immobilizer YAMAHA TDM 900 2005 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2005, Model line: TDM 900, Model: YAMAHA TDM 900 2005Pages: 88, PDF Size: 3.93 MB
Page 2 of 88
EAU26941
DECLARATION of CONFORMITY
We
Hereby declare that the product:
is in compliance with following norm(s) or documents: Type-designation:
5SL-00, 5VS-00, 5VX-00, 3HT-00, 5UX-00, 5UX-10, 5KS-00 and 5KS-10
R&TTE Directive(1999/5/EC)
EN300 330-2 v1.1.1(2001-6), EN60950(2000)
Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC)
Place of issue: Shizuoka, Japan
Date of issue: Aug. 1
st 2002 Kind of equipment: IMMOBILIZER Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan Company: MORIC CO., LTD.
Kazuji Kawai
representative name and signature
Page 6 of 88
TABLE OF CONTENTS
SAFETY INFORMATION
...................1-1
DESCRIPTION
...................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS
........................................3-1
Immobilizer system ..........................3-1
Main switch/steering lock .................3-2
Indicator and warning lights .............3-3
Tachometer unit ...............................3-5
Coolant temperature gauge .............3-6
Multi-function display .......................3-7
Anti-theft alarm (optional) ................3-8
Handlebar switches .........................3-8
Clutch lever ....................................3-10
Shift pedal ......................................3-10
Brake lever ....................................3-10
Brake pedal ...................................3-11
ABS (for ABS models) ...................3-11
Fuel tank cap .................................3-12
Fuel ................................................3-13
Fuel tank breather hose .................3-13
Catalytic converter .........................3-14
Seat ...............................................3-14
Storage compartment ....................3-15
Adjusting the front fork ...................3-15
Adjusting the shock absorber
assembly ....................................3-17Luggage strap holders .................. 3-18
Sidestand ...................................... 3-19
Ignition circuit cut-off system ......... 3-19
PRE-OPERATION CHECKS
.............. 4-1
Pre-operation check list ................... 4-2
OPERATION AND IMPORTANT RIDING
POINTS
............................................... 5-1
Starting the engine .......................... 5-1
Shifting ............................................ 5-2
Tips for reducing fuel
consumption ................................ 5-3
Engine break-in ............................... 5-3
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND MINOR
REPAIR
............................................... 6-1
Owner’s tool kit ................................ 6-1
Periodic maintenance and lubrication
chart ............................................. 6-2
Removing and installing cowlings and
panels .......................................... 6-5
Checking the spark plugs ................ 6-6
Engine oil and oil filter element ....... 6-7
Coolant .......................................... 6-10
Replacing the air filter element ...... 6-12
Adjusting the engine idling
speed ......................................... 6-13
Checking the throttle cable free
play ............................................ 6-14Valve clearance ............................ 6-14
Tires .............................................. 6-15
Cast wheels .................................. 6-17
Adjusting the clutch lever free
play ............................................ 6-18
Adjusting the rear brake light
switch ......................................... 6-19
Checking the front and rear brake
pads ........................................... 6-19
Checking the brake fluid level ....... 6-20
Changing the brake fluid ............... 6-21
Drive chain slack ........................... 6-21
Cleaning and lubricating the drive
chain .......................................... 6-23
Checking and lubricating the
cables ........................................ 6-23
Checking and lubricating the throttle
grip and cable ............................ 6-24
Checking and lubricating the brake
and shift pedals ......................... 6-24
Checking and lubricating the brake
and clutch levers ........................ 6-24
Checking and lubricating the
sidestand ................................... 6-25
Lubricating the rear suspension .... 6-25
Checking the front fork .................. 6-25
Checking the steering ................... 6-26
Checking the wheel bearings ........ 6-27
Battery ........................................... 6-27
Replacing the fuses ...................... 6-28
Replacing a headlight bulb ........... 6-29
Page 15 of 88
3-1
2
34
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU10972
Immobilizer system
This vehicle is equipped with an immo-
bilizer system to help prevent theft by
re-registering codes in the standard
keys. This system consists of the fol-
lowing.
a code re-registering key (with a
red bow)
two standard keys (with a black
bow) that can be re-registered with
new codes
a transponder (which is installed in
the code re-registering key)
an immobilizer unit
an ECU
an immobilizer system indicator
light (See page 3-3.)
