mentary 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 manu-
al. 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 ve-
hicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-
cant 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!

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

WARNING
the motorcycle operator, a bystander or a person checking or repairing the mo-
torcycle.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.

NOTE: 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) ap-
pears.
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 sequen-
tially.
2 1

3
4

8
5

7
 EAS00008

1 2
SYMBOLS
GEN The following symbols are not relevant to every
SPEC vehicle.
INFO Symbols 1 to 9 indicate the subject of each
3 4 chapter.
1 General information
CHK 2 Specifications
ADJ CHAS 3 Periodic checks and adjustments
4 Chassis
5 6 5 Engine
6 Cooling system
ENG COOL 7 Fuel injection system
8 Electrical system
9 Troubleshooting
7 8

FI ELEC Symbols 10 to 17 indicate the following.

10 Serviceable with engine mounted
11 Filling fluid
9 10
12 Lubricant
TRBL 13 Special tool
14 Tightening torque
SHTG 15 Wear limit, clearance
11 12 16 Engine speed
17 Electrical data

Symbols 18 to 23 in the exploded diagrams indi-

13 14
cate the types of lubricants and lubrication
points.
18 Engine oil
19 Gear oil
20 Molybdenum-disulfide oil
15 16 17 21 Wheel-bearing grease
22 Lithium-soap- based grease
23 Molybdenum-disulfide grease

18 19 20 Symbols 24 to 25 in the exploded diagrams indi-

cate the following.
24 Apply locking agent (LOCTITE)
25 Replace the part

21 22 23

24 25
 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 Standard Limit
Model code 5PS4 (EUR) SSS
5PS5 (OCE) SSS

ENGINE SPECIFICATIONS
Item Standard Limit
Throttle bodies
Model (manufacturer) quantity 38EIS (MIKUNI) 2 SSS
Intake vacuum pressure 33 X 36 kPa SSS
Throttle cable free play (at the flange 3 X 5 mm SSS
of the throttle grip)
ID mark 5PS1 10 SSS
Throttle valve size #50 SSS

CHASSIS SPECIFICATIONS
Item Standard Limit
Front tire
Tire type Tubeless SSS
Size 120/70ZR 18 M/C (59W) SSS
Model (manufacturer) MEZ4 FRONT (METZELER)/ SSS
D220FSTJ (DUNLOP)
Tire pressure (cold)
0 X 90 kg 225 kPa (2.25 kgf/cm2, 2.25 bar) SSS
90 X 203 kg 225 kPa (2.25 kgf/cm2, 2.25 bar) SSS
High-speed riding 225 kPa (2.25 kgf/cm2, 2.25 bar) SSS
Min. tire tread depth SSS 1.6 mm
Rear tire
Tire type Tubeless SSS
Size 160/60ZR 17 M/C (69W) SSS
Model (manufacturer) MEZ4 (METZELER)/ SSS
D220STJ (DUNLOP)
Tire pressure (cold)
0 X 90 kg 250 kPa (2.5 kgf/cm2, 2.5 bar) SSS
90 X 203 kg 290 kPa (2.9 kgf/cm2, 2.9 bar) SSS
High-speed riding 250 kPa (2.5 kgf/cm2, 2.5 bar) SSS
Min. tire tread depth 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 termi-
nals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear ! Repair or replace.
Improperly connected ! Properly connect.
Incorrect continuity reading ! Replace the switch.

1 Main switch 6 Turn signal switch 11 Neutral switch

2 Horn switch 7 Clutch switch 12 Rear brake light switch
3 Pass switch 8 Engine stop switch 13 Fuses
4 Dimmer switch 9 Start switch 14 Sidestand switch
5 Hazard switch 10 Front brake light switch

–2–
 ELECTRIC STARTING SYSTEM ELEC
EAS00755

ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM

–3–
 ELECTRIC STARTING SYSTEM ELEC
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

–4–
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 side-
stand 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 cur-
rent 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 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Starting circuit cut-off relay
7 Diode (starting circuit cut-off relay)
8 Clutch switch
9 Sidestand switch
10 Neutral switch
11 Start switch
12 Starter relay
13 Starter motor
14 Diode (starting circuit cut-off relay)

