Yamaha TDM 900 S 2004 User Manual [ru]

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the
TDM900 (S) 2004. For complete service information procedures it is necessary to use this Supplemen­tary Service Manual together with the following manual.

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.
is expressly prohibited.

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 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.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve­hicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi­cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!

WARNING

CAUTION:

NOTE: A NOTE provides key information to make procedures easier or clearer.

Failure to follow WARNING instructions could result in severe injury or death
the motorcycle operator, a bystander or a person checking or repairing the mo­torcycle.

A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.

to

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. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter.
Refer to “SYMBOLS”.

2

Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) ap­pears.

3

Sub-section titles appear in smaller print than the section title.

4

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.

5

Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.

6

Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.

7

A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.

8

Jobs requiring more information (such as special tools and technical data) are described sequen­tially.

4

5

6

7

12

3

8

1

GEN

INFO

3

CHK

ADJ

5

ENG

7

2

SPEC

4

CHAS

6

COOL

8

EAS00008

SYMBOLS

The following symbols are not relevant to every
vehicle.
Symbols
chapter.

1

General information

2

Specifications

3

Periodic checks and adjustments

4

Chassis

5

Engine

6

Cooling system

7

Fuel injection system

8

Electrical system

9

Troubleshooting

1

to 9 indicate the subject of each

FI ELEC

9

10

TRBL

SHTG

11 12

1413

16 1715

19 2018

Symbols 10 to 17 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

18

to 23 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 24 to 25 in the exploded diagrams indi­cate the following.

24

Apply locking agent (LOCTITE)

25

Replace the part

22

24 25

2321

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS

FRONT AND REAR BRAKES 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT BRAKE PADS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT BRAKE MASTER CYLINDER 16. . . . . . . . . . . . . . . . . . . . . . . . .

FRONT BRAKE CALIPERS 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL

CHECKING THE SWITCHES 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMMOBILIZER SYSTEM 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYSTEM DIAGRAM 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT DIAGRAM 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KEY ID REGISTRATION METHOD 23. . . . . . . . . . . . . . . . . . . . . . . . . . . .

SELF-DIAGNOSIS ERROR CODE INDICATION 25. . . . . . . . . . . . . . . .

TROUBLESHOOTING 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE IMMOBILIZER SYSTEM 27. . . . . . . . . . . . . . . . . . . . .

REPLACEMENT PARTS ON TROUBLES 29. . . . . . . . . . . . . . . . . . . . . .

TDM900 (S) 2004 WIRING DIAGRAM

GENERAL SPECIFICATIONS/CHASSIS SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

SPEC

Model code 5PS6 (for EUR)

5PS7 (for OCE)

CHASSIS SPECIFICATIONS

Item Standard Limit

Front suspension

Suspension type
Front fork type
Front fork travel
Spring

Free length

Spacer length
Installed length
Spring rate (K1)
Spring rate (K2)
Spring stroke (K1)

Spring stroke (K2)
Optional spring available
Fork oil

Recommended oil

Quantity (each front fork leg)

Level (from the top of the inner

tube, with the inner tube fully

compressed, and without

the fork spring)

Inner tube outer diameter

Inner tube bend
Spring preload adjusting positions

Minimum

Standard

Maximum
Rebound damping adjusting
positions

Minimum

Standard

Maximum

Telescopic fork
Coil spring/ oil damper
150 mm (5.91 in)

349.9 mm (13.78 in)

125 mm (4.92 in)

332.9 mm (13.11 in)

5.39 N/mm (0.55 kg/mm, 30.78 lb/in)

7.84 N/mm (0.80 kg/mm, 44.77 lb/in)
0 X 82 mm (0.00 X 3.23 in)
82 X 150 mm (3.23 X 5.91 in)
No

Yamaha fork oil 10 W or equivalent
545 cm
127 mm (5.00 in)

43 mm (1.69 in)

SSS

8
7
1

1
2
4

3

(19.22 lmp oz, 18.43 US oz)

SSS
SSS

SSS
SSS
SSS

342.9 mm
(13.50 in)

