Yamaha TDM900 S 2004, 5PS1-AE3 2004 Manual

SYMBOLS

The following symbols are not relevant to every vehicle.

Symbols to indicate the following.

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

Symbols to in the exploded diagrams indicate the types of lubricants and lubrication points.

18. Engine oil
19. Gear oil
20. Molybdenum-disulfide oil
21. Wheel-bearing grease
22. Lithium-soap- based grease
23. Molybdenum-disulfide grease

Symbols to in the exploded diagrams indicate the following.

24. Apply locking agent (LOCTITE®)
25. Replace the part

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item	Standard	Limit
Model code	5PS6 (for EUR)
	5PS7 (for OCE)

CHASSIS SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

CABLE ROUTING

1. Throttle cables
2. Clutch cable
3. Handlebar switch lead (left)
4. Main switch lead and immobilizer lead
5. Cover 7
6. Horn lead
7. Horn
8. Cover 8
9. Brake hose
10. Handleber switch lead (right)
11. Front fork
12. Clamp
13. Turn signal light (right)
14. Headlight sub-wire harness
15. Auxiliary light lead
16. Stay 3
17. Turn signal light (left)
18. Meter lead
19. Auxiliary light
20. Meter
21. Stay 1
22. Headight coupler
23. Headilight adjusting knob

1. Fasten the handlebar switch lead (left) to the handlebar with a band.
2. Through the handlebar switch lead (left) and clutch cable to the wire guide on the upper bracket.
3. Fasten the main switch lead and immobilizer lead to the wire guide with a clamp. There should be no slack between main switch and wire guide. Cut the clamp tip leaving 3 to 8 mm (0.12 to 0.31 in).
4. Route the main switch lead through the cover 7 so that it route beneath the handlebar switch lead (left).
5. Route the clutch cable through the hole in front of the head pipe on the frame.
6. Route the handlebar switch lead (right) and throttle cables (2 cables) through the cover 8.
7. Route the brake hose through the guide.
8. Always route the hose so that the brake hose passes by the outside of the throttle cables.
9. Route the handlebar switch lead (right), brake hose and throttle cables through the wire guide of the upper bracket.
10. Fasten the handlebar switch lead (right) to the handlebar with a band.
11. Fasten the main switch lead and immobilizer lead with a clamp so that it faces the front side of the vehicle.
12. Fasten the horn lead to the front (left side) with a clamp as shown in the drawing. Cut the clamp tip leaving 3 to 8 mm (0.12 to 0.31 in).
13. Fasten the horn lead to the upper side of the under bracket as shown in the drawing. Cut the clamp tip leaving 3 to 8 mm (0.12 to 0.31 in).
14. 10 mm (0.39 in)
15. Fasten the turn signal light lead (right) together with the coupler to the stay 1.
16. Clamp the white tape of headlight sub-wire harness to the stay 1. (For detail of the clamp, refer to section BB.)
17. Fasten the main harness and turn signal light lead (left) together with the coupler to the stay 1. And locate the turn signal light lead, under the wire harness.
18. Route the main harness through the outside of the bolt.
19. To the headlight relay.
20. To the ECU.
21. After the clamping, direct the band point to the front.
22. Clamp the meter lead, indicator lead, headlight lead and sub-wire harness to the stay 1 with a band.
23. Route the all leads through inside of the headlight adjusting knob. Because of the protruding of the wire harness, it does not have to become the disturbance of operation of the headlight adjusting knob.
24. Clamp the headlight sub-wire harness to the dent in the stay 1.
25. Clamp the headlight sub-wire harness to the stay 1 with a band.
26. Fasten the headlight sub-wire harness with the clamp that is passed through the center hole of stay 1.

1. Stay 3
2. Ignition coil assembly
3. Neutral switch lead
4. O₂ sensor lead
5. Speed sensor lead
6. Sidestand switch lead
7. Pickup coil lead
8. Air filter drain hose
9. Coolant reservoir tank drain hose
10. Fuel tank drain hose
11. Battery negative lead
12. Seat lock cable
13. Immobilizer coupler
14. Tail/brake light lead
15. Rear turn signal light (left)
16. Rear turn signal light lead (left)
17. Rectifier/regulator lead
18. Rear shock absorber
19. Swingarm
20. Sidestand switch
21. O₂ sensor
22. Cylinder identification sensor lead
23. Headlight relay
24. ECU
25. ECU lead
26. Stay 1
27. 4 poles waterproof coupler
28. Plate
29. Boss
30. Starter relay lead
31. Oil pipe
32. Engine
33. Frame

