Yamaha TDM900A 2005 Supplementary Service Manual
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Yamaha TDM900A 2005 Supplementary Service Manual

Yamaha TDM900A 2005 Supplementary Service Manual

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2005
TDM900A(T)
5PS1-AE4
SUPPLEMENTARY
SERVICE MANUAL

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Summary of Contents for Yamaha TDM900A 2005

  • Page 1 2005 TDM900A(T) 5PS1-AE4 SUPPLEMENTARY SERVICE MANUAL...
  • Page 3 TDM900(R) 2003 SUPPLEMENTARY SERVICE MANUAL: 5PS1-AE2 TDM900(S) 2004 SUPPLEMENTARY SERVICE MANUAL: 5PS1-AE3 TDM900A(T) 2005 SUPPLEMENTARY SERVICE MANUAL ©2004 by Yamaha Motor Co., Ltd. First Edition, December 2004 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 deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. 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. The manual is divided into chapters.
  • Page 6 EAS00008 SYMBOLS The following symbols are not relevant to every vehicle. Symbols indicate the subject of each chapter. General information Specifications Periodic checks and adjustments Chassis Engine Cooling system Fuel injection system Electrical system Troubleshooting Symbols indicate the following. Serviceable with engine mounted Filling fluid Lubricant Special tool...

  • Page 7: Table Of Contents

    CONTENTS GENERAL INFORMATION FEATURES ..........INSTRUMENT PANEL.
  • Page 8 ANTI-LOCK BRAKE SYSTEM (ABS) ......CIRCUIT DIAGRAM........ABS COMPONENTS .

  • Page 9: General Information

    FEATURES INFO GENERAL INFORMATION FEATURES INSTRUMENT PANEL Clock TRIP/ODO meter SELECT button RESET button Engine trouble warning light Function indication The indications of the self-diagnosis function can be checked and inspection operations can be per- formed through the use of the multi-function meter on the instrument panel. Based on the signals received from the sensors, the ECU inputs the signals into the multi-function meter.
  • Page 10 FEATURES INFO CO ADJUSTMENT MODE Cylinder identification For #1 For #2 CO data Example: lean rich –128 DIAGNOSTIC MONITORING MODE Diagnostic monitoring code Example: code “01” Monitoring data WHEN THE COMMUNICATION ERROR Error code OCCURRED BETWEEN ECU AND METER: Example: When the error code is “Er-1” For details of error codes, refer to “FAIL-SAFE ACTION TABLE”...
  • Page 11 FEATURES INFO CO adjustment and diagnostic monitoring mode Mode Selection CO/DIAG mode Normal mode 1. While keeping both the SELECT and Turn “ON” the main switch RESET buttons pressed, turn “ON” the • The self-diagnostic function starts a system main switch. Keep the buttons pressed for check 8 seconds or more.

  • Page 12: Special Tools

    SPECIAL TOOLS INFO EB104000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inap- propriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes.

  • Page 13: Specifications

    GENERAL SPECIFICATIONS/ SPEC ENGINE SPECIFICATIONS/CHASSIS SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 2B01 (EUR) • • • Weight Wet (with oil and a full fuel tank) 224 kg (494 lb) • • • Dry (without oil and fuel) 193 kg (426 lb) •...

  • Page 14: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit Ignition system Ignition system type Transistorized coil ignition (digital) • • • Ignition timing 10° BTDC at 1,150 r/min • • • Advancer type Electric • • • 192 ~ 288 Ω/L/Y-G/W Pickup coil resistance/color •...

  • Page 15: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening Thread torque Part to be tightened Remarks size m•kg ft•lb Lower bracket pinch bolt 16.6 Upper bracket and wire guide Throttle cable adjusting nut Engine mounting: Rear upper mounting bolt and nut 32.5 Rear lower mounting bolt and nut 32.5...

