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Yamaha TRX850 1996 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: TRX850 Year: 1996 Codes Engine Code Identifier: Likely based on the TDM850 engine series, specific code not provided but implied by model designation. 👋 Introduction Market Position Class: Sport Touring Motorcycle Competitive Analysis Key Competitors Era: Competed with other parallel-twin sport-touring bikes of the mid-1990s, offering a blend of performance and versatility. Key Features Unique Selling Points: Distinctive styling, parallel-twin engine with strong mid-range torque, capable chassis for both sporty riding and touring. 📋 Manual Details Coverage Areas Covered Models: Yamaha TRX850 1996 (all styles covered) Page Count Estimated Page Count: Hundreds of pages (exact count not specified, but described as complete). Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Fuel system, Cooling system, Engine top end, Clutch, Engine lubrication system, Crankshaft/Transmission Chassis Systems: Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame Electrical Systems: Electrical System (including troubleshooting and wiring diagrams) Procedures Included Maintenance And Repair: Step-by-step instructions for repair and service, based on complete disassembly. Includes detailed substeps, notes, cautions, and warnings. Technical Depth Depth: Complete disassembly and reassembly procedures, suitable for both do-it-yourselfers and experienced mechanics. Offers in-depth detail with photos and illustrations. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Printable without restriction (entire manual or selected pages). Binding Type Binding: Digital download (user printable for desired binding). Paper Type Paper Format: Digital (user printable on desired paper type). Software Requirements Reader Requirement: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve, parallel-twin Displacement: 849 cc Performance Horsepower: Approximately 80-85 HP (claimed, varies by market). Torque: Approximately 75-80 Nm (claimed, varies by market). Fuel System Carburetion: Dual Mikuni carburetors (likely 36mm or similar, specific size in manual). Fuel Delivery: Carburetor Engine Lubrication System Oil Type: Yamaha recommends Yamalube or equivalent 4-stroke motorcycle oil (specific viscosity and API classification available in manual, e.g., 10W-40 or 20W-50). Oil Capacity: Approximately 3.0 - 3.5 liters with filter change (exact figure in manual). Cooling System Coolant Type: Permanent type antifreeze coolant, mixed 1:1 with distilled water (specific Yamaha coolant or equivalent mentioned in manual). Engine Top End Valve Clearance Intake: Specified in manual, typically around 0.10-0.18 mm cold. Valve Clearance Exhaust: Specified in manual, typically around 0.13-0.21 mm cold. 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Optional Optional Transmissions: None Features Clutch Type: Wet, multi-plate Transmission Oil Type: Same as engine oil (Yamaha recommends Yamalube or equivalent 4-stroke motorcycle oil). Transmission Oil Capacity: Included in overall engine oil capacity, specific transmission gear oil level check procedure outlined. 📐 Dimensions Exterior Length: Approx. 2,155 mm (84.8 in) Width: Approx. 770 mm (30.3 in) Height: Approx. 1,215 mm (47.8 in) Weights Dry Weight: Approx. 183 kg (403.4 lbs) Wet Weight: Approx. 201 kg (443.1 lbs) (with all fluids) Wheels Tires Front Tire Size: 120/70 ZR17 M/C (58W) Rear Tire Size: 160/60 ZR17 M/C (69W) Front Wheel Type: Cast aluminum Rear Wheel Type: Cast aluminum Wheelbase: Approx. 1,435 mm (56.5 in) 🛡️ Safety Features Ratings Safety Ratings: Motorcycle safety ratings are not typically standardized like automobiles. Focus is on rider safety features and handling. Active Features Braking System: Dual front disc brakes, single rear disc brake. Specifics on caliper type and disc diameter in manual. Suspension Front: Telescopic fork, adjustable preload and rebound damping (specifics in manual). Suspension Rear: Monoshock with linkage, adjustable preload and rebound damping (specifics in manual). Passive Features Lighting: Halogen headlamp, LED tail light (typical for the era), turn signals. 