Yamaha TDM900A Service Manual

2005TDM900A(T)5PS1-AE4SUPPLEMENTARYSERVICE MANUAL

GENINFO2CO ADJUSTMENT MODECylinder identificationFor #1 For #2CO dataExample:lean rich–128 0 128DIAGNOSTIC MONITORING MODEDiagnostic monitoring codeEx

ELEC92EAS008036. The fuel level gauge fails to operate.1. Fuel sender• Drain the fuel from the fuel tank and removethe fuel pump assembly from the fue

ELEC93EAS008057. The clock fails to operate.1. Voltage• Connect the pocket tester (DC V 20) to themeter assembly (wire harness side) asshown.Positive

ELEC94EAS00884ANTI-LOCK BRAKE SYSTEM (ABS)CIRCUIT DIAGRAMHEADLIGHT SUB-WIRE HARNESS 2DWIRE HARNESSHEADLIGHT SUB-WIRE HARNESS 1CWIRE HARNESSA E F HGBWW

ELEC95Fuse (ABS)Fuse (main)Fuse (ABS motor)BatteryMain switchABS test terminalECU (ABS)ABS wire leadFail safe relayHydraulic unitFront wheel sensorRea

SPEC96EAS00882ABS COMPONENTSFront brake hose (front brake master cylinder tohydraulic unit)ABS test couplerABS warning lightFront brake hose (hydrauli

ELEC97EAS00883ABS CONNECTOR LOCATION CHARTWire harness endWire har-ness endECU (ABS) couplerABS wire lead couplerWire harness endABS test terminalcoup

ELEC98EAS00888ECU (ABS) AND FAIL-SAFE RELAYOrder Job/Part Q’ty RemarksRemoving the ECU (ABS) and fail-safe relayRemove the parts in the order listed.S

ELEC99Order Job/Part Q’ty Remarks9 ECU (ABS) coupler 3 Disconnect.For installation, reverse the removalprocedure.10 Nm (1.0 m•kg, 7.2 ft•lb)ANTI-LOCK

ELEC100Maintenance of the ECU (ABS)• Removing the ECU (ABS)1. Remove:• ECU (ABS) NOTE:NOTE:When removing the ECU (ABS), take care notto damage the ECU

ELEC101\• Checking the fail-safe relay1. Check:• solenoid relay for continuityConnect the pocket tester (Ω × 1) to the ter-minals.Check for continuity

GENINFO3CO adjustment and diagnostic monitoring mode(The engine cannot be started in this mode)Mode SelectionNormal modeTurn “ON” the main switch• The

ELEC1022. Check:• ABS motor relay for continuityConnect the pocket tester (Ω × 1) to the ter-minals of the ABS motor relay.Check for continuity betwee

ELEC103TROUBLESHOOTINGCheck:1. ABS motor, ABS, main and signal fuses.2. Battery.3. Main switch.4. Wiring (of the entire anti-lock brake sys-tem).NOTE:

ELEC104CHECKING THE ANTI-LOCK BRAKE SYSTEM1. Only the ABS warning light fail to come onwhen the main switch is turned ON.2. All ABS warning and other

ELEC1053. 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?YESN

ELEC1063. ABS warning light continues to come on.1) Check the ABS fuse• Blown fuse → Replace2) Check the battery voltageThe voltage should be always h

ELEC107TROUBLESHOOTING BY THE SELF DIAGNOSISMALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS (PAST MALFUNCTION)Remove the side cowling (right) and check th

ELEC108MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS (PRESENT MALFUNCTION)NOTE:Before proceeding to read the part of “Arrangement and the function of te

ELEC109• Diagnosis by the malfunction codeMalfunction codes are used to determine the malfunctions that have occurred. (Refer to “P107 ABSmalfunction

ELEC110*1 Malfunction code 11 is indicated if the rear wheel rotates for more than 20 seconds with the frontwheel stopped.NOTE:Malfunction code 15 (fr

ELEC111• Malfunction code 11 (Front wheel sensor signal is not received correctly.)Set the main switch to “OFF”, then back to “ON” after removing the

GENINFO4EB104000SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly.Use only the appropriate special

ELEC112• Malfunction codes 13 (front wheel) and 14 (rear wheel) (Incorrect signal is detected fromeither the front or rear wheel.)1) The wheel sensors

ELEC113• Malfunction code 31 (Disconnection is detected between the fail-safe relay and the hydrau-lic unit solenoid.)Check the following:1) ABS motor

