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Yamaha TDM850 TDM 850 1996 1997 1998 1999 Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: TDM850 Model Designation: TDM 850 Generation Generation Code: 1st Generation (4TX/3VD) Codes Internal Model Codes: Likely 3VD (early), 4TX (later) 👋 Introduction Market...
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Type: Motorcycle
Vendor:
Sku: 389497
Yamaha TDM850 TDM 850 1996 1997 1998 1999 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TDM850
Model Designation:
TDM 850
Generation
Generation Code:
1st Generation (4TX/3VD)
Codes
Internal Model Codes:
Likely 3VD (early), 4TX (later)
👋 Introduction
Market Position
Motorcycle Type:
Sport Touring Motorcycle
Target Audience:
Motorcyclists seeking versatility for commuting, touring, and spirited riding, emphasizing practicality and reliability.
Competitive Analysis
Key Competitors:
Honda Transalp, Kawasaki KLR650, Suzuki V-Strom (later generations).
Key Features
Engine Layout:
Parallel-twin, crossplane crankshaft (unique for its time in this segment), offering a distinctive torque character.
Design Philosophy:
Combines the performance of a sportbike with the comfort and practicality of a touring machine, often described as a 'supermoto' inspired adventure tourer.
Suspension Travel:
Long-travel suspension, contributing to its off-road capability and comfortable ride over varied terrain.
Braking Performance:
Dual front disc brakes with opposed piston calipers, offering strong stopping power.
📋 Manual Details
Coverage Areas
Model Years Covered:
1996, 1997, 1998, 1999
Page Count
Total Pages:
209
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed coverage of the 849cc parallel-twin engine, including disassembly, assembly, timing, lubrication, cooling, and fuel systems.
Transmission:
Coverage of the gearbox, clutch operation, and related components.
Chassis And Suspension:
Comprehensive details on frame, forks, rear shock absorber, swingarm, and steering components.
Braking System:
Information on front and rear brake systems, including hydraulic lines, calipers, master cylinders, and disc wear.
Fuel System:
Detailed coverage of the carburetor system (likely twin Mikuni CV carbs), fuel tank, fuel pump, and fuel lines.
Exhaust System:
Information on the exhaust pipes, mufflers, and emissions control components.
Electrical System
Electrical Components:
Wiring diagrams, ignition system, charging system (stator, regulator/rectifier), lighting, instrumentation, and starter system.
Bodywork And Trim
Body Panels:
Instructions for removal and installation of fairings, fuel tank cover, seat, and other body panels.
Procedures Included
Maintenance:
Regular maintenance tasks, fluid changes, filter replacements, lubrication, and general upkeep.
Troubleshooting:
Diagnostic procedures for common problems, symptom-based troubleshooting guides, and fault finding.
Repair:
Step-by-step repair instructions for all major components and systems.
Disassembly And Assembly:
Detailed procedures for taking apart and reassembling various components and sub-assemblies.
Adjustments:
Instructions for clutch adjustment, throttle cable adjustment, valve clearance adjustment, and carburetor synchronization.
Special Tool Usage:
Reference to and illustrations of specific tools required for certain repair operations.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to major component overhauls and diagnostics. Suitable for both DIY mechanics and professional technicians.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printability:
Yes, all pages are printable.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Quality:
N/A (Digital PDF)
Software Requirements
Reader:
Adobe Reader
Compatibility:
Windows, Mac, Linux OS
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, DOHC, parallel-twin
Displacement:
849 cc (849cc)
Bore X Stroke:
92.0 mm x 63.8 mm
Compression Ratio:
9.2:1 (typical for this generation)
Performance
Horsepower:
Approximately 80 HP at 7,500 RPM (claimed)
Torque:
Approximately 74 Nm (55 ft-lb) at 6,000 RPM (claimed)
Fuel System
Carburetion:
Twin Mikuni CV (Constant Velocity) carburetors (e.g., BST36) with accelerator pump.
Fuel Capacity:
Approximately 20 Liters (5.3 US gal)
🔧 Transmission
Standard
Transmission Type:
5-speed manual
Features
Drive Type:
Chain drive
Clutch Type:
Wet, multi-disc, cable-actuated
📐 Dimensions
Exterior
Length:
Approximately 2,155 mm (84.8 in)
Width:
Approximately 770 mm (30.3 in)
Height:
Approximately 1,270 mm (50.0 in)
Weights
Dry Weight:
Approximately 197 kg (434 lbs)
Wet Weight:
Approximately 215 kg (474 lbs)
Load Capacity:
Refer to manual for specific limits, typically around 180-200 kg including rider and luggage.
🛡️ Safety Features
Ratings
Crash Safety:
N/A (Motorcycle specific safety is primarily rider-focused and component-based, not typically rated like cars).
Active Features
Braking System:
Dual front hydraulic disc brakes, single rear hydraulic disc brake.
Suspension Geometry:
Designed for stability and predictable handling.
Passive Features
Lighting:
Halogen headlamp, integrated turn signals, taillight/stoplight.
Frame Construction:
Steel diamond frame, providing a robust structure.
💡 Technology Features
Infotainment
Dashboard Instrumentation:
Analog speedometer, tachometer, fuel gauge, odometer, trip meter, warning lights (oil pressure, neutral, high beam, turn signals).
Driver Assistance
ABS:
ABS was not a standard or widely available option for this model year.
Connectivity
Bluetooth Usb:
Not applicable for this era of motorcycle.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 5,000-7,500 km or annually, whichever comes first (refer to manual for precise interval).
Valve Clearance:
Initial check at 1,000 km, then every 10,000-15,000 km (refer to manual for precise interval).
Fluid Specifications
Engine Oil Type:
API SG or higher, JASO MA certified 10W-40 or 20W-50 (check manual for specific viscosity based on temperature).
Engine Oil Capacity:
Approximately 2.7 L (with filter change) / 2.5 L (without filter change) (verify with manual).
Coolant Type:
Permanent Antifreeze/Coolant mixture (ethylene glycol-based) with distilled water (50:50 mix).
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid.
Known Issues
Common Wear Items:
Headlight bulbs, rear brake pads, chain and sprockets, fork seals, battery.
Potential Issues:
Carburetor synchronization drift, occasional electrical connector corrosion, fuel tap diaphragm wear (less common).
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Japan
Yamaha Legacy:
Yamaha has a long history of producing reliable and performance-oriented motorcycles across various segments.
Model Evolution
Tdm Introduction:
The TDM series was introduced in the early 1990s, aiming to bridge the gap between sportbikes and adventure bikes.
Generations:
The 1996-1999 models represent a significant evolution, with the 4TX chassis and other refinements over the earlier 3VD models.
Production
Production Period:
1991-2001 for the 850cc model.
🏆 Awards & Recognition
Recognitions
Model Reputation:
Highly regarded for its durability, reliability, and unique character, making it a popular choice for long-distance touring and adventure riding.
Ratings
Owner Satisfaction:
Generally high, with owners appreciating its ruggedness and capability.
Certifications
Emissions Compliance:
Compliant with relevant emissions standards for its model years.
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