1. To the headlight.
2. Route the 4 poles water proof coupler through inside of the ECU lead, and the 10 poles coupler through outside of the ECU lead.
3. Connect the headlight sub-wire harness coupler in front of ECU and make it not to route above the ECU lead.
4. Fasten the wire harness to the stay 1 with a clamp. The clump through the hole of the stay 1. The knot should be faced to the outside of the vehicle.
5. Pass the cylinder identification sensor lead above the left radiator hose.
6. Pass the rectifier/regulator lead above the frame cross tube.
7. Route the tail/brake light lead through the guides (3 places) of the tail/brake lgiht bracket.
8. Fasten the tail/brake light lead at outside of the frame with a clamp. After connecting the tail/brake light lead coupler, insert the surplus wiring between frame, and positioning without routing above the frame.
9. Fasten the rectifier/regulator lead with the clamp installed with the rear fender. The clamp tip should face the inner side of the vehicle.
10. Route the fuel drain hoses (2 hoses), air filter case drain hose, and coolant reservoir tank drain hose trough the clamp. For the fuel drain hose, the white paint mark should be under the clamp. The position is regardless of ranks. Arrange the end of coolant reservoir tank drain hose, air filter case drain hose and fuel drain hose from the clamp.
11. The O₂ sensor lead should not stick out from the boss seat face to the outside of the vehicle.
12. Fasten the neutral switch lead, O₂ sensor lead, speed sensor lead, sidestand switch lead and rectifier/regulator lead with the clamp as shown in the drawing. Cut the clamp tip leaving 3 to 8 mm (0.12 to 0.31 in) and make if face to the outside of the vehicle.
13. Less than 20 mm (0.79 in)
14. Fasten the cylinder identification sensor lead to the inner side of the frame with a clamp.
15. Fasten the ECU lead with the clamp installed to the plate of front side hole. Align the positioning tape and the clamp. Install the clamp to the out side of plate.
16. Route the fuel drain hoses (2 hoses), air filter case drain hose and radiator reservoir tank drain hose through the guide located behind the swingarm head pipe. Do not make hoses to cross in the area between C and D.
17. Pass the radiator reservoir tank drain hose through right side of the battery negative lead.
18. Pass the fuel drain hose and air filter case drain hose behind the battery negative lead.

1. Hose 2
2. Hose
3. Ignition coil assembly
4. Stay 2
5. Radiator
6. Clutch cable
7. Rear brake light switch lead
8. Starter relay lead
9. Coolant reservoir tank drain hose
10. Rear brake light switch
11. Fuel tank return hose
12. Fuel hose
13. Fuel tank drain hose

1. Throttle cable
2. Handlebar switch lead (right)
3. Stay
4. Thermo wax hose
5. Intake vacuum hose
6. Sub-wire harness (air filter case)
7. Rear brake light switch lead
8. Coolant reservoir tank hose
9. Oil level switch lead
10. Fuel injection system relay
11. Coolant reservoir tank
12. Turn signal relay
13. Battery band
14. Battery
15. Rectifier/regulator
16. Starter motor lead
17. Battery positive lead
18. Lean angle cut-off switch
19. Atmospheric pressure sensor
20. Fuse (main)
21. Starter relay
22. Rear turn signal light lead (right)
23. Rear turn signal light (right)
24. Tail/brake light lead
25. Tail/brake light
26. Rear turn signal light lead (left)
27. Rear turn signal light (left)
28. Immobilizer coupler
29. Seat lock cable
30. Fuse box
31. Battery negative lead
32. Radiator fan motor relay
33. Starting circuit cut-off relay
34. Fuel pump lead 2
35. Fuel pump lead 1
36. Sub-wire harness (throttle body)
37. Cylinder identification sensor lead
38. Radiator fan motor lead
39. Bracket 1
40. Hose 1
41. Air induction system lead
42. Coolant temperature sensor lead
43. Cover
44. Cover 2
45. main switch lead and immobilizer lead
46. Handlebar switch lead (left)
47. Frame
48. Wire harness
49. Clamp

