Yamaha TDM900 2004 Service Manual
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Yamaha TDM900 2004 Service Manual

Yamaha TDM900 2004 Service Manual

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  • Page 3 TDM900 (N) 2001 SERVICE MANUAL: 5PS1-AE1 TDM900 (R) SUPPLEMENTARY SERVICE MANUAL: 5PS1-AE2 TDM900 (S) 2004 SUPPLEMENTARY SERVICE MANUAL E2003 by Yamaha Motor Co., Ltd. First Edition, September 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
  • Page 4 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.

  • Page 5: How To Use This Manual

    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.
  • Page 6 EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system COOL 7 Fuel injection system 8 Electrical system...

  • Page 7: Table Of Contents

    CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS ........CHASSIS SPECIFICATIONS .

  • Page 9: Specifications

    82 X 150 mm (3.23 X 5.91 in) Optional spring available Fork oil Recommended oil Yamaha fork oil 10 W or equivalent Quantity (each front fork leg) 545 cm (19.22 lmp oz, 18.43 US oz) Level (from the top of the inner 127 mm (5.00 in)

  • Page 10: Electrical Specifications

    CHASSIS SPECIFICATIONS/ SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Front brakes Brake type Dual-disc brake Operation Right-hand operation Recommended fluid DOT 4 Brake discs Diameter thickness 5 mm (11.73 0.20 in) Min. thickness 4.5 mm (0.18 in) Max. deflection 0.1 mm (0.0039 in) Brake pad lining thickness 4.5 mm (0.18 in) 0.5 mm (0.02 in)

  • Page 11: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Throttle cables Turn signal light (right) Clutch cable Headlight sub-wire harness Handlebar switch lead (left) Auxiliary light lead Main switch lead and immobilizer lead Stay 3 Cover 7 Turn signal light (left) Horn lead Meter lead Horn Auxiliary light Cover 8...
  • Page 12 SPEC CABLE ROUTING A Fasten the handlebar switch lead (left) to the han- G Route the brake hose through the guide. dlebar with a band. H Always route the hose so that the brake hose B Through the handlebar switch lead (left) and clutch passes by the outside of the throttle cables.
  • Page 13 SPEC CABLE ROUTING M Fasten the horn lead to the upper side of the under T To the ECU. bracket as shown in the drawing. Cut the clamp tip U After the clamping, direct the band point to the front. leaving 3 to 8 mm (0.12 to 0.31 in).
  • Page 14 SPEC CABLE ROUTING Stay 3 Seat lock cable Headlight relay Ignition coil assembly Immobilizer coupler Neutral switch lead Tail / brake light lead ECU lead sensor lead Rear turn signal light (left) Stay 1 Speed sensor lead Rear turn signal light lead (left) 4 poles waterproof coupler Sidestand switch lead Rectifier/ regulator lead...
  • Page 15 SPEC CABLE ROUTING A To the headlight. H Fasten the tail / brake light lead at outside of the B Route the 4 poles water proof coupler through in- frame with a clamp. After connecting the tail / brake side of the ECU lead, and the 10 poles coupler light lead coupler, insert the surplus wiring between through outside of the ECU lead.
  • Page 16 SPEC CABLE ROUTING K The O sensor lead should not stick out from the P Route the fuel drain hoses (2 hoses), air filter case boss seat face to the outside of the vehicle. drain hose and radiator reservoir tank drain hose L Fasten the neutral switch lead, O sensor lead, through the guide located behind the swingarm...
  • Page 17 SPEC CABLE ROUTING Hose 2 A Position of the rear brake light switch lead and start- Hose er relay lead make possible with whichever. Ignition coil assembly B Route the clutch cable through the guide of stay 2. Stay 2 C Direct the rear brake light switch lead to the front.
  • Page 18 SPEC CABLE ROUTING Throttle cable Battery Handlebar switch lead (right) Rectifier/ regulator Stay Starter motor lead Thermo wax hose Battery positive lead Intake vacuum hose Lean angle cut-off switch Sub-wire harness (air filter case) Atmospheric pressure sensor Rear brake light switch lead Fuse (main) Coolant reservoir tank hose Starter relay...
  • Page 19 SPEC CABLE ROUTING Rear turn signal light (left) Bracket 1 Immobilizer coupler Hose 1 Seat lock cable Air induction system lead Fuse box Coolant temperature sensor lead Battery negative lead Cover Radiator fan motor relay Cover 2 Starting circuit cut-off relay main switch lead and immobilizer lead Fuel pump lead 2 Handlebar switch lead (left)
  • Page 20 SPEC CABLE ROUTING A Put the cover on the coupler for the immobilizer lead I Fasten the sub wire harness (air filter case) to the and wire harness. inner side of the frame with the wrapping clamp of B Install the projection part of the coupler pointing to the wire harness.
  • Page 21 SPEC CABLE ROUTING P Pass the rear turn signal light lead (left) through the X Route the wire harness, cylinder identification sen- left hole of the fender. sor and radiator fan motor leads under the bracket Q Pass the rear turn signal light leads (right and left) between the ribs of the rear fender.
  • Page 22 SPEC CABLE ROUTING DD Fasten the cylinder identification sensor and ra- diator fan motor leads to the frame with the clamp as shown in the illustration. Point the tip of the clamp to the downside. EE Pass the wire harness through the small diameter side of the clamp and the coolant reservoir tank drain hose through the large diameter side and then clamp therm.

