This manual covers the TDM900, produced for the 2002, 2003, and 2004 model years. As a sport-touring motorcycle, the TDM900 is engineered for comfortable long-distance travel with a dynamic performance edge, building on the legacy of the TDM850 with an 897cc parallel-twin engine featuring electronic fuel injection. Its robust construction and versatile design make it suitable for a variety of riding conditions, embodying a reputation for reliability and performance. This comprehensive service and repair manual provides detailed information for maintaining and repairing your TDM900. It covers all essential systems, including the engine, transmission, chassis, brakes, and electrical components, with step-by-step instructions for maintenance, diagnostics, and repair procedures. This resource is invaluable for owners and technicians seeking to ensure optimal performance and longevity of the motorcycle, offering factory-level technical depth with abundant illustrations and torque specifications. 🏷️ Basic Information Identification Make: Yamaha Model: TDM900 Model Codes: P, R, S Years Covered: 2002, 2003, 2004 👋 Introduction Market Position Market Segment: Sport Touring / Adventure Motorcycle Competitive Analysis Key Competitors: Honda VFR800, Kawasaki GTR1000, BMW R1100/1150RT (during its production era) Key Features Vehicle Philosophy: Designed for comfortable long-distance touring with a sporty edge, combining power, versatility, and reliability 📋 Manual Details Coverage Areas Manual Coverage: Complete service and repair Page Count Page Count: Not specified (assumed comprehensive for full service) Manual Type Manual Type: Official Factory Service Manual / Repair Manual Language Language: English Format File Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnostics, tuning, lubrication, cooling, fuel injection system, ignition system Transmission: Clutch operation, gearbox inspection and repair, shift mechanism Chassis: Frame inspection and repair, suspension (front forks, rear shock absorber), steering system Brakes: Hydraulic system, caliper service, master cylinder, disc inspection, bleeding procedures Electrical: Wiring diagrams, lighting system, ignition system, starting system, charging system, sensors, ECU diagnostics Fuel System: Fuel pump, injectors, fuel pressure regulation, evaporative emission control system Bodywork: Fairing removal and installation, seat, fuel tank, body panels Cooling System: Radiator service, fan operation, thermostat, coolant flow diagnostics. Exhaust System: Component identification, inspection, and potential repair guidelines. Wheel And Tire: Tire pressure, wear inspection, wheel bearing service, spoke tensioning (if applicable to specific models, though TDM900 uses cast wheels). Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, tire pressure, brake pad replacement Troubleshooting: Diagnostic charts, symptom-based troubleshooting for common and complex issues Repair: Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly Diagnostics: Fault code interpretation, sensor testing, electrical system analysis Engine Rebuild: Detailed instructions for engine disassembly, internal component inspection, measurement, and reassembly. Suspension Rebuild: Instructions for fork seal replacement, fork oil change, and rear shock absorber servicing. Torque Specifications: All critical fastener torque values are provided for engine, chassis, and bodywork components. Technical Depth Depth: Factory-level, from basic adjustments to complete engine rebuilds and complex electrical diagnostics Wiring Schematics: Comprehensive wiring diagrams included for all electrical systems. Diagrams Illustrations: Abundant step-by-step illustrations and exploded diagrams for clarity. Special Tools: Lists and descriptions of any specialized tools required for specific procedures. 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Full printable, allowing users to print specific pages or the entire document Binding Type Binding Type: Digital (PDF), no physical binding Paper Type Paper Type: N/A (digital format) Zoom Capabilities Zoom Features: Yes, allows zooming in on diagrams and text for clarity Searchability Search Functionality: Typically searchable PDF for quick information retrieval ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve, parallel-twin Displacement: 897 cc Bore X Stroke: 98.0 mm x 59.0 mm Compression Ratio: 9.6:1 Performance Horsepower: Approx. 90 hp @ 8,000 rpm Torque: Approx. 8.9 kg-m (87 Nm) @ 6,000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (Mikuni DFI) Fuel Type: Unleaded gasoline (95 RON or higher recommended) Ignition Ignition System: Digital TCI (Transistor Controlled Ignition) Lubrication Oil Capacity: Approx. 3.8 liters (4.0 US qt) with filter change 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Clutch Type: Wet, multiple disc, cable-actuated Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: 2,150 mm (84.6 in) Width: 780 mm (30.7 in) Height: 1,305 mm (51.4 in) Weights Dry Weight: Approx. 205 kg (452 lbs) Wet Weight: Approx. 228 kg (503 lbs) (fully fueled) Fuel Tank Capacity: 20 liters (5.3 US gal) 🛡️ Safety Features Ratings Crash Test Ratings: N/A for motorcycles in this era Active Features Braking System: Dual front disc brakes (298mm), single rear disc brake (245mm). ABS optional on some models (S variant). Lighting: Halogen headlights, LED taillight 💡 Technology Features Infotainment Infotainment System: Basic analog/digital instrumentation. No integrated infotainment system. Driver Assistance ABS Availability: Optional Anti-lock Braking System (ABS) available on the 'S' model variant. Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 10,000 km (6,000 miles) or annually Valve Clearance Check: Every 20,000 km (12,000 miles)...