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Yamaha XTZ750 1989-1997 Workshop Service Manual Repair

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The Yamaha XTZ750 Super Ténéré, produced from 1989 to 1997, is a distinguished dual-sport motorcycle engineered for adventure and long-distance touring. Building on Yamaha's rich off-road heritage, this first-generation model,...
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Type: Motorcycle
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Yamaha XTZ750 1989-1997 Workshop Service Manual RepairYamaha XTZ750 1989-1997 Workshop Service Manual RepairYamaha XTZ750 1989-1997 Workshop Service Manual RepairYamaha XTZ750 1989-1997 Workshop Service Manual Repair
The Yamaha XTZ750 Super Ténéré, produced from 1989 to 1997, is a distinguished dual-sport motorcycle engineered for adventure and long-distance touring. Building on Yamaha's rich off-road heritage, this first-generation model, chassis code 3LD, offers a compelling blend of performance and durability, making it suitable for both paved roads and challenging terrain. Its parallel-twin engine, complemented by capable suspension and braking systems, ensures a reliable and comfortable riding experience for adventure riders and touring enthusiasts. This comprehensive workshop service manual serves as an essential guide for maintaining, troubleshooting, and repairing the Yamaha XTZ750 Super Ténéré. Covering a wide array of systems including the engine, transmission, chassis, suspension, brakes, and electrical components, the manual provides detailed procedures for routine maintenance, component overhauls, and diagnostics. With step-by-step instructions and technical specifications, this resource empowers owners and technicians to keep the motorcycle in optimal condition, ensuring its longevity and performance.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
XTZ750
Model Nickname:
Super Ténéré
Model Variant:
XTZ750
Generation
Generation:
First Generation
Codes
Chassis Code:
3LD
👋 Introduction
Market Position
Segment:
Dual-sport / Adventure Motorcycle
Target Audience:
Adventure riders, long-distance touring, off-road enthusiasts
Competitive Analysis
Key Competitors:
Honda Africa Twin (XRV650/750), Suzuki DR750S/DR800S, BMW R80/100GS
Key Features
Vehicle Description:
The Yamaha XTZ750 Super Ténéré is a robust dual-sport motorcycle known for its versatility, capable of handling both paved roads and off-road terrain. It was designed for long-distance travel and adventure touring, offering a blend of performance, comfort, and durability.
Manual Value Proposition:
This workshop manual is an indispensable resource for owners and technicians, providing comprehensive guidance for maintaining, troubleshooting, and repairing the XTZ750. Its detailed instructions and diagrams enable users to perform tasks ranging from routine servicing to major engine work, saving time and money on professional labor.
📋 Manual Details
Coverage Areas
Coverage Years:
1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997
Page Count
Estimated Page Count:
Hundreds of pages (specific number not provided, typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, disassembly, assembly, tuning, cooling system, lubrication system, fuel system, ignition system, exhaust system
Transmission:
Clutch, gearbox, final drive (chain and sprockets), troubleshooting, maintenance
Chassis And Suspension:
Frame, front suspension (forks), rear suspension (shock absorber, swingarm), bearings, adjustments
Brakes:
Front and rear brake systems, hydraulic components, pad replacement, bleeding, troubleshooting
Electrical System:
Wiring diagrams, lighting system, ignition system, charging system (alternator, regulator/rectifier), starter system, battery, fuses, diagnostics
Fuel System:
Carburetor identification, disassembly, cleaning, adjustment, fuel pump, fuel lines
Bodywork And Trim:
Fairing removal and installation, seat, fuel tank, fenders, paneling
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, spark plug service, air filter cleaning/replacement, brake fluid checks, tire pressure checks
Repair Procedures:
Step-by-step instructions for all major component repairs and replacements
Troubleshooting:
Diagnostic guides for common problems, symptom-based troubleshooting charts
Overhaul Procedures:
Detailed instructions for complete engine rebuilds, transmission overhauls, and suspension component overhauls
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical values, part numbers
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and advanced DIY mechanics; covers everything from basic maintenance to full engine rebuilds and electrical diagnostics.