  • Page 16: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Throttle cables Clamp Clutch cable Front turn signal light (right) Left handlebar switch lead Headlight sub-wire harness Main switch lead and immobilizer lead Indicator light lead Cover 7 Stay 3 Horn lead Front turn signal light (left) Horn Meter lead Front wheel sensor lead...
  • Page 17 SPEC CABLE ROUTING Fasten the left handlebar switch lead to the han- It should be 30 ~ 40 mm (1.18 ~ 1.57 in) from the dlebar with a band. lower end of the grommet of the brake hose. Route the right handlebar switch lead, front brake Through the left handlebar switch lead and clutch cable to the wire guide on the upper bracket.
  • Page 18 SPEC CABLE ROUTING Fasten the horn lead to the upper side of the under To the ECU. bracket as shown in the drawing. Cut the clamp tip After the clamping, direct the band point to the front. leaving 3 ~ 8 mm (0.12 ~ 0.31 in). 10 mm (0.39 in) Clamp the headlight sub-wire harness to the stay 1 Fasten the turn signal light lead (right) together...
  • Page 19 SPEC CABLE ROUTING Fasten the headlight sub-wire harness with the clamp that is passed through the center hole of stay 1.
  • Page 20 SPEC CABLE ROUTING Stay 3 Immobilizer coupler Turn signal light relay Ignition coil assembly Joint coupler Headlight relay Tail/brake light lead Neutral switch lead Main relay sensor lead Rear turn signal light Front wheel sensor Speed sensor lead Rear turn signal light lead Sidestand switch lead Rectifier/regulator lead ECU lead...
  • Page 21 SPEC CABLE ROUTING To the headlight. Pass the rectifier/regulator lead above the frame Route the 6 poles water proof coupler through cross tube. Route the tail/brake light lead through the guides inside of the ECU lead, and the 12 poles coupler through outside of the ECU lead.
  • Page 22 SPEC CABLE ROUTING Route the fuel drain hoses (2 hoses), air filter drain Less than 20 mm (0.79 in) hose, and coolant reservoir tank drain hose trough Route the spark plug lead for the right cylinder below the water pipe and behind the hose for the the clamp.
  • Page 23 SPEC CABLE ROUTING Pass the harness for the relay between ECU and the main relay. 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.
  • Page 24 SPEC CABLE ROUTING Seat bracket Rear brake light switch lead Front wheel sensor lead Rear brake light switch Rear wheel sensor lead ECU (ABS) sub-wire harness ECU (ABS) Brake fluid reservoir hose Radiator fan motor relay Clamp ABS check coupler Rear brake hose (OUT) Brake hose holder Rear brake hose (IN)
  • Page 25 SPEC CABLE ROUTING The right and left positions for the starter motor Route the rear brake hose and starter motor lead lead and rear wheel sensor lead can be accepted over the frame cross tube. Route the hydraulic unit drain hose behind the in random oder.
  • Page 26 SPEC CABLE ROUTING Route inside the brake hose holder. Attach the clamp so that its opening section faces in the direction indicated in the drawing. Clamp the grommet which is attached to the sen- sor lead. Make sure to insert it to the deepest point. Make sure to catch more than 3 notches.
  • Page 27 SPEC CABLE ROUTING Throttle cables Battery Handlebar switch lead (right) Rectifier/regulator Rear wheel sensor lead Front brake hose Stay Starter motor lead Front wheel sensor lead Battery band Thermo wax hose Battery positive lead Intake vacuum hose Lean angle cut-off switch Sub-wire harness (air filter case) Atmospheric pressure sensor Oil level switch lead...
  • Page 28 SPEC CABLE ROUTING Rear turn signal light (left) Bracket 1 Joint coupler Air induction system lead Coolant temperature sensor lead Immobilizer coupler Seat lock cable Cover 2 Fuse box Main switch lead and immobilizer lead Battery negative lead Left handlebar switch lead Hydraulic unit motor coupler Boot Coolant reservoir tank drain hose...
  • Page 29 SPEC CABLE ROUTING Put the cover on the coupler for the immobilizer Route the starter motor lead and rear wheel sen- lead and wire harness. sor lead by the right of the battery. The upper and lower positions of the leads can be accepted in Install the projection part of the coupler pointing to the connector housing 2.
  • Page 30 SPEC CABLE ROUTING Pass the seat locking cable through the hole sec- Clamp the coolant reservoir tank hose to the tion of the seat bracket of the rear frame. Either hydraulic unit bracket. To the fuel pump. direction of the seat locking cable can be accepted.
  • Page 31 SPEC CABLE ROUTING Bundle the coolant temperature sensor lead and Fasten the cylinder identification sensor lead air induction system lead with the clamp. Cut the and radiator fan motor lead to the frame with the clamp as shown in the illustration. Point the tip of clamp tip leaving 3 ~ 8 mm (0.12 ~ 0.31 in).
  • Page 32 SPEC CABLE ROUTING Intake vacuum hose joint Hose clamp (carburetor joint upper side) Clip Connect the intake vacuum hose joint of the air fil- ter system assembly side and the pipe of the throt- Intake vacuum hose Clamp (fuel pump side) tle body side.
  • Page 33 SPEC CABLE ROUTING Insert the fuel tank return hose until its end con- 2. After the procedure item 1 as above is finished, tacts the component. insert the clamp of the fuel pump side from the lower side of the engine and check that the To assemble to the carburetor joint 1, it is allowed to apply the engine oil.
  • Page 34 SPEC CABLE ROUTING Rear brake hose (OUT) Clamp Rear brake hose (IN) Drain plug Hydraulic unit drain hose Bracket 2 Frame Hydraulic unit motor coupler Bracket 1 Hydraulic unit assembly Coolant reservoir tank Clamp (to the coolant reservoir tank hose) Wire harness assembly Union bolt Relay stay...
  • Page 35 SPEC CABLE ROUTING Insert the pin of the bracket 1 to the hydraulic unit To the rear brake caliper. assembly. Insert hydraulic unit drain hose to the deepest point. Press front brake hose (IN) to the front brake hose assembly (out) and tighten. Fit the fuel tank mold in the bracket 1.