1. Put the cover on the coupler for the immobilizer lead and wire harness.
2. Install the projection part of the coupler pointing to the connector housing 2.
3. Align the projection part of the connector housing 2 with the hole of the locking bracket.
4. Attach the boot over the immobilizer coupler.
5. Insert the ignition coil lead as shown in the illustration (left, right).
6. To the air induction system.
7. For the throttle cable, route the return side cable by the upper side, and the pull side cable by the lower side.
8. Fasten the coolant reservoir hose, sub wire harness (air filter case) and intake vacuum hose to the inner side of the frame with the clamp. Install the clamp with its opening pointed to the upper side.
9. Fasten the sub wire harness (air filter case) to the inner side of the frame with the wrapping clamp of the wire harness.
10. To the fuel pump.
11. Route the starter motor lead under the rear frame attaching boss section.
12. Route the starter motor lead by the right side of the battery and coolant reservoir tank.
13. Route the battery positive lead under the battery band.
14. Pass the rear turn signal light lead (right) through the right hole of the fender.
15. Pass the rear turn signal light leads (right and left) through the clamp installed to the rear fender. Adjust the length of the rear turn signal light lead (left) by folding and then bundle it.
16. Pass the rear turn signal light lead (left) through the left hole of the fender.
17. Pass the rear turn signal light leads (right and left) between the ribs of the rear fender.
18. Pass the seat locking cable through the hole section of the seat bracket of the rear frame. Either direction of the seat locking cable can be accepted.
19. Set the immobilizer coupler between the ribs of the rear fender.
20. Route the battery negative lead above the seat locking cable.
21. Route the battery positive lead together with the starter relay lead as shown in the illustration.
22. Route the battery negative lead above the battery.
23. Fasten the wire harness to the inner side of the frame with the harness wrapping clamp.
24. Route the wire harness, cylinder identification sensor and radiator fan motor leads under the bracket 1.
25. Route the cylinder identification sensor and radiator fan motor leads above the radiator hose.
26. To the radiator.

AA Bundle the coolant temperature sensor lead and air induction system lead with the clamp. Cut the clamp tip leaving 3 to 8 mm (0.12 to 0.31 in).
BB Bundle the main switch lead, immobilizer lead and handle bar switch leads (right and left) with the clamp. Point the tip of the clamp to the front side and set it between cover and wire harness. Place the clamp at the right side of the vehicle from the coupler as shown in the illustration.
CC Fasten the wire harness to both holes of the cover 2 with the harness wrapping clamps.
DD Fasten the cylinder identification sensor and radiator 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.
FF Clamp the coolant reservoir tank hose and thermo wax hose. Locate of the thermo wax hose under the coolant reservoir tank hose. Opening part of clamp is downward.

CHASSIS

FRONT AND REAR BRAKES

FRONT BRAKE PADS

FRONT BRAKE MASTER CYLINDER

FRONT BRAKE CALIPERS

ELECTRICAL

CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to "CHECKING SWITCH CONTINUITY".
Damage/wear Repair or replace.
Improperly connected Properly connect.
Incorrect continuity reading Replace the switch.

1. Main switch
2. Horn switch
3. Pass switch
4. Dimmer switch
5. Hazard switch
6. Turn signal switch

7. Clutch switch
8. Engine stop switch
9. Start switch
10. Front brake light switch
11. Neutral switch
12. Rear brake light switch

13. Fuses
14. Sidestand switch

IMMOBILIZER SYSTEM

SYSTEM DIAGRAM

1. MAIN SWITCH AND IMMOBILIZER UNIT
2. IMMOBILIZER SYSTEM INDICATOR LIGHT
3. ECU

CIRCUIT DIAGRAM

GENERAL INFORMATION

• 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.
• To check the immobilizer system, follow the steps in the troubleshooting chart.
• To use the immobilizer key, keep it away from other keys. Otherwise, the key code signal may not work or the correct action may be disturbed.
• The key contains the electronic component (transponder). Do not drop or hit it with a solid metal. Do not leave it on the dashboard of vehicle where the temperature may rise. Do not put it in the water. (when washing clothes for example) Do not place it near a magnet or a loud speaker.
• If all keys are missing, the engine control unit (ECU) is required to replace together with the keys and the immobilizer unit.
• Immobilizer unit cannot be operated with the copy key until the transponder code of the code re-registering key is registered to the immobilizer unit.
• Total three key codes are registered to the immobilizer unit, which are one code re-registering key code and two standard key codes.
• Among them, two of standard key codes can be registered to prepare for the case when the key is lost. To register, the code re-registering key is needed.

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-registering/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.

1. As usual steps, when the main switch is turned "ON", the immobilizer system indicator light goes onfor about one second.
2. If the immobilizer system indicator light goes off, it shows that the code re-registering key registra-tion is finished.
3. Check that the engine can be started.
4. Consequently, carry out the standard key registration, according the section below.

Standard key registration:
When you lost a standard key and need a new one. Or when the code re-registering key is re-registered after the immobilizer unit or the ECU, are replaced.

1. Check that the immobilizer system indicator light shows the standby mode.
   To initiate the standby mode, turn "OFF" the main switch and then it will be the standby mode when it passes 30 seconds. When 24 hours passed, the standby mode ends and the immobilizer system indicator light stops flashing.
   