The key with the red bow is used to reg-
ister codes in each standard key. Since
re-registering is a difficult process, take
the vehicle along with all three keys to
a Yamaha dealer to have them re-reg-
istered. Do not use the key with the red
bow for driving. It should only be used
for re-registering the standard keys. Al-
ways use a standard key for driving.
CAUTION:
ECA11820
DO NOT LOSE THE CODE
RE-REGISTERING KEY! CON-
TACT YOUR DEALER IMMEDI-
ATELY IF IT IS LOST! If the code
re-registering key is lost, regis-
tering new codes in the stan-
dard keys is impossible. The
standard keys can still be used
to start the vehicle, however if
code re-registering is required
(i.e., if a new standard key is
made or all keys are lost) the en-
tire immobilizer system must be
replaced. Therefore, it is highly
recommended to use either
standard key and keep the codere-registering key in a safe
place.
Do not submerse any key in wa-
ter.
Do not expose any key to exces-
sively high temperatures.
Do not place any key close to
magnets (this includes, but not
limited to, products such as
speakers, etc.).
Do not place heavy items on any
key.
Do not grind any key or alter its
shape.
Do not disassemble the plastic
part of any key.
Do not put two keys of any im-
mobilizer system on the same
key ring.
Keep the standard keys as well
as keys of other immobilizer
systems away from this vehi-
cle’s code re-registering key.
Keep other immobilizer system
keys away from the main switch
as they may cause signal inter-
ference.
1. Code re-registering key (red bow)
2. Standard keys (black bow)
Page 17 of 88
INSTRUMENT AND CONTROL FUNCTIONS
3-3
2
34
5
6
7
8
9
To unlock the steering
Push the key into the main switch, and
then turn it to “OFF” while still pushing
it.
WARNING
EWA10060
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving,
otherwise the electrical systems will
be switched off, which may result in
loss of control or an accident. Make
sure that the vehicle is stopped be-
fore turning the key to “OFF” or
“LOCK”.
EAU33000
(Parking)
The steering is locked, and the taillight
and auxiliary light are on. The hazard
light and turn signal lights can be turned
on, but all other electrical systems are
off. The key can be removed.
The steering must be locked before the
key can be turned to “ ”.
CAUTION:
ECA11020
Do not use the parking position for
an extended length of time, other-
wise the battery may discharge.
EAU11002
Indicator and warning lights
EAU11020
Turn signal indicator light “”
This indicator light flashes when the
turn signal switch is pushed to the left or
right.
1. Push.
2. Turn.
1. Fuel level warning indicator “ ”
2. Turn signal indicator light “ ”
3. High beam indicator light “ ”
4. Neutral indicator light “ ”
5. Engine trouble warning light “ ”
6. Anti-lock Brake System (ABS) warning
light “ ” (for ABS models)
7. Oil level warning light “ ”
8. Immobilizer system indicator light “ ”
12345678
ABS
Page 18 of 88
INSTRUMENT AND CONTROL FUNCTIONS
3-4
1
2
3
4
5
6
7
8
9
EAU11060
Neutral indicator light “”
This indicator light comes on when the
transmission is in the neutral position.
EAU11080
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU11120
Oil level warning light “”
This warning light comes on when the
engine oil level is low.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
NOTE:
Even if the oil level is sufficient, the
warning light may flicker when riding on
a slope or during sudden acceleration
or deceleration, but this is not a mal-
function.
EAU11371
Fuel level warning indicator “”
This fuel level warning indicator starts
flashing when the fuel level drops be-
low approximately 3.5 L (0.92 US gal)
(0.77 Imp.gal).
EAU11500
Engine trouble warning light “”
This warning light comes on or flashes
when an electrical circuit monitoring the
engine is defective. When this occurs,
have a Yamaha dealer check the
self-diagnosis system.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. If the warning light does not come
on for a few seconds, then go off, have
a Yamaha dealer check the electrical
circuit.
EAU11543
ABS warning light “” (for ABS
models)
If this warning light comes on or flashes
while riding, the ABS may be defective.
If this occurs, have a Yamaha dealer
check the system as soon as possible.