  • Page 36: Swingarm And Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EAS00709 SWINGARM AND DRIVE CHAIN CHECKING THE DRIVE CHAIN 1. Measure: • Measure the dimension between 15-links on the inner side and outer side of the roller and calculate the dimension between pin centers. • Dimension between pin centers = (Inner dimension + Outer dimension...
  • Page 37 CHAS SWINGARM AND DRIVE CHAIN CAUTION: This motorcycle has a drive chain with small rubber O-rings between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain sol- vents (e.g., benzine), or a coarse brush to clean the drive chain.

  • Page 38: Anti-Lock Brake System (Abs)

    ABS OUTLINE Yamaha ABS features 1. The Yamaha ABS (Anti-Lock Brake System) features a dual electronic control system, which acts on the front and rear brakes independently. 2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of the motorcycle.

  • Page 39: Abs

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) EAS00872 The operation of the Yamaha ABS brakes is the same as conventional motorcycles, with a brake lever for operating the front wheel brake and a brake pedal for operating the rear wheel brake. When wheel lockup is detected during emer- gency braking, hydraulic control is performed by the hydraulic system independently.
  • Page 40 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) • Slip ratio: When the brakes are applied, slipping occurs between the tires and the road sur- face. This causes a difference between the wheel speed and the chassis speed. Slip ratio is the value that shows the rate of wheel slippage and is defined by the follow- ing formula.
  • Page 41 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) EAS00875 Wheel slip and hydraulic control The ECU (ABS) calculates the wheel speed of each wheel according to the rotation signal Motorcycle speed received from the front and rear wheel sen- sors. In addition, the ECU (ABS) calculates the motorcycle chassis speed and the rate of speed reduction based on the wheel speed Wheel speed...
  • Page 42 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) The higher the cornering force on a tire, the Brake force less traction there is available for braking. This is true whether the motorcycle is equipped with an ABS or not. Therefore, sudden braking while cornering is not recommended. Exces- sive cornering force, which an ABS cannot pre- Side force vent, could cause the tire to slip sideways.
  • Page 43 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) EAS00877 Electronic ABS features The Yamaha ABS (Anti-lock Brake System) has been developed with the most advanced electronic technology. The ABS control is processed with good response providing various travel conditions for motorcy- cles. The ABS also includes a highly developed self-diagnostic function. The ABS detects any problem conditions and allows normal braking even if the ABS is not operating properly.
  • Page 44 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) EAS000878 ABS component functions • Wheel sensors and sensor rotors Wheel sensors detect the wheel rotation speed and transmit the wheel rotation signal to the ECU (ABS). Each wheel sensor is composed of a perma- nent magnet and a coil.
  • Page 45 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) EAS00879 • Hydraulic unit The hydraulic unit is composed of a hydrau- lic control valve (solenoid valve, flow control valve), a buffer chamber, and a hydraulic pump for each brake and an ABS motor. The hydrau- lic unit adjusts the front and rear wheel brake fluid pressure to control the wheel rotation speed according to signals transmitted from...
  • Page 46 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) • Hydraulic control valve The hydraulic control valve is composed of a flow control valve and solenoid valve. When the ABS is activated, the flow control valve regulates the flow of brake fluid to each brake solenoid valve...
  • Page 47 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) • Electronic control unit (ECU) The ECU (ABS) controls the ABS and is installed inside the right cowling. To protect the ECU (ABS) from water damage, it is protected by a cover...
  • Page 48 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) As shown in the block diagram below, the ECU (ABS) receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. Both a main microcomputer and a sub microcomputer are installed in the ECU (ABS) to provide mutual monitoring. Battery Main switch Meter assembly...
  • Page 49 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) • ABS control operation The ABS control operation performed in the ECU (ABS) is divided into the following two parts. • Hydraulic control • Self-diagnosis These operations are performed once every 8/1,000 of a second. When a failure is detected in the ABS, a malfunction code is stored in the memory of the ECU (ABS) for easy problem identification and troubleshoot-...
  • Page 50 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) • Fail-safe relay The fail-safe relay controls the power supply of the hydraulic unit and is located beside the hydraulic unit. Fail-safe relay Composition and operation The fail-safe relay is composed of the solenoid relay and ABS motor relay .
  • Page 51 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) ABS operation The ABS hydraulic circuit consists of two systems: the front wheel and rear wheel. The following describes the front system only. • Normal braking (ABS not activated) When the ABS is not activated port D of the solenoid valve is closed because a control signal has not been transmitted from the ECU (ABS) and port A and port B...
  • Page 52 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) • Emergency braking (ABS activated) 1) Depressurized state When the front wheel is about to lockup, port D of the solenoid valve is opened by the “depres-surization” signal transmitted from the ECU (ABS). When this occurs, the spool of the flow control valve compresses the return spring to close port B .
  • Page 53 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 2) Pressurized state Port D is closed by the “pressurization” signal transmitted from the ECU (ABS). Before this occurs, the spool of the flow control valve has compressed the return spring to close port B Brake fluid that has entered through port A is further restricted by the orifice and the brake...
  • Page 54 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) EAS00880 Self-diagnosis function • ABS warning light The ABS warning light comes on when a malfunction is detected by the ABS self-diag- nosis. It is located in the meter assembly. • Instances when the ABS warning light comes on Main switch Main switch...
  • Page 55 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 4) The ABS warning light flashes and malti- function code multifunc- is indicated on the tion display when a test coupler adaptor is connected to the 4-pin test coupler troubleshooting the ABS. The 4-pin test coupler can be accessed by removing the side cowling (right).
  • Page 56 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) Cautions for operation ABS warning light: • When the main switch is set to “ON”, the ABS warning light comes on for 2 seconds, then goes off. • If the ABS warning light comes on while riding, stop the motorcycle, and then set the main switch to “OFF”, then set the main switch to “ON”.

