Yamaha XTZ750 1989-1997 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Yamaha Model: XTZ750 Super Ténéré Model Code: XTZ750 (specific chassis codes may vary by market, not provided in source) Generation Generation: First Generation Codes Vin Decoder Reference: Not specified in product information, standard Yamaha VIN structure applies. 👋 Introduction Market Position Category: Adventure Touring Motorcycle Target Audience: Long-distance touring, off-road capability, adventure riders. Competitive Analysis Key Competitors Era: Honda Africa Twin (XRV650/750), BMW R80GS/R100GS, Suzuki DR750/DR800 Big. Key Features Engine Configuration: Parallel-twin, liquid-cooled, DOHC. Frame Design: Steel diamond frame with integral subframe. Suspension Travel: Long-travel suspension for off-road capability. Fuel Capacity: Generous fuel tank for extended range. 📋 Manual Details Coverage Areas Covered Years: 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 Covered Models: All XTZ750 Super Ténéré styles Page Count Estimated Pages: Hundreds (exact count not specified) Manual Type Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Full disassembly and reassembly, cylinder head, piston, crankshaft, lubrication system, cooling system, valve timing. Fuel System: Carburetor assembly, cleaning, adjustment, fuel pump, fuel lines, fuel tank. Ignition System: Ignition timing, ignition coil, CDI unit, spark plugs. Electrical System: Wiring diagrams, charging system (stator, regulator/rectifier), battery, lighting, starting system, instrumentation. Transmission Drivetrain: Clutch operation and adjustment, gearbox inspection and repair, final drive (chain and sprockets). Suspension Steering: Front forks (disassembly, seal replacement, oil levels, spring rates), rear shock absorber, steering head bearings. Braking System: Front and rear brake caliper overhaul, brake disc inspection, brake pad replacement, brake fluid bleeding, master cylinder. Chassis Frame: Frame inspection, swingarm, footpegs, seats, bodywork (fairings, tank cover). Wheels Tires: Wheel bearing inspection and replacement, tire pressure, tire wear. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, spark plug checks, air filter cleaning/replacement. Troubleshooting: Systematic diagnostic procedures for common and uncommon faults, fault codes (if applicable). Component Repair: Detailed step-by-step instructions for repairing or replacing all major components. Overhaul Rebuild: Complete engine and gearbox overhaul procedures. Electrical Diagnostics: Troubleshooting wiring issues, testing electrical components, understanding wiring diagrams. Torque Specifications: Critical torque values for fasteners throughout the motorcycle. Technical Depth Depth: Comprehensive, factory-level detail suitable for professional mechanics and experienced DIY enthusiasts. Illustrations: Hundreds of detailed illustrations, drawings, and photos. Special Tools: Identification and usage of any specialized tools required for specific procedures. 📊 Manual Specifications File Format Format: PDF Compatibility: Windows, Mac OS. Print Quality Printability: Fully printable, all pages. Binding Type Binding: Digital Download (user printable, can be bound after printing). Paper Type Paper Type Recommendation: N/A (Digital) Software Requirements Reader: Adobe PDF Reader. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, DOHC, parallel-twin. Displacement: 749 cc (approx.) Bore X Stroke: 81 mm x 73 mm (approx.) Compression Ratio: 9.5:1 (approx.) Performance Horsepower Hp: Approx. 65-70 HP @ 7500 RPM (market dependent) Torque Lb-Ft: Approx. 65 Nm (48 lb-ft) @ 6000 RPM (market dependent) Fuel System Carburetor Type: Twin Mikuni CV (Constant Velocity) carburetors Carburetor Size: 36 mm (approx.) Lubrication System Oil Capacity W Filter: Approx. 3.0 Liters (specific part number for oil filter should be referenced in manual). Cooling System Coolant Capacity: Approx. 1.6 Liters (specific coolant type should be referenced in manual). 🔧 Transmission Standard Transmission Type: Constant mesh 5-speed Clutch Type: Wet, multi-disc, cable operated Features Final Drive: O-ring sealed chain drive. Transmission Oil Capacity: Approx. 1.0 Liter (specific transmission oil type should be referenced in manual). 📐 Dimensions Exterior Overall Length: Approx. 2290 mm (90.2 in) Overall Width: Approx. 870 mm (34.3 in) Overall Height: Approx. 1430 mm (56.3 in) Weights Dry Weight: Approx. 205 kg (452 lbs) Wet Weight: Approx. 232 kg (511 lbs) (with fluids) Max Load Capacity: Not specified in product information, typical for this class is ~200kg rider + luggage. Wheels Tires Front Tire Size: 90/90-21 M/C 54S Rear Tire Size: 130/80-17 M/C 65S Wheel Bolt Pattern: Not applicable (spoked wheels with axle nuts). 🛡️ Safety Features Ratings Crash Test Ratings: Not applicable for motorcycles of this era. Active Features Braking System Type: Dual disc front, single disc rear. Brake Calipers Front: Dual piston calipers (specific brand/model not specified, likely Brembo or similar). Brake Disc Diameter Front: Approx. 260 mm Passive Features Lighting: Halogen headlight, LED/incandescent tail and brake lights. Instrumentation: Analog speedometer, tachometer, fuel gauge, engine temperature warning light, neutral indicator. 💡 Technology Features Infotainment Infotainment System: None (basic analog instrumentation). Driver Assistance ABS: Not equipped. Connectivity Connectivity Features: None. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual (typically every 5,000 - 10,000 km or 3,000 - 6,000 miles). Spark Plug Check Interval: Refer to manual (typically every 10,000 - 15,000 km or 6,000 - 9,000 miles). Valve Clearance Check Interval: Refer to manual (typically every 20,000 - 30,000 km or 12,000 - 18,000 miles). Fluid Specifications Engine Oil Type: Refer to manual for specific...