ELEC114• Malfunction code 33 (ABS motor operation malfunction is detected. [ABS motor stops anddoes not rotate.])Check the following:1) ABS motor fuse

ELEC115• Malfunction code 41 (Front wheel does not recover from the locking tendency even thoughthe signal is continuously transmitted from the ECU (A

ELEC1165) Hydraulic unit solenoid coupler terminal• Check if the front and rear hydraulic unit solenoid coupler terminals (hydraulic unit and sub-wire

ELEC117• 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 t

ELEC118• Malfunction code 51 (Front wheel does not recover from the locking tendency even thoughthe signal is continuously transmitted from the ECU (A

ELEC119• Malfunction code 52 (Rear wheel does not recover from the locking tendency even thoughthe signal is continuously transmitted from the ECU (AB

ELEC120DELETING THE MALFUNCTION CODE1. Connect the test coupler adapter to thetest coupler . Refer to “P109”.2. Turn the main switch on.The multifu

ELEC1216. Turn the main switch on again.Check that the ABS warning light goes onfor 2 seconds, then goes out for 3 secondsand starts flashing.7. Turn

SPEC5SPECIFICATIONSGENERAL SPECIFICATIONSENGINE SPECIFICATIONSCHASSIS SPECIFICATIONSItem Standard LimitModel code 2B01 (EUR) • • •WeightWet (with oil

ELEC122TROUBLESHOOTINGANTI-LOCK BRAKE SYSTEM (ABS)ABS TROUBLESHOOTING OUTLINEThis section describes the troubleshooting about ABS in details. Read car

TRBLSHTG123“Deleting the malfunction code”When the malfunction service is finished, check the normal operation of motorcycle then delete themalfunctio

TRBLSHTG124BASIC PROCESS FOR TROUBLESHOOTINGNOTE:Do not delete the malfunction code during the troubleshooting procedures. Be sure to delete it whenth

TRBLSHTG125TROUBLESHOOTING AT THE ABS WARNING LIGHTWhen the main switch is turned “ON”. (Engine does not start.)ONLY THE ABS WARNING LIGHT DOES NOT CO

TDM900A(T) 2005 WIRING DIAGRAMA.C. magnetoRectifier/regulatorFuse (fuel injection system)Fuse (ABS)Fuse (main)Fuse (ABS motor)Starter relayStarter mot

YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPAN

HEADLIGHT SUB-WIRE HARNESS 2DWIRE HARNESSHEADLIGHT SUB-WIRE HARNESS 1CWIRE HARNESSAE F HGBWWWL/YG/WGyG/WRBWWWL/RL/BDgLgBrBYG/RBr/WChGLBr/WL/R L/B Dg L

SPEC6ELECTRICAL SPECIFICATIONSItem Standard LimitIgnition systemIgnition system type Transistorized coil ignition (digital) • • •Ignition timing 10° B

SPEC7TIGHTENING TORQUESCHASSIS TIGHTENING TORQUESPart to be tightenedThreadsizeTighteningtorqueRemarksNm m•kg ft•lbLower bracket pinch bolt M8 23 2.3

SPEC8CABLE ROUTINGThrottle cablesClutch cableLeft handlebar switch leadMain switch lead and immobilizer leadCover 7Horn leadHornFront wheel sensor lea

SPEC9Fasten the left handlebar switch lead to the han-dlebar with a band.Through the left handlebar switch lead and clutchcable to the wire guide on t

SPEC10Fasten the horn lead to the upper side of the underbracket as shown in the drawing. Cut the clamp tipleaving 3 ~ 8 mm (0.12 ~ 0.31 in).10 mm (0.

SPEC11Fasten the headlight sub-wire harness with theclamp that is passed through the center hole ofstay 1.CABLE ROUTING

SPEC12Stay 3Ignition coil assemblyNeutral switch leadO2 sensor leadSpeed sensor leadSidestand switch leadPickup coil leadFuel tank drain hoseAir filte

SPEC13To the headlight.Route the 6 poles water proof coupler throughinside of the ECU lead, and the 12 poles couplerthrough outside of the ECU lead.Co

SPEC14Route the fuel drain hoses (2 hoses), air filter drainhose, and coolant reservoir tank drain hose troughthe clamp. For the fuel drain hose, the

SPEC15Pass the harness for the relay between ECU andthe main relay.Fasten the ECU lead with the clamp installed tothe plate of front side hole. Align

SPEC16Seat bracketFront wheel sensor leadECU (ABS) sub-wire harnessECU (ABS)Radiator fan motor relayABS check couplerBrake hose holderStay 2RadiatorCl