SSS
SSS
SSS
SSS
SSS
SSS
SSS

SSS
SSS
SSS

SSS

0.2 mm (0.008 in)

SSS
SSS
SSS

SSS
SSS
SSS

–1–

Item Standard Limit

Front brakes

Brake type
Operation
Recommended fluid
Brake discs

Diameter thickness

Min. thickness

Max. deflection

Brake pad lining thickness
Master cylinder inside diameter
Caliper cylinder inside diameter

Drive chain:

Type (manufacturer)
Link quantity
Drive chain slack
Maximum ten-link section

CHASSIS SPECIFICATIONS/

ELECTRICAL SPECIFICATIONS

Dual-disc brake
Right-hand operation
DOT 4

298 5 mm (11.73 0.20 in)

SSS
SSS

4.5 mm (0.18 in)
16 mm (0.63 in)

30.2 mm and 27 mm (1.19 1.06 in)

DID525HV KAI (DAIDO)
118
50 X 60 mm (1.97 X 2.36 in)

SSS

SPEC

SSS
SSS
SSS

SSS

4.5 mm (0.18 in)

0.1 mm (0.0039 in)

0.5 mm (0.02 in)

SSS
SSS

SSS
SSS
SSS

159.5 mm (6.28 in)

ELECTRICAL SPECIFICATIONS

Item Standard Limit

Horn

Horn type
Model (manufacturer) quantity
Max. amperage
Performance
Coil resistance

Indicator light
(voltage/ wattage quantity)

Neutral indicator light
Turn signal indicator light
Oil level warning light
High beam indicator light
Engine trouble warning light
Immobilizer system indicator light

Fuses (amperage quantity)

Main fuse
Fuel injection system fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan motor fuse
Hazard light fuse
Parking light fuse
Backup fuse
Reserve fuse

Plane
HF-12 (NIKKO) 1
3 A
105 X 118 db/ 2 m (6.56 in)

1.01 X 1.11 Ω

14 V 1.2 W 1
14 V 1.2 W 2
LED 1
14 V 1.4 W 1
14 V 1.4 W 1
LED 1

40 A 1
15 A 1
15 A 1
10 A 1
10 A 1
20 A 1
10 A 1
5 A 1
5 A 1
20 A 1
15 A 1
10 A 1
5 A 1

SSS
SSS
SSS
SSS
SSS

SSS
SSS
SSS
SSS
SSS
SSS

SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS

–2–

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

CABLE ROUTING

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

SPEC

–3–

CABLE ROUTING

SPEC

A Fasten the handlebar switch lead (left) to the han-

dlebar with a band.

B Through the handlebar switch lead (left) and clutch

cable to the wire guide on the upper bracket.

C 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).

D Route the main switch lead through the cover 7 so

that it route beneath the handlebar switch lead (left).

E Route the clutch cable through the hole in front of

the head pipe on the frame.

F Route the handlebar switch lead (right) and throttle

cables (2 cables) through the cover 8.

G Route the brake hose through the guide.
H Always route the hose so that the brake hose

passes by the outside of the throttle cables.

I Route the handlebar switch lead (right), brake hose

and throttle cables through the wire guide of the up­per bracket.

J Fasten the handlebar switch lead (right) to the han-

dlebar with a band.

K Fasten the main switch lead and immobilizer lead

with a clamp so that it faces the front side of the ve­hicle.

L 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).

–4–

CABLE ROUTING

SPEC

M 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).
N 10 mm (0.39 in)
O Fasten the turn signal light lead (right) together with

the coupler to the stay 1.
P Clamp the white tape of headlight sub-wire harness

to the stay 1. (For detail of the clamp, refer to section

BB.)
Q 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.
R Route the main harness through the outside of the

bolt.
S To the headlight relay.

T To the ECU.
U After the clamping, direct the band point to the front.
V Clamp the meter lead, indicator lead, headlight lead

and sub-wire harness to the stay 1 with a band.

W 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.

X Clamp the headlight sub-wire harness to the dent in

the stay 1.

Y Clamp the headlight sub-wire harness to the stay 1

with a band.

Z Fasten the headlight sub-wire harness with the

clamp that is passed through the center hole of stay

1.

–5–