🏷️ Basic Information

Make:

Yamaha

Model:

TDM 850

Year:

1996

Chassis Code:

4TX (specific to this generation/model variant)

Engine Code:

4TX-00

👋 Introduction

Segment:

Sport Touring / Adventure Motorcycle

Target Audience:

Enthusiasts seeking versatile performance for commuting, touring, and light off-road use.

Competitors 1996:

Honda Transalp, Suzuki V-Strom (later models), Kawasaki KLR650 (different category but similar intent).

Engine Configuration:

Parallel-twin, four-stroke, liquid-cooled, DOHC, 5 valves per cylinder (pentad valve technology).

Frame Design:

Deltabox-style aluminum frame for rigidity and light weight.

Suspension Type:

Long-travel suspension with adjustable front forks and rear monoshock, suitable for varied terrain.

Braking System:

Powerful dual front disc brakes and a single rear disc for confident stopping power.

📋 Manual Details

Primary Coverage:

Complete service, repair, and maintenance for the 1996 Yamaha TDM 850.

Secondary Coverage:

Troubleshooting, diagnostics, electrical schematics, torque specifications, adjustments.

Pages:

Approximately 300-400 pages (typical for a comprehensive service manual of this era).

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Digital PDF (Searchable and Printable)

📖 Manual Coverage

Engine:

Detailed breakdown of the 3VD 849cc parallel-twin engine, including top-end, bottom-end, cooling system, lubrication.

Fuel System:

Carburetor system (Mikuni CV carbs), fuel pump, fuel tank, fuel lines.

Ignition System:

CDI ignition, spark plugs, ignition coils, timing.

Transmission:

5-speed gearbox, clutch assembly (wet multi-plate), shift mechanism, lubrication.

Chassis Frame:

Frame construction, steering head, swingarm, rear suspension (monoshock).

Suspension:

Front telescopic forks (adjustable preload and rebound damping), rear monoshock absorber (adjustable preload and rebound damping).

Brakes:

Front dual hydraulic disc brakes with dual-piston calipers, rear hydraulic disc brake with single-piston caliper, brake fluid specifications.

Electrical System:

Wiring diagrams, lighting system, starting system, charging system (alternator, regulator/rectifier), battery, fuses, switches, instrumentation.

Wheels Tires:

Wheel specifications, tire sizes, recommended pressures.

Bodywork:

Fairing, fuel tank, seat, fenders, minor body panel removal and installation.

Maintenance:

Routine checks, oil changes, filter replacements, chain adjustment, brake fluid flush, coolant flush, spark plug replacement.

Engine Repair:

Valve clearance adjustment, piston/cylinder inspection, camshaft replacement, crankshaft inspection, sealing ring replacement.

Carburetor Rebuild:

Disassembly, cleaning, reassembly, jetting adjustments, synchronization.

Suspension Service:

Fork seal replacement, fork oil change and level adjustment, rear shock absorber service (where applicable).

Brake System Service:

Pad replacement, caliper overhaul, master cylinder service, bleeding procedures.

Electrical Troubleshooting:

Diagnostic procedures for starting, charging, lighting, and ignition circuits.

Clutch Service:

Friction plate inspection and replacement, spring replacement.

Wheel Bearing Replacement:

Front and rear wheel bearing service.

Diagnostic Tools:

Emphasis on standard workshop tools, specialized Yamaha tools (with part numbers where applicable), and multimeter usage.

Diagnostic Techniques:

Step-by-step troubleshooting guides for common and uncommon issues, symptom-based diagnosis.

Rebuild Level:

Comprehensive coverage for complete engine rebuilds, transmission overhauls, and major component overhauls.

Specifications:

Detailed torque specifications for all fasteners, engine clearances, suspension settings, electrical resistance values.

📊 Manual Specifications

File Type:

PDF

Searchability:

Fully text-searchable for quick information retrieval.

Printable:

Printable pages, allowing for hard copy reference.

Image Resolution:

High-resolution images and diagrams for clarity.