(See page 3-11.)
WARNING
EWA10081
If the ABS warning light comes on or
flashes while riding, the brake sys-
tem reverts to conventional braking.
Therefore, be careful not to cause
the wheels to lock during emergen-
cy braking. If the warning light
comes on or flashes while riding,
have a Yamaha dealer check the
brake system as soon as possible.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on or
remains on, have a Yamaha dealer
check the electrical circuit.
EAU32990
Immobilizer system indicator light
“”
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
ABS
Page 19 of 88
INSTRUMENT AND CONTROL FUNCTIONS
3-5
2
34
5
6
7
8
9
When the key is turned to “OFF” and 30
seconds have passed, the indicator
light will start flashing indicating the im-
mobilizer system is enabled. After 24
hours have passed, the indicator light
will stop flashing, however the immobi-
lizer system is still enabled.
NOTE:
This model is also equipped with a
self-diagnosis device for the immobiliz-
er system. If the immobilizer system is
defective, the indicator light will start
flashing a pattern and the odometer/
tripmeter will display a 2-digit code
when the key is turned to “ON”. When
this occurs, have a Yamaha dealer
check the self-diagnosis system. How-
ever, if the indicator light slowly flashes
five times, and then quickly flashes two
times repeatedly, error code 52 will be
displayed. This error could be caused
by signal interference. If this occurs, try
the following.
1. Use the code re-registering key to
start the engine.
NOTE:
Make sure there are no other immobi-lizer keys close to the main switch, and
do not keep more than one immobilizer
key on the same key ring! Immobilizer
system keys may cause signal interfer-
ence, which may prevent the engine
from starting.
2. If the engine starts, turn it off, and
try starting the engine with the
standard keys.
3. If one or both of the standard keys
do not start the engine, take the
vehicle, the code re-registering
key and both standard keys to a
Yamaha dealer and have the stan-
dard keys re-registered.
EAU11911
Tachometer unit
The electric tachometer allows the rider
to monitor the engine speed and keep it
within the ideal power range.
When the key is turned to “ON”, the ta-
chometer needle will sweep once
across the r/min range and then return
to zero r/min in order to test the electri-
cal circuit.
CAUTION:
ECA10031
Do not operate the engine in the ta-
chometer red zone.
Red zone: 8000 r/min and above
1. Tachometer
2. Tachometer red zone
3. Clock
2
3
1
Page 38 of 88
5-1
1
2
3
4
5
6
7
8
9
OPERATION AND IMPORTANT RIDING POINTS
EAU15950
WARNING
EWA10270
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU26801
Starting the engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
The transmission is in the neutral
position.
The transmission is in gear with
the clutch lever pulled and the sid-
estand up.
WARNING
EWA10290
Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-19.
Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
CAUTION:
ECA11781
The following warning lights and in-
dicator light should come on for a
few seconds, then go off.
Oil level warning light
Engine trouble warning light
Immobilizer system indicator
light
ABS warning light (for ABS
models)
If a warning or indicator light does
not go off, see page 3-3 for the corre-
sponding warning and indicator
light circuit check.
2. Shift the transmission into the neu-
tral position.
NOTE:
When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir-
cuit.