💡 Technology Features Infotainment Instrumentation: Analog speedometer and tachometer, fuel gauge, odometer, trip meter, neutral indicator, high beam indicator, oil pressure warning light, temperature warning light. Driver Assistance Rider Aids: None in the modern sense (e.g., no ABS, traction control). Connectivity Connectivity Features: N/A (basic motorcycle electronics). 🔧 Maintenance Service Intervals Oil Change Interval: Recommended every 3,000 - 5,000 km (1,800 - 3,000 miles) or 6 months, whichever comes first (detailed in manual). Air Filter Cleaning Interval: Recommended every 6,000 - 10,000 km (3,700 - 6,200 miles) or annually (detailed in manual). Spark Plug Replacement Interval: Recommended every 12,000 - 18,000 km (7,500 - 11,000 miles) (specific plug type and gap in manual). Fluid Specifications Brake Fluid Type: DOT 4 (or DOT 3 as minimum, DOT 4 recommended. Exact specification in manual). Coolant Specification: Ethylene glycol-based permanent antifreeze coolant, mixed 1:1 with distilled water. Known Issues Common Wear Items: Cam chain tensioner (can become noisy), carburetor synchronization, regulator/rectifier unit failures (common on many bikes of this era). Maintenance Focus: Regular oil changes, chain lubrication and adjustment, brake fluid flush, carburetor cleaning and tuning are crucial for longevity. 📚 Vehicle History Brand Heritage Brand Focus: Yamaha's legacy includes performance motorcycles across various categories, from sportbikes to cruisers and off-road. Model Evolution Predecessors: Influenced...
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Yamaha TRX850 1996 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TRX850
Year:
1996
Codes
Engine Code Identifier:
Likely based on the TDM850 engine series, specific code not provided but implied by model designation.
👋 Introduction
Market Position
Class:
Sport Touring Motorcycle
Competitive Analysis
Key Competitors Era:
Competed with other parallel-twin sport-touring bikes of the mid-1990s, offering a blend of performance and versatility.
Key Features
Unique Selling Points:
Distinctive styling, parallel-twin engine with strong mid-range torque, capable chassis for both sporty riding and touring.
📋 Manual Details
Coverage Areas
Covered Models:
Yamaha TRX850 1996 (all styles covered)
Page Count
Estimated Page Count:
Hundreds of pages (exact count not specified, but described as complete).
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Fuel system, Cooling system, Engine top end, Clutch, Engine lubrication system, Crankshaft/Transmission
Chassis Systems:
Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame
Electrical Systems:
Electrical System (including troubleshooting and wiring diagrams)
Procedures Included
Maintenance And Repair:
Step-by-step instructions for repair and service, based on complete disassembly. Includes detailed substeps, notes, cautions, and warnings.
Technical Depth
Depth:
Complete disassembly and reassembly procedures, suitable for both do-it-yourselfers and experienced mechanics. Offers in-depth detail with photos and illustrations.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Printable without restriction (entire manual or selected pages).
Binding Type
Binding:
Digital download (user printable for desired binding).
Paper Type
Paper Format:
Digital (user printable on desired paper type).
Software Requirements
Reader Requirement:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 4-valve, parallel-twin
Displacement:
849 cc
Performance
Horsepower:
Approximately 80-85 HP (claimed, varies by market).
Torque:
Approximately 75-80 Nm (claimed, varies by market).
Fuel System
Carburetion:
Dual Mikuni carburetors (likely 36mm or similar, specific size in manual).
Fuel Delivery:
Carburetor
Engine Lubrication System
Oil Type:
Yamaha recommends Yamalube or equivalent 4-stroke motorcycle oil (specific viscosity and API classification available in manual, e.g., 10W-40 or 20W-50).
Oil Capacity:
Approximately 3.0 - 3.5 liters with filter change (exact figure in manual).