2. After the main switch is turned "ON" with the code re-registering key, within 5 seconds, turn "OFF"the main switch and then turn "ON" the main switch with the standard key (the first new key) that you want to register.
3. It becomes the key registration mode and two standard key IDs that have been stored in the memoryare erased and the first new standard key ID will be registered. At this time, the indicator light quickly blinks ("OFF" for 0.5 sec. and "ON" for 0.5 sec.).
4. In the condition as mentioned above (while the immobilizer system indicator light continues quickflashing), after the main switch is turned "ON" with the first new standard key, turn "OFF" the main switch within 5 seconds, and then turn "ON" the main switch with the standard key that you want to register (which is the second new key or the standard key remained in hand).
   NOTE:
   Fast flashing goes off when it elapses 5 seconds and the registration mode is finished. In this case, the second standard key cannot be registered and only the first standard key is registered.
5. When the registration is finished, the immobilizer system indicator light goes off.
6. Check that the engine can be started with the registered two standard keys.
   

Important note:
If you lost a standard key, immediately re-register your code re-registering key and the remaining standard key (if any). This will delete the stored registration data, protecting the motorcycle against being started with the lost key.

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.

Immobilizer system indicator light code indication
Digit of 10: Cycles of 1 sec. "ON" and 1.5 sec. "OFF".
Digit of 1: Cycles of 0.5 sec. "ON" and 0.5 sec. "OFF".
<Example> 52

TROUBLESHOOTING

1. main, ignition, and backup fuses
2. battery
3. main switch
4. wiring connections
   (of the entire immobilizer system)YESNO

NOTE:

Before troubleshooting, remove the following part(s):

1. seat
2. fuel tank
3. side cowlings

Troubleshoot with the following special tool(s).

Pocket tester 90890-03112, YU-3112

1. Main, ignition and backup fuses
   • Check the main, ignition and backup fuses for continuity. Refer to "CHECKING THE FUSES".
   • Are the main, ignition and backup fuses OK?
     

2. Battery
   • Check the condition of the battery. Refer to "CHECKING AND CHARGING THE BATTERY".
     
     Minimum open-circuit voltage 12.8 V or more at 20º C (68º F)
   • Is the battery OK?
     

3. Main switch
   • Check the main switch for continuity. Refer to "CHECKING THE SWITCHES".
   • Is the main switch OK?
     

4. Wiring
   • Check the entire immobilizer system's wiring. Refer to "CIRCUIT DIAGRAM".
   • Is the immobilizer system's wiring properly connected and without defects?
     

CHECKING THE IMMOBILIZER SYSTEM

The immobilizer system indicator light does not come on

1. Immobilizer system indicator light (LEDs)
   • Check the immobilizer system indicator light continuity. Refer to "CHECKING THE LEDs".
   • Are the immobilizer system indicator light (LEDs) OK?
     

3. Wiring
   • Disconnect the meter coupler and immobilizer unit coupler.
   • Check the immobilizer system indicator light lead (green/blue) continuity. (meter coupler – immobilizer unit coupler).
   • Is the immobilizer system indicator light lead OK?
     

1. Voltage
   • Connect the pocket tester (DC 20 V) to the meter coupler as shown.
     LCD display Positive tester probe brown or red/green
     Negative tester probe black/white
     
   • Turn the main switch to "ON".
   • Measure the voltage (DC 12 V) meter coupler (wire harness side).
   • Is the voltage within specification?
     
2. When the main switch is turned "ON", the immobilizer system indicator light is flashing.
   • 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.
     

REPLACEMENT PARTS ON TROUBLES

	Replacement parts
	Transponder Key	Immobilizer Unit	ECU	*1Main Switch	*2Accessory Lock And Key
When standard key is missing and the replace standard key is required
All keys have been lost (including code re-registering key)
ECU is defective
When the immobilizer unit is defective
When the main switch is defective
When the accessory lock is defective

*¹ There is no parts setting as a single unit. It will be the replacement in a set with the IMMOBILIZER UNIT.
*² Accessory lock means the seat lock, fuel filler cap or the helmet holder.

NOTE:
To replace the single unit of ECU, first turn "ON" the main switch with the code re-registering key. This operation allows the code re-registering key ID to be registered to the new ECU. Register the standard key subsequently.
To replace the single unit of immobilizer unit, first turn "ON" the main switch with the code re-registering key. This operation allows the code re-registering key ID to be registered to the new immobilizer unit. Register the standard key subsequently.

TDM900 (S) 2004 WIRING DIAGRAM