3. Start the engine by pushing the
start switch.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
Page 82 of 88
SPECIFICATIONS
8-3
1
2
3
4
5
6
7
8
9Electrical system:
Ignition system:
Transistorized coil ignition (digital)
Charging system:
AC magneto
Battery:
Model:
GT12B-4
Voltage, capacity:
12 V, 10.0 Ah
Headlight:
Bulb type:
Halogen bulb
Bulb voltage, wattage x quantity:
Headlight:
12 V, 55.0 W
×
2
Tail/brake light:
12 V, 5.0 W/21.0 W
×
1
Front turn signal light:
12 V, 10.0 W
×
2
Rear turn signal light:
12 V, 10.0 W
×
2
Auxiliary light:
12 V, 5.0 W
×
1
Meter lighting:
14 V, 2.0 W
×
2
Neutral indicator light:
14 V, 1.2 W
×
1
High beam indicator light:
14 V, 1.4 W
×
1
Oil level warning light:
LEDTurn signal indicator light:
14 V, 1.2 W
×
1
Engine trouble warning light:
14 V, 1.4 W
×
1
ABS warning light:
14 V, 1.4 W
×
1
Immobilizer system indicator light:
LED
Fuses:
Main fuse:
40.0 A
Headlight fuse:
20.0 A
Signaling system fuse:
10.0 A
Ignition fuse:
10.0 A
Radiator fan fuse:
20.0 A
Turn signal light and hazard fuse:
10.0 A
Fuel injection system fuse:
10.0 A
ABS control unit fuse:
10.0 A
ABS motor fuse:
30.0 A
Backup fuse:
10.0 A
Page 85 of 88
INDEX
A
ABS (for ABS models) .............................3-11
ABS warning light (for ABS models) ..........3-4
Air filter element, replacing ......................6-12
Anti-theft alarm (optional) ..........................3-8
Auxiliary light bulb, replacing ...................6-31
B
Battery .....................................................6-27
Brake and clutch levers, checking and
lubricating ..............................................6-24
Brake and shift pedals, checking and
lubricating ..............................................6-24
Brake fluid, changing ...............................6-21
Brake fluid level, checking .......................6-20
Brake lever ..............................................3-10
Brake pedal .............................................3-11
C
Cables, checking and lubricating .............6-23
Care ...........................................................7-1
Catalytic converter ...................................3-14
Clutch lever ..............................................3-10
Clutch lever free play, adjusting ..............6-18
Coolant ....................................................6-10
Coolant temperature gauge .......................3-6
Cowlings and panels, removing and
installing ..................................................6-5
D
Dimmer switch ...........................................3-9
Drive chain, cleaning and lubricating .......6-23
Drive chain slack .....................................6-21
E
Engine break-in .........................................5-3
Engine idling speed .................................6-13
Engine oil and oil filter element ..................6-7Engine stop switch .................................... 3-9
Engine trouble warning light ...................... 3-4
F
Front and rear brake pads, checking....... 6-19
Front fork, adjusting................................. 3-15
Front fork, checking ................................. 6-25
Fuel ......................................................... 3-13
Fuel consumption, tips for reducing .......... 5-3
Fuel level warning indicator ....................... 3-4
Fuel tank breather hose .......................... 3-13
Fuel tank cap ........................................... 3-12
Fuses, replacing ...................................... 6-28
H
Handlebar switches ................................... 3-8
Hazard switch ............................................ 3-9
Headlight bulb, replacing ......................... 6-29
High beam indicator light ........................... 3-4
Horn switch................................................ 3-9
I
Identification numbers ............................... 9-1
Ignition circuit cut-off system ................... 3-19
Immobilizer system.................................... 3-1
Immobilizer system indicator light ............. 3-4
Indicator and warning lights....................... 3-3
K
Key identification number .......................... 9-1
L
Luggage strap holders............................. 3-18
M
Main switch/steering lock .......................... 3-2
Model label ................................................ 9-2
Multi-function display ................................. 3-7
N
Neutral indicator light................................. 3-4
O
Oil level warning light ................................ 3-4
P
Parking ...................................................... 5-4
Part locations ............................................ 2-1
Pass switch ............................................... 3-9
Periodic maintenance and lubrication
chart ........................................................ 6-2
Pre-operation check list............................. 4-2
R
Rear brake light switch, adjusting ........... 6-19
Rear suspension, lubricating ................... 6-25
S
Safety information ..................................... 1-1
Seat ......................................................... 3-14
Shifting ...................................................... 5-2
Shift pedal ............................................... 3-10
Shock absorber assembly, adjusting ...... 3-17
Sidestand ................................................ 3-19
Sidestand, checking and lubricating........ 6-25
Spark plugs, checking ............................... 6-6
Specifications ............................................ 8-1
Starting the engine .................................... 5-1
Start switch................................................ 3-9
Steering, checking................................... 6-26
Storage...................................................... 7-3
Storage compartment.............................. 3-15
Supporting the motorcycle ...................... 6-32
T
Tachometer unit ........................................ 3-5
Tail/brake light bulb, replacing ................ 6-30
Throttle cable free play, checking ........... 6-14
Throttle grip and cable, checking and
lubricating ............................................. 6-24