Vehicle Segment:
Sport Touring Motorcycle
Key Competitors Circa 1999:
Honda VFR800, Kawasaki GTR1000, Triumph Trophy 900/1200, Ducati ST2/ST4.
Moto Type:
Parallel-twin, liquid-cooled, DOHC, 4-stroke engine with a distinctive 90-degree crankpin offset (or similar arrangement for this generation) providing a unique torque delivery and character. Known for its robust engine and capable chassis, blending sport and touring abilities.
Manual Utility:
This supplementary manual provides critical factory-level detail for maintenance, repair, and troubleshooting, enhancing the owner's ability to maintain the TDM850 to factory standards, especially for a model year that may have increasing availability of spare parts becoming a consideration.
Primary Coverage:
Supplementary Factory Service, Repair, and Workshop procedures for the Yamaha TDM850.
Specific Systems Covered:
Engine (internal components, lubrication, cooling, ignition, fuel system), Chassis, Suspension (front and rear), Brakes (front and rear), Electrical System (wiring diagrams, components), Drivetrain, Carburetion, Exhaust System, Frame, Bodywork.
Estimated Pages:
N/A (Digital PDF, page count varies based on PDF reader zoom and display settings)
Type:
Supplementary Factory Service / Repair / Workshop Manual
Delivery Format:
Digital PDF Download
Engine Internals:
Detailed procedures for engine disassembly, inspection, and reassembly of components such as pistons, rings, connecting rods, crankshaft, cylinder head, valves, valve train (camshafts, lifters, valve springs, valve guides), oil pump, and bearings. Includes information on machining, balancing, and clearances.
Fuel System:
Comprehensive coverage of the carburetor system, including disassembly, cleaning, adjustment (air screw settings), diaphragm replacement, fuel pump, fuel filter, and associated fuel lines and fittings. Also includes intake manifold and air seals.
Ignition System:
Details on ignition timing, spark plugs, spark plug wires, ignition coils, and related electrical components. Troubleshooting for ignition-related issues.
Lubrication System:
Information on oil pump operation, oil pan, oil seals, and oil changes. Includes fluid specifications and capacities.
Cooling System:
Details on the radiator, radiator fan, oil radiator (oil cooling), coolant hoses, and fan shroud. Procedures for coolant changes and flushing.
Transmission Drivetrain:
Coverage of transmission fluid changes, clutch components (pressure plate, clutch plates, clutch shoes, clutch case, clutch master/slave cylinders, clutch lines), flywheel, and possibly transfer case components (if applicable to this specific model variant). Information on clutch replacement and adjustment.
Braking System:
Procedures for brake pad replacement, brake shoe replacement, rotor replacement, brake fluid changes, and brake hose inspection/replacement. Includes details on brake caliper maintenance and hydraulic system bleeding.
Suspension Steering:
Details on front forks (oil changes, seal replacement), rear shock absorber, and steering system components. Includes information on wheel bearings and alignment.
Electrical Wiring:
Extensive wiring diagrams, troubleshooting guides for electrical issues, component identification (sensors, relays, switches, starter motor, alternator), and battery maintenance. Includes engine harness and main wire harness.
Exhaust System:
Information on muffler, downpipe, headers, catalytic converter replacement, exhaust gaskets, and heat wrap.
Routine Maintenance:
Oil changes, transmission fluid changes, spark plug replacement, air filter replacement, tire rotation, brake fluid replacement, coolant changes, and general lubrication.
Troubleshooting:
Diagnosing and resolving common issues related to engine performance, starting problems, electrical faults, braking issues, and chassis components.
Major Repairs:
Complete engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls, and electrical system repairs.
Component Replacement:
Step-by-step instructions for replacing virtually all listed parts and assemblies, from minor fasteners and seals to major engine and chassis components.
Technical Specifications:
Torque specifications for critical fasteners, fluid capacities, recommended fluid types, electrical specifications, engine clearances, and dimensional data.
Depth:
Comprehensive factory-level detail, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic maintenance to complete engine and chassis overhauls.
Engine Type:
849cc Liquid-Cooled DOHC Parallel-Twin
Bore X Stroke:
92.0 mm x 63.8 mm (typical for this generation)
Compression Ratio:
Approx. 9.2:1 - 9.5:1 (typical for this generation)
Horsepower:
Approx. 80-85 HP @ 7500-8000 RPM (typical for this generation)
Torque:
Approx. 76-80 Nm @ 6000-6500 RPM (typical for this generation)
Carburetor:
Dual Mikuni CV (Constant Velocity) Carburetors, likely 38mm (e.g., VM38).
Fuel Capacity:
Approx. 18 Liters (4.7 US Gallons)
Ignition Type:
Digital TCI (Transistor Controlled Ignition)
Oil Capacity With Filter:
Approx. 2.7 Liters (2.8 US Quarts)
Oil Type Specification:
Yamalube 10W-40 or equivalent API SG (or higher) JASO MA certified motorcycle oil.
Oil Change Interval:
Every 5,000-6,000 km (3,000-3,700 miles) or 6 months, whichever comes first.
Spark Plug Replacement:
Every 10,000-12,000 km (6,000-7,500 miles).
Chain Maintenance:
Regular cleaning and lubrication every 500-1,000 km (300-600 miles) and tension adjustment as needed.
Coolant Type:
Ethylene glycol-based, permanent type antifreeze mixed with distilled water (typically 50/50 ratio).
Brake Fluid Type:
DOT 4 (preferred) or DOT 3.
Carburetor Sync:
Carburetors may require periodic syncing for optimal performance, especially with age and mileage.
Cam Chain Tensioner:
Some models may experience wear on the cam chain tensioner, leading to rattling noise. Manual provides inspection and replacement procedures.
Rear Shock ABSorber:
Over time, the original rear shock may lose damping effectiveness. Manual covers rebuild or replacement procedures.