  • Page 57: Abs Components

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) EAS00882 ABS COMPONENTS Front brake hose (front brake master cylinder to Rear brake hose (hydraulic unit to rear brake cali- hydraulic unit) per) ABS test coupler Rear brake hose (rear brake master cylinder to ABS warning light hydraulic unit) Front brake hose (hydraulic unit to front brake cali- Hydraulic unit...

  • Page 58: Front Wheel Sensor And Sensor Rotor

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) EAS00889 FRONT WHEEL SENSOR AND SENSOR ROTOR 40 Nm (4.0 m•kg, 29 ft•lb) 40 Nm (4.0 m•kg, 29 ft•lb) 40 Nm (4.0 m•kg, 29 ft•lb) 72 Nm (7.2 m•kg, 52 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) 40 Nm (4.0 m•kg, 29 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb)
  • Page 59 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) Maintenance of the front wheel sensor and sensor rotor • ABS wheel sensor and sensor rotor CAUTION: • Handle the ABS components with care since they have been accurately adjusted. Keep them away from dirt and do not sub- ject them to shocks.
  • Page 60 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 2. Measure: • front wheel sensor resistance Connect the pocket tester (Ω × 1k) to the terminals of the front wheel sensor coupler. Tester positive probe → Terminal Tester negative probe → Terminal Regulated resistance 1.2 ~ 1.6 kΩ...
  • Page 61 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 2. Install: • front wheel sensor 30 Nm (3.0 m•kg, 22 ft•lb) • front wheel sensor lead holder • brake caliper 40 Nm (4.0 m•kg, 29 ft•lb) • brake hose holder NOTE: NOTE: When installing the front wheel sensor, check the wheel sensor lead for twists and the sensor electrode for foreign materials.

  • Page 62: Rear Wheel Sensor And Sensor Rotor

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) EAS00890 REAR WHEEL SENSOR AND SENSOR ROTOR 40 Nm (4.0 m•kg, 29 ft•lb) 27 Nm (2.7 m•kg, 20 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 150 Nm (15.0 m•kg, 108 ft•lb) Order Job/Part Q’ty Remarks Removing the rear wheel sensor and Remove the parts in the order listed.
  • Page 63 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) Maintenance of the rear wheel sensor and sensor rotor CAUTION: • Be sure not to contact the sensor elec- trode to any metal part when removing the front wheel sensor from the sensor hous- ing. •...
  • Page 64 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) • Installing the rear wheel sensor 1. Install: • rear wheel NOTE: NOTE: • Align the slot of the sensor housing with the projection of the rear brake caliper bracket , and then assemble them. •...

  • Page 65: Hydraulic Unit

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) EAS00891 HYDRAULIC UNIT 30 Nm (3.0 m•kg, 22 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 16 Nm (1.6 m•kg, 12 ft•lb) 16 Nm (1.6 m•kg, 12 ft•lb) Order Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the hydraulic unit Seat Refer to “SEAT”...
  • Page 66 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 30 Nm (3.0 m•kg, 22 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 16 Nm (1.6 m•kg, 12 ft•lb) 16 Nm (1.6 m•kg, 12 ft•lb) Order Job/Part Q’ty Remarks Rear brake hose (rear brake master cylinder to hydraulic unit) Union bolt/copper washers Rear brake hose...
  • Page 67 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) Maintenance of the hydraulic unit CAUTION: Do not remove the hydraulic unit to check the resistance of the solenoid valves and the ABS motor for continuity. WARNING Refill with the same type of brake fluid that is already in the system.
  • Page 68 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) • Checking the resistance of the solenoid valves and ABS motor for continuity CAUTION: When check the hydraulic unit solenoid relay and ABS motor, do not remove the brake hoses. 1. Measure:. • resistance of the solenoid valve (front) Connect a pocket tester (Ω...
  • Page 69 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) • Removing the hydraulic unit 1. Remove: • brake hose (from the front brake master cylinder) • brake hose (to the front brake caliper) • brake hose (from the rear brake master cylinder) • brake hose (to the rear brake caliper) NOTE: NOTE:...
  • Page 70 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) • Installing the hydraulic unit Proceed in the reverse order of disassembly. Pay attention to the following items. 1. Install: • hydraulic unit bracket 2 16 Nm (1.6 m•kg, 12 ft•lb) NOTE: NOTE: Tighten the nuts in the proper sequence. 2.
  • Page 71 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 5. Fill: • brake master cylinder reservoirs Recommended brake fluid DOT 4 6. Bleed the brake system. 7. Check the operation of the hydraulic unit according to the brake lever and the brake pedal response. (Refer to “P68 Hydraulic unit operation test 1”.) CAUTION: Always check the operation of the hydrau-...