–5–
 ELECTRIC STARTING SYSTEM ELEC
EAS00757 EAS00739

TROUBLESHOOTING 2. Battery

The starter motor fails to turn. S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
Check: THE BATTERY” in chapter 3. (Manual No.:
1. main and ignition fuses 5PS1-AE1)
2. battery
3. starter motor Minimum open-circuit voltage
4. starting circuit cut-off relay 12.8 V or more at 20_C
5. diode S Is the battery OK?
6. starter relay
7. main switch YES NO
8. engine stop switch
9. neutral switch
10. sidestand switch S Clean the battery
11. clutch switch terminals.
12. start switch S Recharge or re-
13. wiring connections place the battery.
(of the entire starting system)
NOTE:
EAS00758
S Before troubleshooting, remove the following
part(s): 3. Starter motor
1. seat S Connect the positive battery terminal 1 and
2. fuel tank starter motor lead 2 with a jumper lead 3 .
3. air filter case
4. side cowlings
S Troubleshoot with the following special
tool(s).

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 chap-
ter 3. (Manual No.: 5PS1-AE1)
S Are the main and ignition fuses OK?
YES NO
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, other-
wise 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?

Replace the fuse(s).
YES NO

Repair or replace the

starter motor.

–6–
 ELECTRIC STARTING SYSTEM ELEC
EAS00759

4. Starting circuit cut-off relay Tester positive probe !

sky blue 1
S Disconnect the starting circuit cut-off relay Tester negative probe !
from the wire harness. black/yellow 2
S Connect the pocket tester (Ω 1) and bat-
Tester positive probe !
tery (12 V) to the starting circuit cut-off relay
sky blue 1 Continuity
terminals as shown.
Tester negative probe !
Battery positive terminal ! red/black 1 blue/yellow 3
Battery negative terminal !
Tester positive probe !
black/yellow 2
blue/green 4
Tester positive prove ! blue/white 3 Tester negative probe !
Tester negative prove ! black 4 blue/yellow 3
Tester positive probe !
black/yellow 2
Tester negative probe !
sky blue 1
Tester positive probe !
blue/yellow 3 No conti-
Tester negative probe ! nuity
sky blue 1
Tester positive probe !
S Does the starting circuit cut-off relay have blue/yellow 3
continuity between blue/white and black? Tester negative probe !
blue/green 4
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. NOTE:
S Connect the pocket tester (Ω 1) to the When you switch the tester’s positive and
starting circuit cut-off relay terminals as negative probes, the readings in the above
shown. chart will be reversed.
S Measure the starting circuit cut-off relay for
continuity as follows. S Are the testing readings correct?

YES NO

Replace the starting

circuit cut-off relay.

–7–
 ELECTRIC STARTING SYSTEM ELEC
EAS00761 EAS00750

6. Starter relay 8. Engine stop switch

S Disconnect the starter relay from the cou- S Check the engine stop switch for continuity.
pler. Refer to “CHECKING THE SWITCHES”.
S Connect the pocket tester (Ω 1) and bat- S Is the engine stop switch OK?
tery (12 V) to the starter relay terminals as
shown. YES NO
Battery positive terminal ! red/white 1
Battery negative terminal ! Replace the right
blue/white 2 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 be-
tween red and black? EAS00752

10. Sidestand switch

YES NO
S Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Replace the starter S Is the sidestand switch OK?
relay.
YES NO
EAS00749

7. Main switch Replace the side-

S Check the main switch for continuity. stand switch.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK? EAS00763

11. Clutch switch

YES NO
S Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
Replace the main S Is the clutch switch OK?
switch.
YES NO

Replace the clutch

switch.

–8–
 ELECTRIC STARTING SYSTEM ELEC
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?

YES NO

The starting system Properly connect or

circuit is OK. repair the starting
system’s wiring.

–9–
 LIGHTING SYSTEM ELEC
EAS00780

LIGHTING SYSTEM
CIRCUIT DIAGRAM

–10–
 LIGHTING SYSTEM ELEC
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

–11–
 LIGHTING SYSTEM ELEC
EAS00781 EAS00739

TROUBLESHOOTING 2. Battery
Any of the following fail to light: headlight, S Check the condition of the battery.
high beam indicator light, taillight, auxilia- Refer to “CHECKING AND CHARGING
ry light or meter light. THE BATTERY” in chapter 3. (Manual No.:
5PS1-AE1)
Check:
Minimum open-circuit voltage
1. main, signaling system and headlight fuses
12.8 V or more at 20_C
2. battery
3. main switch S Is the battery OK?
4. headlight relay
5. dimmer switch YES NO
6. pass switch
7. wiring connections
S Clean the battery
(of the entire lighting system)
terminals.
NOTE: S Recharge or re-
S Before troubleshooting, remove the following place the battery.
part(s): EAS00749
1. fuel tank
2. front cowling 3. Main switch
3. rear cowling S Check the main switch for continuity.
S Troubleshoot with the following special Refer to “CHECKING THE SWITCHES”.
tool(s). S Is the main switch OK?