Approx. 3.0 Liters (specific part number for oil filter should be referenced in manual).
Cooling System
Coolant Capacity:
Approx. 1.6 Liters (specific coolant type should be referenced in manual).
🔧 Transmission
Standard
Transmission Type:
Constant mesh 5-speed
Clutch Type:
Wet, multi-disc, cable operated
Features
Final Drive:
O-ring sealed chain drive.
Transmission Oil Capacity:
Approx. 1.0 Liter (specific transmission oil type should be referenced in manual).
📐 Dimensions
Exterior
Overall Length:
Approx. 2290 mm (90.2 in)
Overall Width:
Approx. 870 mm (34.3 in)
Overall Height:
Approx. 1430 mm (56.3 in)
Weights
Dry Weight:
Approx. 205 kg (452 lbs)
Wet Weight:
Approx. 232 kg (511 lbs) (with fluids)
Max Load Capacity:
Not specified in product information, typical for this class is ~200kg rider + luggage.
Wheels Tires
Front Tire Size:
90/90-21 M/C 54S
Rear Tire Size:
130/80-17 M/C 65S
Wheel Bolt Pattern:
Not applicable (spoked wheels with axle nuts).
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not applicable for motorcycles of this era.
Active Features
Braking System Type:
Dual disc front, single disc rear.
Brake Calipers Front:
Dual piston calipers (specific brand/model not specified, likely Brembo or similar).
Brake Disc Diameter Front:
Approx. 260 mm
Passive Features
Lighting:
Halogen headlight, LED/incandescent tail and brake lights.
Instrumentation:
Analog speedometer, tachometer, fuel gauge, engine temperature warning light, neutral indicator.
💡 Technology Features
Infotainment
Infotainment System:
None (basic analog instrumentation).
Driver Assistance
ABS:
Not equipped.
Connectivity
Connectivity Features:
None.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual (typically every 5,000 - 10,000 km or 3,000 - 6,000 miles).
Spark Plug Check Interval:
Refer to manual (typically every 10,000 - 15,000 km or 6,000 - 9,000 miles).
Valve Clearance Check Interval:
Refer to manual (typically every 20,000 - 30,000 km or 12,000 - 18,000 miles).
Fluid Specifications
Engine Oil Type:
Refer to manual for specific viscosity (e.g., 10W-40, 20W-50) and API classification (e.g., SG or higher).
Brake Fluid Type:
DOT 4 recommended (refer to manual for confirmation).
Coolant Type:
Permanent antifreeze, ethylene glycol-based, with corrosion inhibitor (refer to manual for exact specification).
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, fork seals.
Potential Electrical Issues:
Aging wiring harness, stator failure (though generally robust).
Carburetor Issues:
Vacuum slide diaphragm wear, carb synchronization drift over time.
📚 Vehicle History
Brand Heritage
Yamaha Motorcycles:
Yamaha Motor Company is a Japanese manufacturer of motorcycles, marine products, and other motorized products. Renowned for innovation and performance.
Model Evolution
Super Tenere Lineage:
The XTZ750 was a significant model in Yamaha's adventure touring lineup, building on the legacy of earlier dual-sport and trail bikes, and preceding the larger displacement TDM and later XT1200Z Super Ténéré models.
Production
Production Period:
1989-1997
Manufacturing Location:
Japan (primary)
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
Generally praised for its robust build, off-road capability, and touring comfort for its era. Often cited as a reliable long-distance machine.
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