  • Page 72: Hydraulic Abs

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) HYDRAULIC ABS EAS00892 Bleeding the ABS system WARNING Always bleed the brake system when the brake related parts are removed. CAUTION: Bleed the brake system in the following order. 1st: Front brake caliper 2nd: Rear brake caliper •...
  • Page 73 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) Bleeding instruction Hydraulic unit Buffer chamber Hydraulic pump pressure Brake caliper Hydraulic pump Solenoid valve Brake master cylinder pressure EAS00134 Bleeding the ABS brake WARNING Bleed the ABS whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced.
  • Page 74 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 1. Remove: • seat Refer to “SEAT” in chapter 3. (Manual No.: 5PS1-AE1) 2. Bleed: • ABS a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b. Install the diaphragm (brake master cylin- der reservoir or brake fluid reservoir).
  • Page 75 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) l. Tighten the bleed screw to the specified torque. Bleed screw 6 Nm (0.6 m•kg, 4.3 ft•lb) m. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
  • Page 76 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 2. Check: • installation of the wheel sensors to the sen- sor housings (Refer to “P51 Maintenance of the front wheel sensor and sensor rotor” and “P55 Maintenance of the rear wheel sensor and sensor rotor”.) Wheel sensor 30 Nm (3.0 m•kg, 22 ft•lb) Hydraulic unit operation test...
  • Page 77 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 4. Check: • battery voltage Battery voltage Higher than 12.8 V Lower than 12.8 V → Charge or replace the battery. NOTE: NOTE: • If the battery voltage is lower than 12.8 V, charge the battery and perform hydraulic unit operation test 1.
  • Page 78 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 9. After releasing the start switch, operate the brake lever and the brake pedal simulta- neously. NOTE: NOTE: • A reaction-force pulsating action is generated in the brake lever 0.5 second after the brake lever and the brake pedal are operated simultaneously and continues for approxi- mately 1 second.

  • Page 79: Anti-Lock Brake System (Abs)

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 12.Set the main switch to “OFF”. 13.Remove the test coupler adaptor from the test coupler. 14.Set the main switch to “ON”. 15.Set the engine stop switch to “ ”. • Hydraulic unit operation test 2 WARNING Securely support the motorcycle so that there is no danger of it falling over.
  • Page 80 CHAS ANTI-LOCK BRAKE SYSTEM (ABS) 6. Set the main switch to “ON” while operating the brake lever and the brake pedal simulta- neously. CAUTION: When the main switch is set to “ON”, be sure to operate both the brake levers and the brake pedal simultaneously.

  • Page 81: Checking The Reservoir Tank Fluid Level

    CHAS ANTI-LOCK BRAKE SYSTEM (ABS) CHECKING THE RESERVOIR TANK FLUID LEVEL 1. Check: • brake fluid level Keep the reservoir cap horizontal and check the level. Less than the low level → Add the brake fluid more than low level Recommended brake fluid DOT #4 CAUTION:...

  • Page 82: Electrical

    ELEC ELECTRICAL COMPONENTS ‘ EAS00729 ELECTRICAL ELECTRICAL COMPONENTS Wire harness Rear brake light switch Ignition coil Oil level switch Front brake light switch Radiator fan motor Clutch switch ECU (ABS) Fail safe relay Horn Starter relay Fuse box Battery Neutral switch Sidestand switch...
  • Page 83 ELEC ELECTRICAL COMPONENTS Coolant temperature sensor Cylinder identification sensor Atomospheric pressure sensor Intake air tempreture sensor Intake air pressure sensor Lean angle cut-off switch Turn signal relay Fuel injection system relay Radiator fan motor relay Rear wheel sensor Starting circuit cut-off relay Speed sensor sensor Crankshaft position sensor...

  • Page 84: Checking The Switches

    ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch. Main switch Turn signal switch Neutral switch...

  • Page 85: Electric Starting System

    ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Fuse (main) Starter relay Starter motor Battery Main switch Starting circuit cut-off relay Sidestand switch Neutral switch Engine stop switch Start switch Clutch switch Fuse (ignition)

  • Page 86: Starting Circuit Cut-Off System Operation

    ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...

