2004 Yamaha TDM900(S) Supplementary Service Manual
Field service reference for the TDM900(S) 2004, covering engine, chassis, and electrical systems with part number 5PS1-AE3.
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Sample pages from the 2004 Yamaha TDM900(S) Supplementary Service Manual manual
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Yamaha Models Covered & Key Technical Specifications
Models: Yamaha TDM900(S), Yamaha TDM900(R)
Sub-models / Variants: 5PS1-AE3, 5PS6 (EUR), 5PS7 (OCE), 5PS4 (EUR), 5PS5 (OCE)
Trade Names: TDM900
Build Years: 2002–2004
Serial Numbers: 5PS1-AE1, 5PS1-AE2, 5PS1-AE3
Technical Data:
- Engine: Liquid-cooled 4-stroke
- Fuel System: Electronic Fuel Injection (FI) with 38EIS Mikuni throttle bodies
- Idle Speed: 1,100–1,200 r/min
- Front Suspension Travel: 150 mm
- Front Fork Oil Quantity: 545 cm3
- Front Tire Size: 120/70ZR 18 M/C
- Rear Tire Size: 160/60ZR 17 M/C
- Electrical System Voltage: 12 V DC
- Fuel Pressure Relief Setting: 441–637 kPa
Yamaha Manual Features & Content Preview
Technical Coverage and Specifications
- Covers 2002–2004 Yamaha TDM900 models, including the 5PS1-AE1 through 5PS1-AE3 variants and regional configurations for Europe and Oceania
- Official Yamaha publication encompassing the TDM900 (P) 2002, TDM900 (R) 2003, and TDM900 (S) 2004 supplementary service series
- Contains 82 pages of technical data, wiring schematics, cable routing diagrams, and factory service manual references
- Stored against your account so you can retrieve it after a hard-drive loss
- Indexed PDF search covers every chapter and appendix
- Documents the complex electronic fuel injection system and immobilizer registration methods for all TDM900 units
- This 2004 supplementary publication is required for technicians servicing 5PS-series fuel systems alongside the base 2001 service documentation
Component and System Documentation
The 2002–2004 Yamaha TDM900 supplementary service manual documents the technical integration of engine, chassis, and advanced electrical systems. The content describes the function of the ECU load control, the three-way catalytic converter, and the air induction system, providing a deep dive into the fuel injection architecture. Major sections focus on diagnostic procedures for the immobilizer unit, including key ID registration, system-wide circuit checks, and troubleshooting pathways for the starting system and lighting components.
Specifications and Reference Values
Technical data previews include the front fork travel of 150 mm, idle engine speed of 1,100–1,200 r/min, and the standard intake vacuum pressure of 33–36 kPa. The fuel pump relief valve is documented to open between 441 and 637 kPa. Intake air temperature sensor resistance values and coolant temperature sensor characteristics are charted for performance verification. This official 82-page Yamaha OEM publication defines the maintenance scope for the TDM900 platform, documenting ignition timing, fuel delivery, and electrical circuit standards for the 5PS1-series build.
Note: This page is a contents overview for the manual. It does not provide repair or diagnostic instructions. An official 82-page Yamaha OEM supplementary service manual documenting technical specifications, fuel injection, electrical, and chassis data for the 2002–2004 TDM900 motorcycle lineup.
Document Reference: Yamaha Motor Co., Ltd. 5PS1-AE1, 5PS1-AE2, 5PS1-AE3
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