YES NO
Pocket tester
90890-03132
Replace the main
EAS00738 switch.
1. Main, signaling system and headlight
fuses 4. Headlight relay
S Check the main, signaling system and head- S Disconnect the headlight relay from the wire
light fuses for continuity. harness.
Refer to “CHECKING THE FUSES” in chap- S Connect the pocket tester (Ω 1) and bat-
ter 3. (Manual No.: 5PS1-AE1) tery (12 V) to the headlight relay terminal as
S Are the main, parking lighting and headlight shown.
fuses OK? S Check the headlight relay for continuity.

YES NO Battery positive terminal ! red/yellow 1

Battery negative terminal !
yellow/black 2
Replace the fuse(s).
Tester positive probe ! red/yellow 3
Tester negative probe ! blue/black 4

–12–
 LIGHTING SYSTEM ELEC
EAS00787
S Dose the headlight relay have continuity be-
7. Wiring
tween red/yellow and green/blue?
S Check the entire lighting system’s wiring.
YES NO Refer to “CIRCUIT DIAGRAM”.
S Is the lighting system’s wiring properly con-
nected and without defects?
Replace the head-
light relay. YES NO

Check the condition Properly connect or

of each of the lighting repair the lighting
system’s circuits. system’s wiring.
EAS00784 Refer to “CHECK-
5. Dimmer switch ING THE LIGHTING
SYSTEM”.
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 NO

The pass switch is

faulty. Replace the
left handlebar
switch.