  • Page 87: Troubleshooting

    ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Check: Refer to “CHECKING AND CHARGING 1.main and ignition fuses THE BATTERY” in chapter 3. (Manual No.: 2.battery 5PS1-AE1) 3.starter motor Minimum open-circuit voltage...
  • Page 88 ELEC ELECTRIC STARTING SYSTEM EAS00759 Tester positive probe → 4. Starting circuit cut-off relay black/yellow • Disconnect the starting circuit cut-off relay Tester negative probe → from the wire harness. sky blue • Connect the pocket tester (Ω × 1) and bat- Tester positive probe →...
  • Page 89 ELEC ELECTRIC STARTING SYSTEM EAS00761 EAS00750 6. Starter relay 8. Engine stop switch • Disconnect the starter relay from the cou- • Check the engine stop switch for continuity. pler. Refer to “CHECKING THE SWITCHES”. • Connect the pocket tester (Ω × 1) and bat- •...
  • Page 90 ELEC ELECTRIC STARTING SYSTEM EAS00764 12. Start switch • Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the start switch OK? Replace right handlebar switch. EAS00766 13. Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”.

  • Page 91: Signaling System

    ELEC SIGNALING SYSTEM EAS00780 SIGNALING SYSTEM CIRCUIT DIAGRAM...
  • Page 92 ELEC SIGNALING SYSTEM Fuse (main) Battery Main switch Fuse (backup) Starting circuit cut-off relay Neutral switch Fuel pump Oil level warning light Neutral indicator light Multi-function meter Engine trouble warning light Turn signal indicator light Oil level switch Turn signal relay Front brake light switch Horn switch Hazard switch...

  • Page 93: Troubleshooting

    ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. • Any of the following fail to light: turn sig- Refer to “CHECKING AND CHARGING nal light, brake light or an indicator light. THE BATTERY” in chapter 3. (Manual No.: •...

  • Page 94: Checking The Signal System

    ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNAL SYSTEM 1. The horn fails to sound. • Disconnect the black connector at the horn terminal. 1. Horn switch • Connect a jumper lead to the horn termi- • Check the horn switch for continuity. nal and ground the jumper lead.
  • Page 95 ELEC SIGNALING SYSTEM EAS00797 2. The tail/brake light fails to come on. 3. Voltage 1. Tail/brake light bulb and socket • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) • Check the tail/brake light bulb and socket as shown.
  • Page 96 ELEC SIGNALING SYSTEM EAS00799 3. The turn signal light, turn signal indicator • Set the main switch to “ON”. light or both fail to blink. • Measure the voltage (DC 12 V) on brown/ green at the turn signal relay coupler 1.
  • Page 97 ELEC SIGNALING SYSTEM EAS00800 4. The neutral indicator light fails to come on. 5. Voltage • Connect the pocket tester (DC 20 V) to the 1. Neutral indicator light bulb and socket turn signal light coupler or meter assembly • Check the neutral indicator light bulb and coupler (wire harness side) as shown.
  • Page 98 ELEC SIGNALING SYSTEM EAS00753 4. Voltage 3. Starting circuit cut-off relay (diode) • Connect the pocket tester (DC 20 V) to the • Disconnect the starting circuit cut-off relay meter assembly coupler (wire harness side) from the wire harness. • Connect the pocket tester (Ω × 1) to the as shown.
  • Page 99 ELEC SIGNALING SYSTEM 2. Engine oil level switch 4. Voltage • Drain the engine oil and remove the engine • Connect the pocket tester (DC 20 V) to the oil level switch from the oil tank. engine oil level switch coupler as shown. •...
  • Page 100 ELEC SIGNALING SYSTEM EAS00803 6. The fuel level gauge fails to operate. 1. Fuel sender • Drain the fuel from the fuel tank and remove the fuel pump assembly from the fuel tank. • Connect the pocket tester (Ω × 1) to the fuel sender as shown.
  • Page 101 ELEC SIGNALING SYSTEM EAS00805 7. The clock fails to operate. 1. Voltage • Connect the pocket tester (DC V 20) to the meter assembly (wire harness side) as shown. Positive tester probe → brown Negative tester probe → black/white • Set the main switch to “ON”. •...

  • Page 102: Anti-Lock Brake System (Abs)

    ELEC ANTI-LOCK BRAKE SYSTEM (ABS) EAS00884 ANTI-LOCK BRAKE SYSTEM (ABS) CIRCUIT DIAGRAM...
  • Page 103 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) Fuse (ABS) Fuse (main) Fuse (ABS motor) Battery Main switch ABS test terminal ECU (ABS) ABS wire lead Fail safe relay Hydraulic unit Front wheel sensor Rear wheel sensor Multi-function meter ABS indicator light Front brake light switch Start switch Rear brake light switch...

  • Page 104: Abs Components

    SPEC ANTI-LOCK BRAKE SYSTEM (ABS) EAS00882 ABS COMPONENTS Front brake hose (front brake master cylinder to Rear brake hose (rear brake master cylinder to hydraulic unit) hydraulic unit) ABS test coupler Hydraulic unit ABS warning light Rear wheel sensor rotor Front brake hose (hydraulic unit to front brake cali- Rear wheel sensor per)

  • Page 105: Abs Connector Location Chart

    ELEC ANTI-LOCK BRAKE SYSTEM (ABS) EAS00883 ABS CONNECTOR LOCATION CHART Wire har- Wire harness end ness end Wire har- ness end ECU (ABS) coupler ABS wire lead coupler Wire har- ness end Wire har- Wire har- Wire har- ness end Wire harness end ness end ness end...