  • Page 23: Chassis

    CHAS FRONT AND REAR BRAKES EAS00577 CHASSIS FRONT AND REAR BRAKES FRONT BRAKE PADS 6 Nm (0.6 mSkg, 4.3 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Brake caliper bolt Brake pad clip Brake pad pin...

  • Page 24: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER 10 Nm (1.0 mSkg, 7.2 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain.
  • Page 25 CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake Disassembly the parts in the order listed. master cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder body Push rod For assembly, reverse the disassembly procedure.

  • Page 26: Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00615 FRONT BRAKE CALIPERS 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job/Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. calipers The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring...

  • Page 27: Electrical

    ELEC CHECKING THE SWITCHES 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.

  • Page 28: Immobilizer System

    ELEC IMMOBILIZER SYSTEM IMMOBILIZER SYSTEM SYSTEM DIAGRAM 1 MAIN SWITCH AND IMMOBILIZER UNIT 2 IMMOBILIZER SYSTEM INDICATOR LIGHT 3 ECU ..Brown Br/ L . . . Brown/ Blue G / L . . . Green / Blue .

  • Page 29: Circuit Diagram

    ELEC IMMOBILIZER SYSTEM CIRCUIT DIAGRAM Fuse (main) Battery Main switch Immobilizer unit Fuse (backup) Multi-function meter Immobilizer system indicator light Fuse (ignition) Fuse (signal) –21–...

  • Page 30: General Information

    ELEC IMMOBILIZER SYSTEM GENERAL INFORMATION S When the main switch is turned “ON” with the registered key, the immobilizer system indicator light comes on for about 0.5 second and then goes off. S To check the immobilizer system, follow the steps in the troubleshooting chart. S To use the immobilizer key, keep it away from other keys.

  • Page 31: Key Id Registration Method

    ELEC IMMOBILIZER SYSTEM KEY ID REGISTRATION METHOD Initially one code re-registering key and two standard keys have been registered with the immobilizer system. In the course of use, you may encounter the following case where re-registration of code re-register- ing/standard key is required. Code re-registering key registration: When the immobilizer unit or ECU, failed and the unit was replaced, the unit cannot be used until the key ID is registered because it is not registered to the unit.
  • Page 32 ELEC IMMOBILIZER SYSTEM e. When the registration is finished, the immobilizer system indicator light goes off. f. Check that the engine can be started with the registered two standard keys. Code re-registering First unregistered When one standard key standard key is registered.

  • Page 33: Self-Diagnosis Error Code Indication

    ELEC IMMOBILIZER SYSTEM SELF-DIAGNOSIS ERROR CODE INDICATION When the system failure occurred, the error code number is indicated in the LCD display of meter and the immobilizer system indicator light flashes at the same time. The pattern of flashing also shows the error code.

  • Page 34: Troubleshooting

    ELEC IMMOBILIZER SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. S When the main switch is turn “ON”, the Refer to “CHECKING AND CHARGING immobilizer system indicator light does THE BATTERY” in chapter 3. (Manual No.: not come on or flashing.

  • Page 35: Checking The Immobilizer System

    ELEC IMMOBILIZER SYSTEM EAS00788 3. Wiring CHECKING THE IMMOBILIZER SYSTEM 1. The immobilizer system indicator light S Disconnect the meter coupler and immobi- does not come on. lizer unit coupler. S Check the immobilizer system indicator light 1. Immobilizer system indicator light (LEDs) lead (green/blue) continuity.
  • Page 36 ELEC IMMOBILIZER SYSTEM 2. When the main switch is turned “ON”, the immobilizer system indicator light is flashing. S Check if the metallic obstacle or the transponder of other vehicle exists near the immobilizer unit. If it exists, eliminate it and recheck the condition. Turn “ON”...

  • Page 37: Replacement Parts On Troubles

    ELEC IMMOBILIZER SYSTEM REPLACEMENT PARTS ON TROUBLES Replacement parts Immobilizer Main Accessory Transponder Key Unit Switch Lock And Key When standard key is missing and the replace standard key is required All keys have been lost (includ- ing code re-registering key) ECU is defective When the immobilizer unit is defective...

  • Page 38: Wiring Diagram

    WIRING DIAGRAM Crankshaft position sensor Right handlebar switch A.C. magneto Front brake light switch Rectifier/ regulator Engine stop switch Fuse (main) Start switch Fuse (fuel injection system) Fuse (hazard) Starter relay Fuse (signal) Starter motor Rear brake light switch Battery Tail / brake light switch Main switch Auxiliary light...

  • Page 41: Tdm900 (S) 2004 Wiring Diagram

    TDM900 (S) 2004 WIRING DIAGRAM...

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Tdm900 s 2004

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