–13–
 TRBL
FAULTY LIGHTING SYSTEM SHTG
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–
WIRING DIAGRAM (EUR)
1 Crankshaft position sensor 62 Headlight fuse
2 A.C magneto 63 Hazard fuse
3 Rectifier/ regulator 64 Signaling system fuse
4 Main fuse 65 Radiator fan motor fuse
5 Battery 66 Rear brake light switch
6 Fuel injection system fuse 67 Tail/ brake light
7 Starter relay 68 Radiator fan relay
8 Starter motor 69 Radiator fan motor
9 Main switch 70 Auxiliary light
10 Alarm
11 Buck up fuse
12 Starting circuit cut-off relay
13 Sidestand switch
14 Neutral switch COLOR CODE
15 Cylinder identification sensor B ....... Black
16 Throttle position sensor Br . . . . . . Brown
17 Intake air pressure sensor Ch . . . . . Chocolate
18 Atmospheric pressure sensor Dg . . . . . Dark green
19 Intake air temperature sensor G ...... Green
20 Coolant temperature sensor Gy . . . . . Gray
21 Lean angle cut-off relay L ....... Blue
22 O2 sensor Lg . . . . . . Light green
23 ECU O ...... Orange
24 Injector (#1) P ....... Pink
25 Injector (#2) R....... Red
26 Al system solenoid Sb . . . . . . Sky blue
27 Intake solenoid W ...... White
28 Ignition coil Y ....... Yellow
29 Spark plug B/ L . . . . . Black/ Blue
30 Fuel pump B/ W . . . . Black/ White
31 Speed sensor B/ Y . . . . Black/ Yellow
32 Meter assembly Br/ B . . . . Brown/ Black
33 Oil level warning light Br/ G . . . Brown/ Green
34 Neutral indicator light Br/ L . . . . Brown/ Blue
35 Multi-function meter Br/ R . . . . Brown/ Red
36 Engine trouble warning light Br/ W . . . Brown/ White
37 Hi beam indicator light G/B . . . . Green / Black
38 Left turn signal indicator light G/R . . . . Green / Red
39 Right turn signal indicator light G/W . . . . Green / White
40 Meter light G/Y . . . . Green / Yellow
41 Oil level switch Gy/ G . . . Gray / Green
42 Turn signal relay Gy/ R . . . Gray / Red
43 Left handlebar switch L/B . . . . . Blue/ Black
44 Horn switch L/G . . . . Blue/ Green
45 Pass switch L/R . . . . Blue/ Red
46 Dimmer switch L/W . . . . Blue/ White
47 Hazard switch L/Y . . . . . Blue/ Yellow
48 Turn signal switch P/ W . . . . Pink/ White
49 Clutch switch R/ B . . . . Red/ Black
50 Horn R/ G . . . . Red/ Green
51 Rear turn signal light (left) R/ L . . . . Red/ Blue
52 Rear turn signal light (right) R/ W . . . . Red/ White
53 Front turn signal light (left) R/ Y . . . . Red/ Yellow
54 Front turn signal light (right) W/ B . . . . White/ Black
55 Headlight W/ Y . . . . White/ Yellow
56 Headlight relay Y/ B . . . . Yellow/ Black
57 Right handlebar switch Y/ G . . . . Yellow/ Green
58 Front brake light switch Y/ L . . . . . Yellow/ Blue
59 Engine stop switch
60 Start switch
61 Ignition fuse
WIRING DIAGRAM (OCE)
1 Crankshaft position sensor 62 Radiator fan motor fuse
2 A.C magneto 63 Radiator fan relay
3 Rectifier/ regulator 64 Radiator fan motor
4 Main fuse 65 Auxiliary light
5 Battery 66 Rear brake light switch
6 Fuel injection system fuse 67 Tail/ brake light
7 Starter relay
8 Starter motor
9 Main switch
10 Buck up fuse
11 Starting circuit cut-off relay COLOR CODE
12 Sidestand switch B ....... Black
13 Neutral switch Br . . . . . . Brown
14 Cylinder identification sensor Ch . . . . . Chocolate
15 Throttle position sensor Dg . . . . . Dark green
16 Intake air pressure sensor G ...... Green
17 Atmospheric pressure sensor Gy . . . . . Gray
18 Intake air temperature sensor L ....... Blue
19 Coolant temperature sensor Lg . . . . . . Light green
20 Lean angle cut-off switch O ...... Orange
21 O2 sensor P ....... Pink
22 ECU R....... Red
23 Injector (#1) Sb . . . . . . Sky blue
24 Injector (#2) W ...... White
25 Al system solenoid Y ....... Yellow
26 Intake solenoid B/ L . . . . . Black/ Blue
27 Ignition coil B/ W . . . . Black/ White
28 Spark plug B/ Y . . . . Black/ Yellow
29 Fuel pump Br/ B . . . . Brown/ Black
30 Speed sensor Br/ L . . . . Brown/ Blue
31 Meter assembly Br/ R . . . . Brown/ Red
32 Oil level warning light Br/ W . . . Brown/ White
33 Neutral indicator light G/B . . . . Green / Black
34 Multi function meter G/R . . . . Green / Red
35 Engine trouble warning light G/W . . . . Green / White
36 Hi beam indicator light G/Y . . . . Green / Yellow
37 Left turn signal indicator light Gy/ G . . . Gray / Green
38 Right turn signal indicator light Gy/ R . . . Gray / Red
39 Meter light L/B . . . . . Blue/ Black
40 Oil level switch L/G . . . . Blue/ Green
41 Turn signal relay L/R . . . . Blue/ Red
42 Left handlebar switch L/W . . . . Blue/ White
43 Horn switch L/Y . . . . . Blue/ Yellow
44 Pass switch P/ W . . . . Pink/ White
45 Dimmer switch R/ B . . . . Red/ Black
46 Turn signal switch R/ G . . . . Red/ Green
47 Clutch switch R/ L . . . . Red/ Blue
48 Horn R/ W . . . . Red/ White
49 Rear turn signal light (left) R/ Y . . . . Red/ Yellow
50 Rear turn signal light (right) W/ Y . . . . White/ Yellow
51 Front turn signal light (left) Y/ B . . . . Yellow/ Black
52 Front turn signal light (right) Y/ G . . . . Yellow/ Green
53 Headlight Y/ L . . . . . Yellow/ Blue
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
TDM900 (R) 2003 WIRING DIAGRAM (EUR)
D C B A E

Gy G/W G/W L/Y

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
Gy L G Ch Y B B Y Ch G L B/W W W B/W B/L B/L R/L L L R/L B/L Br/W Br/W B/L
1 4
G/W
R R R R
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
R HEADLIGHT HEADLIGHT SUB-WIRE SUB-WIRE SUB-WIRE
WIRE SUB-WIRE WIRE WIRE WIRE 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
W W 6 WIRE HARNESS SUB-WIRE HARNESS 2 HARNESS HARNESS 1 HARNESS HARNESS 2 HARNESS HARNESS 1 HARNESS HARNESS 3
R R -
2 W W 3
R R/W L/W
W W R R/B 28
205