  • Page 106: Ecu (Abs) And Fail-Safe Relay

    ELEC ANTI-LOCK BRAKE SYSTEM (ABS) EAS00888 ECU (ABS) AND FAIL-SAFE RELAY 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job/Part Q’ty Remarks Removing the ECU (ABS) and fail- Remove the parts in the order listed. safe relay Side cowling (right) Refer to “FRONT COWLINGS” in chapter 3.
  • Page 107 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job/Part Q’ty Remarks ECU (ABS) coupler Disconnect. For installation, reverse the removal procedure.
  • Page 108 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) Maintenance of the ECU (ABS) • Removing the ECU (ABS) 1. Remove: • ECU (ABS) NOTE: NOTE: When removing the ECU (ABS), take care not to damage the ECU (ABS) or ECU (ABS) cou- plers. 2.
  • Page 109 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) • Checking the fail-safe relay 1. Check: • solenoid relay for continuity Connect the pocket tester (Ω × 1) to the ter- minals. Check for continuity between terminals of the solenoid relay. Tester positive probe → Terminal Tester negative probe →...
  • Page 110 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) 2. Check: • ABS motor relay for continuity Connect the pocket tester (Ω × 1) to the ter- minals of the ABS motor relay. Check for continuity between terminals of the ABS motor relay. Tester positive probe → Terminal Tester negative probe →...

  • Page 111: Troubleshooting

    ELEC ANTI-LOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING EB802401 2. Battery • ABS warning light fail to come on. • Check the condition of the battery. • All ABS warning and other indicator lights Refer to “CHECKING AND CHARGING fail to come on. THE BATTERY”...

  • Page 112: Checking The Anti-Lock Brake System

    ELEC ANTI-LOCK BRAKE SYSTEM (ABS) CHECKING THE ANTI-LOCK BRAKE 3. ABS warning light circuit. SYSTEM • Remove the ECU coupler and check the 1. Only the ABS warning light fail to come on continuity at the white/red terminal on the when the main switch is turned ON.
  • Page 113 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) 3. Main fuse. • Check the main fuse for continuity. Refer to “CHECKING THE FUSES” in chap- ter 3. (Manual No.: 5PS1-AE1) • Is the main fuse OK? Replace the fuse. 4. Wiring • Check the entire anti-lock brake system’s wiring.
  • Page 114 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) 3. ABS warning light continues to come on. 1) Check the ABS fuse • Blown fuse → Replace 2) Check the battery voltage The voltage should be always higher than the regulated voltage in order to operate the ABS cor- rectly.

  • Page 115: Troubleshooting By The Self Diagnosis

    ELEC ANTI-LOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING BY THE SELF DIAGNOSIS Arrangement and the function of test couplers • ECU becomes the malfunction diagnostic mode when the T/C terminal is grounded. • Malfunction code which the ECU generated in the malfunction diagnostic mode (rise and fall of voltage) is output at the T/F terminal.

  • Page 116: Malfunction Check By The Abs Self Diagnosis (Present Malfunction)