Digital Binding:

N/A (Digital Format)

Digital Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, four-stroke, DOHC, parallel-twin, 5 valves per cylinder

Displacement:

849 cc

Bore X Stroke:

92.0 mm x 64.0 mm

Compression Ratio:

9.2:1

Horsepower:

Approx. 75 HP @ 7500 RPM (claimed at crankshaft)

Torque:

Approx. 76 Nm (56 lb-ft) @ 5500 RPM (claimed at crankshaft)

Carburetors:

Two Mikuni BSR36 CV (Constant Velocity) carburetors

Fuel Capacity:

20 Liters (5.3 US gal)

Ignition Type:

Digital CDI (Capacitor Discharge Ignition)

Cooling Method:

Liquid-cooled

Oil Capacity:

3.5 Liters (with filter change)

Recommended Oil Type:

Yamalube 4 (or equivalent) 10W-40 API SG or higher (specific viscosity may vary based on climate)

🔧 Transmission

Type:

Constant mesh 5-speed

Clutch Type:

Wet, multi-plate

Final Drive:

O-ring sealed chain

Transmission Oil Type:

Yamalube 10W-30 API SE, SF, or SG (specific capacity in manual)

📐 Dimensions

Length:

Approx. 2,230 mm (87.8 in)

Width:

Approx. 820 mm (32.3 in)

Height:

Approx. 1,345 mm (52.9 in)

Wheelbase:

Approx. 1,500 mm (59.1 in)

Ground Clearance:

Approx. 180 mm (7.1 in)

Dry Weight:

Approx. 190 kg (419 lbs)

Wet Weight:

Approx. 215 kg (474 lbs) (with all fluids)

Front Tire Size:

110/80R18 M/C 58H

Rear Tire Size:

130/80R17 M/C 65H

Front Wheel:

Cast aluminum 18-inch

Rear Wheel:

Cast aluminum 17-inch

🛡️ Safety Features

Safety Certification:

N/A (Motorcycle safety ratings are typically not standardized like automobiles)

Braking:

Dual front disc brakes, single rear disc brake, braided stainless steel lines (potentially aftermarket, but stock were robust).

Lighting:

Halogen headlight, taillight, turn signals.

💡 Technology Features

Infotainment System:

N/A (Analog instrumentation typical for the era)

Electronic Aids:

N/A (No ABS, traction control, or other electronic rider aids)

🔧 Maintenance

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Oil Filter Change Interval:

With every oil change (6,000 km / 3,700 miles).

Valve Clearance Check Interval:

Every 24,000 km (15,000 miles).

Spark Plug Replacement Interval:

Every 10,000 km (6,200 miles) or as needed.

Air Filter Cleaning Interval:

Every 6,000 km (3,700 miles), inspect and clean as needed.

Engine Oil Grade:

Yamalube 4 (or equivalent) 10W-40 API SG or higher.

Brake Fluid Type:

DOT 4

Coolant Type:

High-quality ethylene glycol-based coolant with corrosion inhibitors (50% solution).

Fork Oil Type:

Yamaha No. 10 fork oil or equivalent (SAE 10W).

Carburetor Issues:

Pilot jet clogging, needle wear, vacuum slide diaphragm degradation (common on CV carbs of this era).

Electrical Issues:

Rotor/stator failure, regulator/rectifier overheating, wiring harness degradation at stress points.

Engine Component Wear:

Cam chain tensioner failure (potential for rattle or engine damage if ignored), valve guide wear over high mileage.

Suspension Wear:

Fork seal leaks, rear shock absorber seal failure/loss of damping.

Clutch Wear:

Slipping clutch due to worn friction plates, especially if ridden aggressively or used for heavy touring.

📚 Vehicle History

Manufacturer:

Yamaha Motor Company, Ltd. - Known for performance, innovation, and reliability in motorcycles and marine products.

Generation 1 Start:

The TDM 850 was first introduced in 1991. This 1996 model represents the second generation (often referred to as the '4TX' model) which received significant updates, including styling, chassis enhancements, and revised suspension.

Key Updates 1996:

Introduction of the Deltabox aluminum frame, revised fairing and bodywork, upgraded front suspension (adjustable), and a larger fuel tank compared to the first generation.

Production Years Mk2:

1996-2001

Manufacturing Location:

Japan

🏆 Awards & Recognition

Industry Acclaim:

While specific awards for the 1996 model year are not prominently documented, the TDM 850 series was widely praised for its versatility, comfortable ergonomics for long-distance riding, and robust parallel-twin engine character, earning it a dedicated following in the sport-touring segment.