Yamaha XTZ750 1989-1997 Workshop Repair Service Manual

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Typ: Motorcycle

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Art.-Nr: 66382

Stichworte: 1989 1990 1991 1992 1993 1994 1995 1996 1997 Marine Motorcycle Sterndrive XTZ750 Yamaha

Produktvarianten

Beschreibung

This document pertains to the XTZ750, a dual-purpose adventure touring motorcycle produced from 1989 to 1997. Known for its robust parallel-twin, 4-stroke engine with DOHC and 5 valves per cylinder, the XTZ750 was engineered for both long-distance touring and off-road capability, featuring long-travel suspension and dual front disc brakes. Its design philosophy emphasized reliability and performance, making it a competitive option in its segment alongside models like the Honda Africa Twin and Suzuki DR750/800 Big. This comprehensive Workshop Repair Service Manual, available in English, provides detailed guidance for maintaining and repairing the XTZ750 across its production years. It covers a wide array of systems including engine mechanicals, fuel, ignition, lubrication, exhaust, electrical, transmission, chassis, suspension, brakes, and bodywork. The manual offers step-by-step instructions for routine maintenance, diagnostics, repairs, overhauls, tune-ups, and component installation, ensuring owners and technicians can effectively manage the vehicle's upkeep and address potential issues.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XTZ750

Codes

Engine Codes:

2KF, 3TS

Generation

First Generation Years:

Last Generation Years:

👋 Introduction

Market Position

Market Segment:

Dual-purpose adventure touring motorcycle.

Competitive Analysis

Key Competitors:

Honda Africa Twin (XRV750), Suzuki DR750/800 Big, Kawasaki KLR650.

Key Features

Engine Type:

Parallel-twin, 4-stroke, DOHC, 5 valves per cylinder.

Suspension Type:

Long-travel telescopic front forks and Monocross rear suspension.

Design Philosophy:

Designed for long-distance touring and off-road capability.

📋 Manual Details

Coverage Areas

Years Covered:

1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997

Page Count

Page Count:

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full engine disassembly, assembly, overhaul, troubleshooting, and repair.

Fuel System:

Carburetor overhaul, adjustment, fuel pump, fuel lines, and tank maintenance.

Ignition System:

CDI unit, spark plugs, ignition timing, and troubleshooting.

Lubrication System:

Oil pump, oil passages, oil filter, and lubrication system maintenance.

Exhaust System:

Exhaust pipes, muffler, and catalytic converter (if applicable) inspection and maintenance.

Electrical System:

Wiring diagrams, starter motor, generator, battery, lighting system, and electronic components.

Transmission:

Gearbox disassembly, assembly, inspection, and troubleshooting.

Chassis And Suspension:

Front forks, rear shock absorber, swingarm, steering system, and frame inspection.

Brakes:

Front and rear brake systems, hydraulic lines, calipers, discs, and master cylinders.

Wheels And Tires:

Wheel bearing service, tire pressure, and tire replacement guidelines.

Bodywork And Trim:

Fairings, seat, fuel tank, and other body components removal and installation.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, and general inspection procedures.

Diagnostics:

Troubleshooting common problems with detailed diagnostic flowcharts and symptom analysis.

Repair:

Step-by-step instructions for component repair and replacement.

Overhaul:

Comprehensive rebuild procedures for major components like the engine and transmission.

Tune Ups:

Procedures for carburetor synchronization, valve adjustments, and ignition timing.

Installation:

Instructions for installing various components and accessories.

Technical Depth

Depth:

Extensive, covering everything from routine maintenance to full engine and transmission rebuilds, suitable for professional technicians.

📊 Manual Specifications

File Format

File Format:

Print Quality

Printability:

Yes, pages are printable.

Binding Type

Binding Type:

Digital (PDF Download)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, parallel-twin, 5 valves per cylinder

Displacement:

749 cc

Bore X Stroke:

81.0 mm x 73.3 mm

Compression Ratio:

9.5:1

Performance

Horsepower:

Approx. 60-65 HP (specific to market and year)

Torque:

Approx. 60-65 Nm (specific to market and year)

Fuel System

Carburetors:

Dual Mikuni BSR34 CV carburetors

Fuel Tank Capacity:

20 Liters (approx. 5.3 US gallons)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Optional

Clutch Type:

Wet, multi-disc

Features

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Overall Length:

Approx. 2235 mm (88.0 in)

Overall Width:

Approx. 875 mm (34.4 in)

Overall Height:

Approx. 1345 mm (52.9 in)

Wheelbase:

Approx. 1470 mm (57.9 in)

Weights

Dry Weight:

Approx. 180 kg (397 lbs)

Wet Weight:

Approx. 202 kg (445 lbs)

Cargo

Cargo Capacity:

N/A (Designed for luggage carrying with aftermarket racks/bags)

🛡️ Safety Features

Ratings

Safety Standards:

Meets relevant motorcycle safety standards of its era.

Active Features

Braking System:

Dual front disc brakes, single rear disc brake.

Lighting:

Halogen headlight, taillight, turn signals.

Passive Features

Frame Construction:

Steel diamond frame.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic analogue instrumentation).

Driver Assistance

Assistance Features:

N/A (Focus on mechanical reliability and rider input).

Connectivity

Connectivity Options:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km or 12 months, whichever comes first (refer to manual for exact specifications).

Valve Clearance Check:

Every 12,000 km or 24 months.

Air Filter Cleaning:

Every 6,000 km, or more frequently in dusty conditions.

Fluid Specifications

Engine Oil Type:

Yamalube 4 (or equivalent SAE 10W-40, API SE, SF, SG, or SH, JASO MA).

Engine Oil Capacity:

3.1 Liters without filter change, 3.3 Liters with filter change.

Brake Fluid Type:

DOT 4.

Coolant Type:

Ethylene glycol-based antifreeze, 50% mixture with distilled water.

Known Issues

Common Problems:

Cam chain noise, voltage regulator failure, carb icing (in cold weather), starter clutch wear. (Manual provides troubleshooting for these).

📚 Vehicle History

Brand Heritage

Yamaha Legacy:

Yamaha has a long history of producing reliable and performance-oriented motorcycles, including successful adventure and off-road models.

Model Evolution

Xtz750 Introduction:

Introduced in 1989 as Yamaha's answer to the growing adventure touring market, building on the success of its XT series.

Updates:

Received minor updates throughout its production run, focusing on refinements and emissions compliance.

Production

Production Period:

1989-1997

Manufacturing Location:

Japan (primarily)

🏆 Awards & Recognition

Recognitions

Model Acclaim:

Well-regarded for its robust engine and long-distance comfort during its production era.