    ELEC ANTI-LOCK BRAKE SYSTEM (ABS) MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS (PRESENT MALFUNCTION) NOTE: Before proceeding to read the part of “Arrangement and the function of test coupler”. Remove the battery cover and check the location of test coupler. Connect the test coupler adapter with the test coupler in order to ground the T/C terminal (sky-blue).
  • Page 117 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) • Diagnosis by the malfunction code Malfunction codes are used to determine the malfunctions that have occurred. (Refer to “P107 ABS malfunction check by the ABS self-diagnosis (past malfunction)” and “P108 ABS malfunction check by the ABS self-diagnosis (present malfunction)”.) The malfunction codes are explained in the fol- lowing table.
  • Page 118 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) Malfunction Problem Check point Reference code Defective operation of the ABS motor is • Fail-safe relay Malfunction detected. (ABS motor keeps running and will not • ABS wire harness circuit code 34 stop.) • ABS motor circuit (P114) Front wheel will not recover from the locking ten- •...
  • Page 119 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) • Malfunction code 11 (Front wheel sensor signal is not received correctly.) Set the main switch to “OFF”, then back to “ON” after removing the test coupler adaptor. 1) ABS warning light remains on. → Defective connection in the front wheel sensor circuit. →...
  • Page 120 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) • Malfunction codes 13 (front wheel) and 14 (rear wheel) (Incorrect signal is detected from either the front or rear wheel.) 1) The wheel sensors or sensor rotors are not properly installed. Installation of the front or rear wheel sensor →...
  • Page 121 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) • Malfunction code 31 (Disconnection is detected between the fail-safe relay and the hydrau- lic unit solenoid.) Check the following: 1) ABS motor fuse • Check if the ABS motor fuse beside the battery is blown. 2) Hydraulic unit solenoid coupler •...
  • Page 122 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) • Malfunction code 33 (ABS motor operation malfunction is detected. [ABS motor stops and does not rotate.]) Check the following: 1) ABS motor fuse • Check if the ABS motor fuse beside the battery is blown. 2) Fail-safe relay →...
  • Page 123 • Check the brake hose lines for kinks and deterioration. WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines. • Check that the connections of the brake hose lines from the brake master cylinder to the hydrau- lic unit and to the front brake caliper from the hydraulic unit are correct.
  • Page 124 • Check the brake hose lines for kinks and deterioration (particularly between the hydraulic unit and the rear brake caliper). WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake hose lines.
  • Page 125 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) • Check that the connections of the brake hose lines from the brake master cylinder to the hydrau- lic unit and to the rear brake caliper from the hydraulic unit are correct. WARNING The rear brake will not function properly if the connections are reversed. •...
  • Page 126 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) • Malfunction code 51 (Front wheel does not recover from the locking tendency even though the signal is continuously transmitted from the ECU (ABS) to release the hydraulic pressure [when the battery voltage is low].) Check the following: 1) Rotation of the front wheel Refer to “P115 Malfunction code 41”.
  • Page 127 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) • Malfunction code 52 (Rear wheel does not recover from the locking tendency even though the signal is continuously transmitted from the ECU (ABS) to release the hydraulic pressure [when the battery voltage is low].) Check the following: 1) Rotation of the rear wheel Refer to “P116 Malfunction code 42”.

  • Page 128: Deleting The Malfunction Code

    ELEC ANTI-LOCK BRAKE SYSTEM (ABS) DELETING THE MALFUNCTION CODE 1. Connect the test coupler adapter to the test coupler . Refer to “P109”. 2. Turn the main switch on. The multifunction display indicates previ- ously recorded mulfunction codes. NOTE: NOTE: The ABS error code is not displayed during the diagnosis of the fuel injection.
  • Page 129 ELEC ANTI-LOCK BRAKE SYSTEM (ABS) 6. Turn the main switch on again. Check that the ABS warning light goes on for 2 seconds, then goes out for 3 seconds Main switch and starts flashing. 7. Turn the main switch off. Flashing 8.

  • Page 130: Troubleshooting

    ELEC ANTI-LOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING ANTI-LOCK BRAKE SYSTEM (ABS) ABS TROUBLESHOOTING OUTLINE This section describes the troubleshooting about ABS in details. Read carefully this service manual before repairing various malfunctions, understand and perform the service. Electronic control unit (ECU) has the self diagnostic function. When failures occur in the system, the ABS warning light on the meter assembly indicates a mulfunction.

  • Page 131: Basic Instruction For Troubleshooting

    TRBL ANTI-LOCK BRAKE SYSTEM (ABS) SHTG “Deleting the malfunction code” When the malfunction service is finished, check the normal operation of motorcycle then delete the malfunction code (Refer to “P120”). By deleting the malfunction code memory, it is possible to pur- sue the cause correctly if the next defective phenomenon occurred.

  • Page 132: Basic Process For Troubleshooting

    TRBL ANTI-LOCK BRAKE SYSTEM (ABS) SHTG BASIC PROCESS FOR TROUBLESHOOTING It does not go on. Goes on for 2 seconds and goes off afterward. Check the ABS warning light. Flashing Keeps coming on. “P108” “P104” “P106” “P106” “P107” Present Warning light Warning light Warning light Past malfunction...

  • Page 133: Troubleshooting At The Abs Warning Light

    TRBL TROUBLESHOOTING AT THE ABS WARNING LIGHT SHTG TROUBLESHOOTING AT THE ABS WARNING LIGHT When the main switch is turned “ON”. (Engine does not start.) ONLY THE ABS WARNING LIGHT DOES NOT COME ON. • Blown, damaged, or incorrect fuse (ABS fuse) •...

  • Page 134: Tdm900A(T) 2005 Wiring Diagram

    TDM900A(T) 2005 WIRING DIAGRAM A.C. magneto Hazard switch Rectifier/regulator Turn signal switch Fuse (fuel injection system) Clutch switch Fuse (ABS) Horn Fuse (main) Rear turn signal light (left) Fuse (ABS motor) Rear turn signal light (right) Starter relay Front turn signal light (left) Starter motor Front turn signal light (right) Battery...
  • Page 136 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 137 TDM900A(T) 2005 WIRING DIAGRAM Y P/W W/R W/B P/W L/W L/R L/B Dg Lg Br G/L R/G Y/L G/B R/B Br/B R/W Br/B Br R/W W/G R/W W B/W B Y Br/W Br/W L R/L Br/W B Y G/R Br/W Ch G L W/Y W B/W Br/W Br/W B/L...

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