2002-2011 Yamaha TDM900 / TDM900A Service Manual

Official Yamaha TDM900 and TDM900A Service Manual

• Covers 2002–2011 Yamaha TDM900 and TDM900A models, including the 5PSC, 5PSD, and 2B03 variants with ABS and fuel injection systems
• Official Yamaha publication P/N 5PS-28197-E0, first edition July 2006
• Contains 47 detailed exploded-view diagrams, 15 complete cable routing layouts, and comprehensive engine and chassis tightening torque tables
• File delivered as a direct download the moment payment clears
• Indexed PDF search covers every chapter and appendix
• Laid out for standard letter and A4 printing
• This 2006 first edition provides the primary technical reference for the 2002–2011 build cycle, including all ABS-specific maintenance and electrical configuration data

Documentation Overview

This 622-page factory service manual details the technical specifications and maintenance requirements for the 2002–2011 Yamaha TDM900 series. The document is structured into technical chapters beginning with general identification of the vehicle, VIN and model label locations, followed by a description of the electronically controlled fuel injection system. Detailed sections explain the ABS layout, component functions including wheel speed sensors, the hydraulic unit, and electronic self-diagnosis operations. Comprehensive chapters provide specifications for the DOHC 897cc engine, transmission, cooling system, and electrical components, alongside how factory workshop documentation is structured for these motorcycles.

Technical Specification Highlights

The documentation provides extensive technical data, including valve clearances, piston ring end gaps, and gear ratios for the 6-speed constant mesh transmission. Camshaft lobe dimensions for intake and exhaust are documented, and cylinder head warpage limits are explicitly provided. Crankshaft bearing color codes and oil clearance limits are listed for precise engine assembly.

Coolant system capacity for the TDM900 is documented at 1.75 liters. Cylinder head bolt torque values are specified in a multi-stage sequence, with final-stage angles of 150° required. Engine idling speed for the TDM900 is specified at 1100–1200 r/min.

All service data shown here is for reference only — qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work. An official 622-page Yamaha OEM workshop manual covering the 2002–2011 TDM900 and TDM900A, documenting engine, chassis, electrical, and fuel-injection specifications for the 5PS-series build.