Cooling System
Coolant Type:
Permanent type antifreeze coolant, mixed 1:1 with distilled water (specific Yamaha coolant or equivalent mentioned in manual).
Engine Top End
Valve Clearance Intake:
Specified in manual, typically around 0.10-0.18 mm cold.
Valve Clearance Exhaust:
Specified in manual, typically around 0.13-0.21 mm cold.
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Optional
Optional Transmissions:
None
Features
Clutch Type:
Wet, multi-plate
Transmission Oil Type:
Same as engine oil (Yamaha recommends Yamalube or equivalent 4-stroke motorcycle oil).
Transmission Oil Capacity:
Included in overall engine oil capacity, specific transmission gear oil level check procedure outlined.
📐 Dimensions
Exterior
Length:
Approx. 2,155 mm (84.8 in)
Width:
Approx. 770 mm (30.3 in)
Height:
Approx. 1,215 mm (47.8 in)
Weights
Dry Weight:
Approx. 183 kg (403.4 lbs)
Wet Weight:
Approx. 201 kg (443.1 lbs) (with all fluids)
Wheels Tires
Front Tire Size:
120/70 ZR17 M/C (58W)
Rear Tire Size:
160/60 ZR17 M/C (69W)
Front Wheel Type:
Cast aluminum
Rear Wheel Type:
Cast aluminum
Wheelbase:
Approx. 1,435 mm (56.5 in)
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycle safety ratings are not typically standardized like automobiles. Focus is on rider safety features and handling.
Active Features
Braking System:
Dual front disc brakes, single rear disc brake. Specifics on caliper type and disc diameter in manual.
Suspension Front:
Telescopic fork, adjustable preload and rebound damping (specifics in manual).
Suspension Rear:
Monoshock with linkage, adjustable preload and rebound damping (specifics in manual).
Passive Features
Lighting:
Halogen headlamp, LED tail light (typical for the era), turn signals.
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer and tachometer, fuel gauge, odometer, trip meter, neutral indicator, high beam indicator, oil pressure warning light, temperature warning light.
Driver Assistance
Rider Aids:
None in the modern sense (e.g., no ABS, traction control).
Connectivity
Connectivity Features:
N/A (basic motorcycle electronics).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Recommended every 3,000 - 5,000 km (1,800 - 3,000 miles) or 6 months, whichever comes first (detailed in manual).
Air Filter Cleaning Interval:
Recommended every 6,000 - 10,000 km (3,700 - 6,200 miles) or annually (detailed in manual).
Spark Plug Replacement Interval:
Recommended every 12,000 - 18,000 km (7,500 - 11,000 miles) (specific plug type and gap in manual).
Fluid Specifications
Brake Fluid Type:
DOT 4 (or DOT 3 as minimum, DOT 4 recommended. Exact specification in manual).
Coolant Specification:
Ethylene glycol-based permanent antifreeze coolant, mixed 1:1 with distilled water.
Known Issues
Common Wear Items:
Cam chain tensioner (can become noisy), carburetor synchronization, regulator/rectifier unit failures (common on many bikes of this era).
Maintenance Focus:
Regular oil changes, chain lubrication and adjustment, brake fluid flush, carburetor cleaning and tuning are crucial for longevity.
📚 Vehicle History
Brand Heritage
Brand Focus:
Yamaha's legacy includes performance motorcycles across various categories, from sportbikes to cruisers and off-road.
Model Evolution
Predecessors:
Influenced by and shares mechanical components with the Yamaha TDM850, which predates the TRX850.
Successors:
While not a direct successor in name, Yamaha's sport-touring segment evolved with models like the FJR1300.
Production
Production Years:
Introduced for the 1996 model year, production ran for several years in the late 1990s and early 2000s.
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
Received positive reviews for its torquey engine and versatile performance, though styling was sometimes polarizing.
Ratings
Reliability Reputation:
Generally considered reliable Yamaha engineering, with common wear items being manageable with regular maintenance.
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