The TDM900, produced between 2002 and 2004, is a versatile sport-touring motorcycle known for its robust parallel-twin engine and capable chassis. Designed for riders seeking a balance of performance for spirited riding and comfort for longer journeys, the TDM900 features a liquid-cooled, 897 cc DOHC engine with electronic fuel injection and controlled throttle. Its design philosophy emphasizes reliability and a comfortable riding position, making it suitable for a wide range of road conditions. Available in variants P, R, and S, this model represents a commitment to engineering quality and practical motorcycle design. This comprehensive service repair manual provides in-depth guidance for the maintenance, troubleshooting, and repair of the TDM900. It covers all essential systems, including the engine, transmission, chassis, brakes, and electrical components, with detailed procedures for routine maintenance, major repairs, and component overhauls. The manual includes crucial technical specifications, torque values, diagnostic charts for common issues, and information on special tools. This resource is designed to assist owners, mechanics, and technicians in keeping their TDM900 motorcycles in optimal condition, ensuring longevity and performance. 🏷️ Basic Information Identification Make: Yamaha Model: TDM900 Model Variants: P, R, S Model Years: 2002, 2003, 2004 👋 Introduction Market Position Segment: Sport-touring / Adventure-sport motorcycle Target Audience: Riders seeking a versatile motorcycle for commuting, touring, and spirited riding Competitive Analysis Key Competitors: Honda VFR800, Triumph Tiger 955i, Suzuki V-Strom 650/1000 (depending on era) Key Features Engine Type: Parallel-twin, liquid-cooled, DOHC, 4-stroke Design Philosophy: Robust engine, comfortable ergonomics, capable chassis for varied road conditions 📋 Manual Details Coverage Areas Overall Coverage: Comprehensive service, maintenance, and repair Page Count Estimated Pages: Likely 300-500 pages (typical for this model and depth) Manual Type Type: Service Repair Manual Language Language: English (standard for Yamaha service manuals) Format Format: Digital (PDF) or Printed 📖 Manual Coverage Systems Covered Engine: Internal components, lubrication, cooling, fuel injection, ignition, exhaust, starting system Transmission: Clutch, gearbox, drive chain, shifting mechanism Chassis: Frame, suspension (front fork, rear shock), steering, wheels, tires Brakes: Front and rear brake systems (calipers, master cylinders, lines, discs), ABS (if applicable to specific variants) Electrical: Wiring diagrams, battery, charging system, lighting, instrumentation, ECUs, sensors, ignition coils Fuel System: Fuel tank, fuel pump, injectors, throttle body, evaporative emission control Bodywork And Trim: Fairings, seat, fuel tank cover, fenders, controls Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug servicing, chain adjustment, brake fluid changes, coolant checks Troubleshooting: Diagnostic charts for common problems and symptoms Major Repairs: Engine disassembly and reassembly, transmission overhaul, suspension component replacement, electrical system diagnostics and repair Component Overhaul: Carburetor (if applicable to earlier TDM models, though 900 is FI), fuel injection system, suspension forks, rear shock absorber Special Tools: Identification and usage of Yamaha-specific special tools Technical Depth Depth: In-depth technical specifications, torque values, diagnostic procedures, and component tolerances for full rebuilds 📊 Manual Specifications File Format Digital Format: PDF (Searchable text, printable pages, often high resolution for diagrams) Print Quality Print Quality: High-resolution diagrams and schematics for clarity Binding Type Binding Type: Comb-bound or perfect-bound (for printed versions) for durability Paper Type Paper Type: Durable, often coated paper to withstand shop use (for printed versions) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve parallel-twin Displacement: 897 cc (Cubic Centimeters) Bore X Stroke: 92.0 mm x 67.5 mm Compression Ratio: 9.6:1 Performance Horsepower: Approx. 89.0 bhp @ 7,500 rpm (claimed) Torque: Approx. 9.1 kg-m (66 ft-lb) @ 6,000 rpm (claimed) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with dual throttle valves (YCC-T, Yamaha Chip Controlled Throttle) Ignition System: Digital TCI (Transistor Controlled Ignition) Exhaust System: Catalytic converter (Euro 2 compliant) Cooling System Coolant Type: Yamaha Genuine Coolant or equivalent (high-quality ethylene glycol-based antifreeze) Coolant Capacity: Approx. 1.8 L Oil System Oil Type: Yamalube 4 (or equivalent) 10W-40 API SG or higher, JASO MA certified motorcycle oil Oil Capacity W Filter: Approx. 3.1 L Oil Capacity Wo Filter: Approx. 2.7 L Spark Plugs Spark Plug Type: NGK CR9EK (or equivalent) Spark Plug Gap: 0.7 - 0.8 mm 🔧 Transmission Standard Transmission Type: 5-speed sequential Clutch Type: Wet, multi-plate Final Drive: O-ring sealed chain drive Features Gear Ratios: Not specified, but the manual will detail individual gear ratios and final drive ratio Transmission Oil Type: Yamalube 4 (or equivalent) 10W-40 API SG or higher, JASO MA certified motorcycle oil 📐 Dimensions Exterior Length: Approx. 2,120 mm (83.5 in) Width: Approx. 800 mm (31.5 in) Height: Approx. 1,265 mm (49.8 in) Wheelbase: Approx. 1,490 mm (58.7 in) Ground Clearance: Approx. 150 mm (5.9 in) Weights Dry Weight: Approx. 193 kg (425 lbs) Wet Weight: Approx. 213 kg (470 lbs) (with fluids and full tank) Fuel Tank Capacity: 20 L (5.3 gal) Wheels And Tires Front Tire Size: 120/70ZR18M/C (59W) Rear Tire Size: 170/60ZR17M/C (72W) Front Brake Type: Dual hydraulic disc Rear Brake Type: Hydraulic disc...