2004 Yamaha TDM900(S) Supplementary Service & Repair Manual

• Covers the TDM900(P) 2002 model codes 5PS1 (Europe) and 5PS2 (Oceania), TDM900(R) 2003 codes 5PS4/5PS5, TDM900(S) 2004 codes 5PS6/5PS7, and the European TDM900A(T) 2005 ABS model code 2B01.
• Includes Yamaha publication numbers 5PS1-AE1 through 5PS1-AE4: the full base service manual plus the 2003, 2004, and 2005 model-change supplements.
• Covers engine removal and internal repair for the camshafts and timing chain, cylinder head and valves, pistons, clutch, starter clutch and generator, oil pump, crankshaft and balancer shaft, and transmission.
• Details wheel and brake repair, master-cylinder and caliper service, hydraulic brake bleeding, front-fork disassembly and seal installation, steering-head work, rear suspension, swingarm, drive chain, radiator, thermostat, and water pump service.
• Provides ECU and fuel-injection diagnosis, throttle-body synchronization, CO adjustment, injector and fuel-pump testing, pressure-regulator checks, fail-safe fault tracing, and system coverage for the catalytic converter and air-induction system.
• Adds 2003 starting and lighting circuit changes, 2004 immobilizer key registration and system diagnosis, and 2005 ABS wheel-sensor, hydraulic-unit, self-diagnosis, code-deletion, bleeding, operation-test, and trial-run procedures.
• Contains four PDF files totaling 681 pages, with exploded views, job charts, cable-routing drawings, regional wiring diagrams, connector charts, torque tables, wear limits, pressure-test data, adjustment specifications, and electrical test values.

Coverage and Publication Structure

This set follows Yamaha’s service-publication chain rather than treating 2002–2005 as one unchanged model range. 5PS1-AE1 is the full base manual. The 5PS1-AE2, 5PS1-AE3, and 5PS1-AE4 books are change-only supplements that add the service data and procedures introduced for the 2003 TDM900(R), 2004 TDM900(S), and 2005 TDM900A(T). They do not repeat every unchanged engine or chassis chapter. Because the base volume and each preceding supplement are included, technicians can move through the required reference sequence without relying on a standalone supplement.

The 2002–2004 publications identify separate Europe and Oceania model codes, while the 2005 ABS supplement is assigned to the European 2B01 configuration. That distinction is especially useful before choosing wiring diagrams, throttle-body data, brake parts, or year-specific test procedures.

Component and System Documentation

The base manual covers the liquid-cooled parallel-twin from routine adjustment through major internal repair. Engine sections address removal and installation, camshaft timing, cylinder-head and valve service, piston and ring inspection, clutch repair, starter-clutch and generator work, dry-sump lubrication components, crankshaft and connecting rods, balancer-shaft service, and transmission and shift-fork inspection. Cooling-system chapters cover the radiator, thermostat, and water pump, while the chassis material carries wheel, brake, fork, steering-head, shock, swingarm, and drive-chain work through disassembly, inspection, assembly, and final adjustment.

The fuel-injection chapters document ECU ignition control, fuel control, self-diagnosis, and load control, together with the three-way catalytic converter and air-induction system. Workshop sections cover the diagnostic monitoring mode, fail-safe actions, sensor fault isolation, throttle-body and injector checks, fuel-pump and pressure-regulator operation, throttle-body synchronization, and exhaust-gas/CO adjustment. Electrical repair sections trace the ignition, starting, charging, lighting, signaling, cooling-fan, and fuel-injection circuits.

The 2003 supplement updates the electric starting and lighting systems and supplies separate EUR and OCE wiring diagrams. The 2004 book adds revised front-brake assemblies, extensive cable routing, and the immobilizer system: system and circuit diagrams, key ID registration, self-diagnosis indications, troubleshooting charts, component checks, and a replacement-parts matrix linking the transponder keys, immobilizer unit, ECU, main switch, and accessory locks. The 2005 ABS volume adds front and rear wheel sensors and rotors, the hydraulic unit, brake-hose routing, ABS operation tests, current and stored malfunction diagnosis, malfunction-code deletion, reservoir checks, and the required post-service trial run.

Diagrams, Tools, and Factory Reference Data

Diagram coverage includes the engine oil-flow diagrams, cooling-system diagrams, fuel-injection circuit diagram, air-induction system diagrams, immobilizer system and circuit diagrams, and the ABS connector-location chart. Full motorcycle wiring is provided for the covered regional and model-year configurations, supported by component-location views, cable-routing drawings, and exploded assemblies with job-order tables.

Named Yamaha tools include the fuel-pressure gauge 90890-03153 with adapter 90890-03176, fork-seal driver weight 90890-01367 with attachment 90890-01374, valve-spring compressor 90890-04019 with attachment 90890-04108, and ABS test-coupler adapter 90890-03149. The specification sections supply component-specific torque data, lubrication points, fluid capacities, wear and clearance limits, pressure-test specifications, sensor and switch test values, and model-year electrical data.

Several repair cautions are specific to these systems. Yamaha warns against dropping the fuel pump or touching the sender base, and calls for a new pump gasket and correct fuel-hose holder placement to avoid sender damage or an insecure fuel connection. The immobilizer section shows that losing all keys or replacing the ECU or immobilizer unit changes which matched components and registration work are required; skipping that process can leave the engine disabled. On the ABS model, dirt in a wheel hub can damage the internal sensor rotor and wheel sensor, while incorrectly connected hydraulic-unit hoses are identified through the prescribed lever-and-pedal operation test.

These publications were written for Yamaha dealers and qualified mechanics. Pressurized fuel, brake fluid, electrical diagnosis, and ABS hydraulic work require proper shop equipment, safe fluid handling, correct bleeding, and functional checks before the motorcycle is returned to service.