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Yamaha XTZ750 1989-1997 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Yamaha Model: XTZ750 Codes Engine Codes: 2KF, 3TS Generation First Generation Years: 1989 Last Generation Years: 1997 👋 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: 425 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: PDF 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: N/A. 🔧 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.
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Yamaha XTZ750 1989-1997 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
XTZ750
Codes
Engine Codes:
2KF, 3TS
Generation
First Generation Years:
1989
Last Generation Years:
1997
👋 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:
425
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:
PDF
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:
N/A.
🔧 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.
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