SPEC17The right and left positions for the starter motorlead and rear wheel sensor lead can be acceptedin random oder.Pass the brake fluid reservoir h

SPEC18Route inside the brake hose holder.Attach the clamp so that its opening section facesin the direction indicated in the drawing.Clamp the grommet

SPEC19Throttle cablesHandlebar switch lead (right)Front brake hoseStayFront wheel sensor leadThermo wax hoseIntake vacuum hoseSub-wire harness (air fi

SPEC20Rear turn signal light (left)Joint couplerImmobilizer couplerSeat lock cableFuse boxBattery negative leadHydraulic unit motor couplerCoolant res

SPEC21Put the cover on the coupler for the immobilizerlead and wire harness.Install the projection part of the coupler pointing tothe connector housin

TDM900A(T) 2005SUPPLEMENTARYSERVICE MANUAL©2004 by Yamaha Motor Co., Ltd.First Edition, December 2004All rights reserved.Any reproduction or unauthori

SPEC22Pass the seat locking cable through the hole sec-tion of the seat bracket of the rear frame. Eitherdirection of the seat locking cable can beacc

SPEC23Bundle the coolant temperature sensor lead andair induction system lead with the clamp. Cut theclamp tip leaving 3 ~ 8 mm (0.12 ~ 0.31 in).To th

SPEC24Intake vacuum hose jointClipIntake vacuum hoseClamp (fuel pump side)Clamp (injector side)Air filter caseAir filter drain hoseFuel pumpFuel hoseF

SPEC25Insert the fuel tank return hose until its end con-tacts the component.To assemble to the carburetor joint 1, it is allowedto apply the engine o

SPEC26Rear brake hose (OUT)Rear brake hose (IN)Bracket 2FrameBracket 1Coolant reservoir tankWire harness assemblyRelay stayProtectorOil level sensor c

SPEC27Insert the pin of the bracket 1 to the hydraulic unitassembly.Press front brake hose (IN) to the front brake hoseassembly (out) and tighten.Inse

CHAS28EAS00709SWINGARM AND DRIVE CHAINCHECKING THE DRIVE CHAIN1. Measure:• Measure the dimension between 15-linkson the inner side and outer side

CHAS29CAUTION:This motorcycle has a drive chain withsmall rubber O-rings between the drivechain side plates. Never use high-pressurewater or air, st

CHAS30ANTI-LOCK BRAKE SYSTEM (ABS)ABS OUTLINEYamaha ABS features1. The Yamaha ABS (Anti-Lock Brake System) features a dual electronic control system,

CHAS31EAS00872ABSThe operation of the Yamaha ABS brakes isthe same as conventional motorcycles, with abrake lever for operating the front wheel brakea

EAS00002NOTICEThis manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-ers and their qualified mechanics. It is not

CHAS32• Slip ratio:When the brakes are applied, slippingoccurs between the tires and the road sur-face. This causes a difference between thewheel spee

CHAS33EAS00875Wheel slip and hydraulic controlThe ECU (ABS) calculates the wheel speed ofeach wheel according to the rotation signalreceived from the

CHAS34The higher the cornering force on a tire, theless traction there is available for braking. Thisis true whether the motorcycle is equipped withan

CHAS35EAS00877Electronic ABS featuresThe Yamaha ABS (Anti-lock Brake System) has been developed with the most advanced electronictechnology.The ABS co

CHAS36EAS000878ABS component functions• Wheel sensors and sensor rotorsWheel sensors detect the wheel rotationspeed and transmit the wheel rotation

CHAS37EAS00879• Hydraulic unitThe hydraulic unit is composed of a hydrau-lic control valve (solenoid valve, flow controlvalve), a buffer chamber, an

CHAS38• Hydraulic control valveThe hydraulic control valve is composed ofa flow control valve and solenoid valve.When the ABS is activated, the flow c

CHAS39• Electronic control unit (ECU)The ECU (ABS) controls the ABS and isinstalled inside the right cowling. To protect theECU (ABS) from water dam

CHAS40As shown in the block diagram below, the ECU (ABS) receives wheel sensor signals from the frontand rear wheels and also receives signals from ot

CHAS41• ABS control operationThe ABS control operation performed in theECU (ABS) is divided into the following twoparts.• Hydraulic control• Self-diag

EAS00007HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all insta

CHAS42• Fail-safe relayThe fail-safe relay controls the power supply ofthe hydraulic unit and is located beside thehydraulic unit.Fail-safe relayCompo

