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2002 TDM900P
User Manuals: Yamaha 2002 TDM900P Motorcycle Parts
Manuals and User Guides for Yamaha 2002 TDM900P Motorcycle Parts. We have
1
Yamaha 2002 TDM900P Motorcycle Parts manual available for free PDF download: 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
Adjusting the Valve Clearance
99
Synchronizing the Throttle Bodies
104
Checking and Adjusting the Exhaust Gas at Idle
107
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 Brake Pads
180
Rear Brake Pads
181
Replacing the Front Brake Pads
182
Replacing the Rear Brake Pads
185
Front Brake Master Cylinder
187
Disassembling the Front Brake Master Cylinder
188
Disassembling the Rear Brake Master Cylinder
191
Checking the Front and Rear Brake Master Cylinders
192
Assemblying and Installing the Front Brake Master Cylinder
193
Assembling the Rear Brake Master Cylinder
195
Front Brake Calipers
197
Rear Brake Caliper
199
Disassembling the Front Brake Calipers
201
Disassembling the Rear Brake Caliper
202
Checking the Front and Rear Brake Calipers
203
Assembling and Installing the Front Brake Calipers
204
Assembling and Installing the Rear Brake Caliper
206
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
Handling the Rear Shock Absorber and Gas Cylinder
232
Disposing of a Rear Shock Absorber and Gas Cylinder
232
Removing the Rear Chock Absorber Assembly
233
Checking the Rear Shock Absorber Assembly and Gas Cylinder
234
Installing the Rear Shock Absorber Assembly
234
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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