W W W B - R R R O

7 R/W 29
B
R
5 L/W L/W L/W R/B Lg R

R R R L/W G/R R/B B R/L

B B B B R/L R/B 28
11 B/W B/R L/W L/Y R/W L/G L/Y Sb B/Y Lg
B B B R/L O A R/L R/B 205

9 B 8 12 L/Y Gy/R 24 R/L Gy/R

10 R/W R/B R/B A R/B R/L 29
ON B B/Y
OFF B B B L/Y B R/L G
P B B B L/W 25
R/G R/W B B/Y Sb L/Y L/G 30
R B B B R/L G/Y G/B G/B A G/B R/L R/L G/B G B/W
Br/R L/B L/Y Br/L G/W
W/B Br/R
B L Y B/L B/L B B/L B/L Br/B
Br/L L/Y B 16 B/L L R/L B
L/Y B Br/R Br/R B R
B Y Y B Y Y
23 Br/R R/W
Br/L B B/W
B L L L A L P/W
L/G 26
B 15 W/B P Br Br/R Br/R R/W
B 13 B/L Br/W R/W
B G/R E
W L/Y
B 17 L Y/G 27 R/W
B/L
P/W P/W B P/W R/W Br/B E Br/B R/W
B B B/L P/W L B/L Y/B Br/B R/W
B Gy/G G/Y
B B B B B L W/B
Y/L
B B L/G B B/L
Sb 18 L W/Y
B/L P L P
B/L
14
61 L
Br/W
Br/L R/W
E B/W B/W
W/Y 31
Br/W B/L 19 Br/W
B/W B/W B/L
B/L E B/L Br/W
62
W L/Y
Br/L R/Y
B/L
R/W R/B B 20
57 B/L G/R
Y/G
G/R B/L 22
58 60
L B/L L W/Y
G/Y B R/W R/W L/W G/Y
- - - B/L
R/B B Br Br B R/B OFF
59 L Y/G B/L
ON
OFF 21
RUN
Gy/G B/L
187

187

G/Y Br B

32 Lg
33 D
63
Lg
Br/R Br/G 34
Br/G
Lg Y/L
Br R/G G C
D C D Y/L
-
Br R/G G Y/L
Br/W 42
Br
Br/G
R/G
64 G
35
Br/L Br Br/W W B/W B/W C B/W
R/Y R/Y Dg Y L/B Br/W R/Y W
R/Y 43 Ch L/Y B B/Y Br C
R 56 Br R/Y L/B Br/W B/Y L/Y
L/B W 36
65 Br R/Y Y/B
R/Y Br/W L/B Y Dg
L/R 44 45 46 47 48 37
Br B/Y B L/Y Ch
D 66 B/Y Y
L/B Y/B OFF OFF HI OFF R B/Y L/Y
L/R L/Y
ON ON LO ON N 38
B B Br Y B/Y L/Y Ch
L/R
L
39
Br B/Y Dg

L/B Br B/W L/Y 40

B L/R Y L D L L
D 49
R/W Br L/B
70 B Y Dg Ch
Y L/R Y L/R B
Br G/Y Br W Y/L B/W Dg - Lg Br R/G
B
L - - - - G L Ch Y
- - Y
R/W G/Y
B L Y
50 D B W
Y B L/B B Ch D Ch W
Y Dg D Dg

68 Y L/B Ch Dg Ch Dg W B
67
G/Y L 51 52 53 54 41
B
Ch - Dg - Ch - Dg -
L
55 B
B B B B

B B
69 B B B B B B
B

L L - Ch - Dg - Ch - Dg
B B B B
B
D
B B
TDM900 (R) 2003 WIRING DIAGRAM (OCE)

HEADLIGHT WIRE HEADLIGHT SUB-WIRE WIRE SUB-WIRE SUB-WIRE

SUB-WIRE WIRE WIRE
WIRE HARNESS SUB-WIRE HARNESS 2 HARNESS HARNESS 1 HARNESS HARNESS 2 HARNESS HARNESS 1 HARNESS HARNESS 3

R L/W G/R 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

Ch L/Y B B/Y Br
Br

R/Y Br/W L/B Y Dg

Br B/Y B L/Y Ch