CHAS43ABS operationThe ABS hydraulic circuit consists of two systems: the front wheel and rear wheel. The followingdescribes the front system only.• N

CHAS44• Emergency braking (ABS activated)1) Depressurized stateWhen the front wheel is about to lockup, port D of the solenoid valve is opened by th

CHAS452) Pressurized statePort D is closed by the “pressurization” signal transmitted from the ECU (ABS). Before thisoccurs, the spool of the flow c

CHAS46EAS00880Self-diagnosis function• ABS warning lightThe ABS warning light comes on when amalfunction is detected by the ABS self-diag-nosis. It

CHAS474) The ABS warning light flashes and malti-function code is indicated on the multifunc-tion display when a test coupler adaptor is connected

CHAS48Cautions for operationABS warning light:• When the main switch is set to “ON”, the ABS warning light comes on for 2 seconds, then goesoff.• If t

CHAS49EAS00882ABS COMPONENTSFront brake hose (front brake master cylinder tohydraulic unit)ABS test couplerABS warning lightFront brake hose (hydrauli

CHAS50EAS00889FRONT WHEEL SENSOR AND SENSOR ROTOROrder Job/Part Q’ty RemarksRemoving the front wheel sensor and sensor rotorRemove the parts in the or

CHAS51Maintenance of the front wheel sensor andsensor rotor• ABS wheel sensor and sensor rotorCAUTION:• Handle the ABS components with caresince they

EAS00008SYMBOLSThe following symbols are not relevant to everyvehicle.Symbols to indicate the subject of eachchapter.General informationSpecificat

CHAS522. Measure:• front wheel sensor resistanceConnect the pocket tester (Ω × 1k) to theterminals of the front wheel sensor coupler.Tester positive

CHAS532. Install:• front wheel sensor • front wheel sensor lead holder • brake caliper • brake hose holder NOTE:NOTE:When installing the front wheel s

CHAS54EAS00890REAR WHEEL SENSOR AND SENSOR ROTOROrder Job/Part Q’ty RemarksRemoving the rear wheel sensor and sensor rotorRemove the parts in the orde

CHAS55Maintenance of the rear wheel sensor andsensor rotorCAUTION:• Be sure not to contact the sensor elec-trode to any metal part when removing thefr

CHAS56• Installing the rear wheel sensor1. Install:• rear wheelNOTE:NOTE:• Align the slot of the sensor housing with the projection of the rear br

CHAS57EAS00891HYDRAULIC UNITOrder Job/Part Q’ty RemarksRemoving the hydraulic unitRemove the parts in the order listed.Seat Refer to “SEAT” in chapter

CHAS58Order Job/Part Q’ty Remarks6 Rear brake hose 1 (rear brake master cylinder to hydraulic unit)7 Union bolt/copper washers 1/28 Rear brake hose 1

CHAS59Maintenance of the hydraulic unitCAUTION:Do not remove the hydraulic unit to checkthe resistance of the solenoid valves andthe ABS motor for con

CHAS60• Checking the resistance of the solenoidvalves and ABS motor for continuityCAUTION:When check the hydraulic unit solenoidrelay and ABS motor, d

CHAS61• Removing the hydraulic unit1. Remove:• brake hose (from the front brake mastercylinder)• brake hose (to the front brake caliper)• brake ho

CONTENTSGENERAL INFORMATIONFEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1INSTRUMENT PANEL. . .

CHAS62• Installing the hydraulic unitProceed in the reverse order of disassembly.Pay attention to the following items.1. Install:• hydraulic unit brac

CHAS635. Fill:• brake master cylinder reservoirs6. Bleed the brake system.7. Check the operation of the hydraulic unitaccording to the brake lever and

CHAS64HYDRAULIC ABSEAS00892Bleeding the ABS systemWARNINGAlways bleed the brake system when thebrake related parts are removed.CAUTION:Bleed the brake

CHAS65Bleeding instructionEAS00134Bleeding the ABS brakeWARNINGBleed the ABS whenever:• the system is disassembled.• a brake hose is loosened, disconn

CHAS661. Remove:•seatRefer to “SEAT” in chapter 3.(Manual No.: 5PS1-AE1)2. Bleed:• ABSa. Fill the brake fluid reservoir to the properlevel with the re

CHAS67l. Tighten the bleed screw to the specifiedtorque.m. Fill the brake fluid reservoir to the properlevel with the recommended brake fluid.Refer to

CHAS682. Check:• installation of the wheel sensors to the sen-sor housings (Refer to “P51 Maintenance ofthe front wheel sensor and sensor rotor”and “P

