This manual provides comprehensive workshop service and repair information for the TDM850, covering production years 1991 through 1995. The TDM850 is a versatile sport touring motorcycle known for its parallel-twin, liquid-cooled 849 cc engine, delivering approximately 80-85 HP. Its robust engineering and dual-purpose design make it suitable for a variety of riding conditions. This manual aims to preserve the performance and longevity of your TDM850 by offering factory-level detail and clear, step-by-step instructions for all maintenance and repair tasks.
The scope of this workshop service repair manual is extensive, encompassing all major systems of the TDM850. It includes detailed coverage of the engine, fuel system, cooling system, clutch, lubrication, chassis, suspension, steering, brakes, and electrical systems. You will find procedures for scheduled maintenance, fluid changes, component inspections, complete disassembly and reassembly, and troubleshooting common mechanical and electrical issues. With hundreds of photos, illustrations, and detailed drawings, this manual is an indispensable resource for owners, mechanics, and technicians seeking to maintain, repair, or restore their TDM850.
Years Covered:
1991, 1992, 1993, 1994, 1995
Engine Code Range:
Likely starting with 4TX or similar, specific to the TDM850 generation
Chassis Code Range:
Likely 4TX or similar, specific to the TDM850 generation
Category:
Sport Touring Motorcycle
Target Audience:
Motorcyclists seeking to maintain and repair their Yamaha TDM850, from enthusiasts to professional mechanics
Positioning Statement:
The TDM850 manual provides essential, factory-authorized information for preserving the performance and longevity of this versatile dual-purpose machine, offering a cost-effective alternative to professional servicing for many tasks.
Content Depth:
Factory original detail, comprehensive coverage of all major systems, clear step-by-step instructions.
Accessibility:
Instant PDF download, print-on-demand flexibility, accessible on multiple devices.
Usage Flexibility:
Allows printing of specific pages or the entire manual as needed.
Primary Coverage:
Complete workshop service and repair for Yamaha TDM850 motorcycles
Geographic Coverage:
Assumed global, factory specifications
Estimated Pages:
Hundreds (exact count not specified but implied by 'hundreds of pages')
Type:
Workshop Service Repair Manual
Delivery Method:
Instant Download (Post-Payment)
Engine:
General Information, Fuel System, Cooling System, Engine Top End, Clutch, Lubrication System, Engine Removal/Installation, Crankshaft/Transmission
Chassis And Suspension:
Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame
Electrical:
Electrical System, Wiring Diagrams, Troubleshooting
Appendix:
Includes supplementary information and potentially specifications not covered in main chapters.
Maintenance:
Scheduled maintenance, fluid changes, component inspections
Repair:
Step-by-step repair procedures for all covered systems, complete disassembly guidance
Troubleshooting:
Diagnostic procedures, troubleshooting guides for common issues, electrical system diagnostics
Diagnostic Features:
Troubleshooting sections combined with detailed wiring diagrams.
Depth:
Comprehensive factory-level detail, suitable for both DIY and professional mechanics
Diagnostic Capabilities:
Detailed guidance on diagnosing mechanical and electrical faults
Rebuild Procedures:
Covers complete disassembly and reassembly of major components
Compatibility:
Windows and Mac OS
Requirements:
Adobe PDF Reader
Portability:
Can be saved to hard drive, burned to CD-ROM, or printed.
Printability:
Printable without restriction, individual pages or entire manual
Visuals:
Hundreds of photos and illustrations, detailed drawings, enlarged insets
Binding:
Digital Download (printable to user's preference)
Paper Type:
N/A (Digital)
Configuration:
Parallel-twin, four-stroke
Displacement:
849 cc (cubic centimeters)
Bore X Stroke:
92.0 mm x 75.0 mm (typical for this model)
Cooling System:
Liquid-cooled
Valve Train:
DOHC, 4 valves per cylinder
Horsepower Estimated:
Approximately 80-85 HP (at crankshaft, varies by specific market tune)
Torque Estimated:
Approximately 75-80 Nm (at crankshaft, varies by specific market tune)
Carburetion:
Dual Keihin CV carburetors (e.g., CVK36)
Fuel Delivery:
Gravity feed from fuel tank
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity Estimated:
Approx. 20 Liters (5.3 US Gallons)
Type:
Constant mesh, 5-speed
Clutch Type:
Wet, multiple-disc, cable-actuated
Final Drive:
O-ring sealed chain drive
Dry Weight Estimated:
Approximately 194 kg (428 lbs)
Wet Weight Estimated:
Approximately 215 kg (474 lbs)
Payload Capacity Estimated:
Dependent on rider and luggage, typically around 180-200 kg (400-440 lbs)
Certification:
CE, EPA (market dependent)
Braking System Front:
Dual 298mm discs with 2-piston calipers
Braking System Rear:
245mm disc with 2-piston caliper
Lighting:
Halogen headlight, LED tail light (later models)
Dashboard:
Analog speedometer, tachometer, odometer, trip meter, engine temperature gauge, fuel level warning light, neutral indicator.
ABS:
Not available on this model generation.
Bluetooth:
Not available on this model generation.
Oil Change:
Every 3,000-5,000 km or 6 months (refer to manual for specific interval)
Spark Plug Inspection:
Every 6,000-10,000 km
Valve Clearance Check:
Every 12,000-18,000 km (critical for performance)
Engine Oil Type:
Yamalube 10W-40 or equivalent API SG or higher motorcycle oil (specific viscosity depends on climate, refer to manual)
Coolant Type:
Yamaha-specific permanent type antifreeze, mixed 50/50 with distilled water
Fork Oil Type:
Yamaha's recommended fork oil or equivalent SAE 10W (specific quantity per leg required)
Carburetor Sync:
Carburetors can go out of sync, requiring regular adjustment for smooth running.
Cam Chain Tensioner:
The automatic cam chain tensioner can sometimes fail, leading to rattling noises. Manual conversion is a common aftermarket solution.
Charging System:
Older models may experience stator or rectifier/regulator failures, impacting battery charging.
Fuel Tap:
Vacuum-operated fuel taps can sometimes leak or fail to operate correctly.
Heritage:
Yamaha Motor Corporation, known for innovation and performance in motorcycles.
Introduction:
The TDM850 was first introduced in 1991, representing Yamaha's foray into the 'supermoto' or 'sport touring' segment with its unique styling and V-twin-like parallel twin engine.
Updates During Period:
Minor updates often included cosmetic changes, suspension tuning, and emissions control refinements across the 1991-1995 production run.
Manufacturing Origin:
Japan (likely)
Award Type:
N/A (No specific awards mentioned in provided text, focus is on the manual's utility)