📊 Manual Specifications
File Format
Format:
PDF
Requirements:
Adobe PDF Reader, WinRAR
Print Quality
Printability:
Full Printable
Zoom Functionality:
YES
Binding Type
Binding:
Digital (N/A for PDF)
Paper Type
Paper Type:
Digital (N/A for PDF)
Delivery
Delivery Method:
Instant Download
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, DOHC, parallel-twin
Displacement:
749 cc
Bore X Stroke:
89.0 mm x 60.0 mm
Compression Ratio:
9.5:1
Power Output Ps:
65 PS @ 6,500 rpm (approximate, may vary by market)
Power Output Kw:
48 kW @ 6,500 rpm (approximate, may vary by market)
Torque Nm:
71.4 Nm @ 5,500 rpm (approximate, may vary by market)
Fuel System
Carburetion:
Dual Mikuni BSW36 carburetors
Fuel Type:
Unleaded gasoline, minimum 91 octane
Lubrication System
Oil Type:
Yamalube 4 (or equivalent SAE 10W-40, API SE, SF, SG type)
Oil Capacity With Filter Change:
2.6 Liters
Oil Capacity Without Filter Change:
2.4 Liters
Oil Capacity Total:
3.1 Liters
🔧 Transmission
Standard
Type:
Constant mesh 5-speed sequential
Clutch:
Wet, multiple disc
Final Drive:
O-ring sealed chain, 525 pitch
Features
Gear Ratios:
Specific ratios detailed in the manual (typically includes 1st through 5th gear ratios and final drive ratio)
Transmission Oil Type:
Yamalube Gear Oil (or equivalent SAE 80 API GL-4 type)
Transmission Oil Capacity:
0.9 Liters
📐 Dimensions
Exterior
Length:
2215 mm
Width:
810 mm
Height:
1440 mm
Wheelbase:
1465 mm
Weights
Dry Weight:
198 kg
Wet Weight:
217 kg (approximate, with fluids and full tank)
Fuel Tank Capacity:
20 Liters (including 5-liter reserve)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycles typically do not have NHTSA/Euro NCAP ratings)
Active Features
Braking System:
Dual front disc brakes, single rear disc brake
Suspension Design:
Telescopic front forks, Monocross rear suspension with adjustable shock absorber for improved handling and stability
Passive Features
Lighting:
Halogen headlight for improved visibility
💡 Technology Features
Infotainment
Infotainment System:
None (This era of motorcycle focused on mechanicals, not digital integration).
Driver Assistance
Rider Aids:
None (ABS was not a common feature on adventure bikes of this vintage).
Connectivity
Connectivity Features:
None
Instrumentation
Dashboard:
Analog speedometer and tachometer, fuel gauge, odometer, trip meter, indicator lights (high beam, neutral, oil pressure, turn signal, etc.)
🔧 Maintenance
Service Intervals
Initial Service:
1000 km (check and adjust chain tension, check fluid levels, check brake operation)
Periodic Oil Change:
Every 4000 km or annually
Periodic Air Filter Service:
Every 8000 km (clean/replace)
Periodic Spark Plug Service:
Every 10000 km (inspect/replace)
Periodic Valve Clearance Check:
Every 16000 km
Fluid Specifications
Engine Oil:
Yamalube 4 (or equivalent SAE 10W-40, API SE, SF, SG type)
Brake Fluid:
DOT 4
Coolant:
Mixture of 50% permanent type antifreeze and 50% distilled water
Known Issues
Common Wear Items:
Clutch plates, fork seals, swingarm bearings, rear shock absorber seals
Electrical Gremlins:
Some models may experience aging electrical connectors or regulator/rectifier issues over time; manual helps diagnose.
Engine Wear:
While generally robust, high-mileage engines may require top-end rebuilds (piston rings, valve guides); manual provides full procedures.
📚 Vehicle History
Brand Heritage
Yamaha Offroad Legacy:
Yamaha has a long and successful history in off-road and adventure motorcycling, dating back to the early days of the Dakar Rally. The XTZ line builds on this heritage, combining Yamaha's engineering prowess with the demands of world travel.
Model Evolution
Xtz Lineage:
The XTZ750 Super Ténéré was Yamaha's flagship adventure touring motorcycle of its era, directly competing with other large-displacement dual-sport machines. It represented Yamaha's commitment to the adventure market.
Production
Production Period:
1989-1997
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The XTZ750 was well-regarded in its segment for its robust build, comfortable ergonomics for long distances, and capable performance, often praised by motorcycle journalists for its adventure touring credentials.
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