CHAS694. Check:• battery voltageLower than 12.8 V → Charge or replace thebattery.NOTE:NOTE:• If the battery voltage is lower than 12.8 V,charge the ba

CHAS709. After releasing the start switch, operate thebrake lever and the brake pedal simulta-neously.NOTE:NOTE:• A reaction-force pulsating action is

CHAS7112.Set the main switch to “OFF”.13.Remove the test coupler adaptor from thetest coupler.14.Set the main switch to “ON”.15.Set the engine stop sw

ANTI-LOCK BRAKE SYSTEM (ABS) . . . . . . . . . . . . . . . . . . . . . . . . 94CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAS726. Set the main switch to “ON” while operatingthe brake lever and the brake pedal simulta-neously.CAUTION:When the main switch is set to “ON”, b

CHAS73CHECKING THE RESERVOIR TANK FLUID LEVEL1. Check:• brake fluid levelKeep the reservoir cap horizontal and checkthe level.Less than the low level

ELEC74‘EAS00729ELECTRICALELECTRICAL COMPONENTSWire harnessIgnition coilFront brake light switchClutch switchFail safe relayStarter relayFuse boxBatter

ELEC75Coolant temperature sensorAtomospheric pressure sensorIntake air tempreture sensorIntake air pressure sensorLean angle cut-off switchTurn signal

ELEC76EAS00731CHECKING THE SWITCHESCheck each switch for damage or wear, proper connections, and also for continuity between the ter-minals. Refer to

ELEC77EAS00755ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAMHEADLIGHT SUB-WIRE HARNESS 2DWIRE HARNESSHEADLIGHT SUB-WIRE HARNESS 1CWIRE HARNESSA E F HGBWWWL/Y

ELEC78EAS00756STARTING CIRCUIT CUT-OFF SYSTEM OPERATIONIf the engine stop switch is set to “ ” and themain switch is set to “ON” (both switches areclo

ELEC79EAS00757TROUBLESHOOTINGThe starter motor fails to turn.Check:1.main and ignition fuses2.battery3.starter motor4.starting circuit cut-off relay5.

ELEC80EAS00759EAS007604. Starting circuit cut-off relay• Disconnect the starting circuit cut-off relayfrom the wire harness.• Connect the pocket teste

ELEC81EAS00761EAS00749EAS00750EAS00751EAS00752EAS007636. Starter relay• Disconnect the starter relay from the cou-pler.• Connect the pocket tester (Ω

GENINFO1GENERAL INFORMATIONFEATURESINSTRUMENT PANELClockTRIP/ODO meterSELECT buttonRESET buttonEngine trouble warning lightFunction indicationThe indi

ELEC82EAS00764EAS0076612. Start switch• Check the start switch for continuity.Refer to “CHECKING THE SWITCHES”.• Is the start switch OK?YESNOReplace t

ELEC83EAS00780SIGNALING SYSTEMCIRCUIT DIAGRAMHEADLIGHT SUB-WIRE HARNESS 2DWIRE HARNESSHEADLIGHT SUB-WIRE HARNESS 1CWIRE HARNESSA E F HGBWWWL/YG/WGyG/W

ELEC84Fuse (main)BatteryMain switchFuse (backup)Starting circuit cut-off relayNeutral switchECUFuel pumpOil level warning lightNeutral indicator light

ELEC85EAS00794TROUBLESHOOTINGCheck:1. main, signaling, hazard light and back upfuses2. battery3. main switch4. wiring connections(of the entire signal

ELEC86EAS00796CHECKING THE SIGNAL SYSTEM1. The horn fails to sound.1. Horn switch• Check the horn switch for continuity.Refer to “CHECKING THE SWITCHE

ELEC87EAS007972. The tail/brake light fails to come on.1. Tail/brake light bulb and socket• Check the tail/brake light bulb and socketfor continuity.R

ELEC88EAS007993. The turn signal light, turn signal indicatorlight or both fail to blink.1. Turn signal indicator light bulb and socket• Check the tur

ELEC89EAS008004. The neutral indicator light fails to come on.5. Voltage• Connect the pocket tester (DC 20 V) to theturn signal light coupler or meter

ELEC90EAS00753EAS008025. The oil level warning light fails to come on.3. Starting circuit cut-off relay (diode)• Disconnect the starting circuit cut-o

ELEC912. Engine oil level switch• Drain the engine oil and remove the engineoil level switch from the oil tank.• Check the engine oil level switch for