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User Manuals: Yamaha XTZ750 Dual-Sport Motorcycle
Manuals and User Guides for Yamaha XTZ750 Dual-Sport Motorcycle. We have
2
Yamaha XTZ750 Dual-Sport Motorcycle manuals available for free PDF download: Service Manual, User Manual
Yamaha XTZ750 Service Manual (426 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 40.81 MB
Table of Contents
Index
1
General Information
2
Motorcycle Identification
3
Frame Serial Number
3
Engine Serial Number
3
Important Information
4
Preparation for Removal
4
All Replacement Parts
4
Gaskets, Oil Seals and O-Rings
4
Lock Washers/Plates and Cotter Pins
5
Bearings and Oil Seals
5
Circlips
5
Special Tools for Tune up
6
Special Tools for Engine Service
7
Special Tools for Chassis Service
9
Special Tools for Electrical Components
10
Specifications
12
General Specifications
13
Maintenance Specifications
17
Tightening Torque
22
General Torque Specifications
32
Definition of Units
32
Lubrication Point and Grade of Lubricant
33
Lubrication Diagram
35
Coolant Diagram
40
Cable Routing
41
Periodic Inspection and Adjustment
52
Periodic Maintenance/Lubrication Intervals
54
Seat, Fuel Tank and Cover Removal
56
Seat, Fuel Tank and Cover Installation
57
Engine Valve Clearance Adjustment
58
Intake
63
Exhaust
63
Timing Chain Adjustment
67
Idle Speed Adjustment
67
Throttle Cable Free Play Adjustment
68
Spark Plug Inspection
70
Ignition Timing Check
71
Compression Pressure Measurement
72
Engine Oil Level Inspection
74
Engine Oil Replacement
75
Clutch Adjustment
77
Air Filter Cleaning
78
Carburetor Joint Inspection
79
Fuel Line Inspection
80
Exhaust System Inspection
80
Coolant Level Inspection
81
Coolant Replacement
82
Cooling System Inspection
85
Chassis
86
Front Brake Adjustment
86
Rear Brake Adjustment
87
Brake Fluid Level Inspection
88
Brake Pad Inspection
89
Brake Light Switch Adjustment
89
Air Bleeding (Hydraulic Brake System)
90
Change Pedal Adjustment
91
Drive Chain Slack Adjustment
91
Drive Chain Lubrication
93
Steering Head Adjustment
93
Front Fork Inspection
95
Rear Shock Absorber Adjustment
96
Tire Inspection
97
Wheel Inspection
99
Spokes Inspection and Tightening
100
Cable Inspection and Lubrication
100
Lever and Pedal Lubrication
100
Sidestand Lubrication
101
Rear Suspension Lubrication
101
Electrical
102
Battery Inspection
102
Fuse Inspection
105
Headlight Beam Adjustment
106
Headlight Beam Variation
106
Headlight Bulb Replacement
107
Engine Overhaul
108
Engine Removal
110
Side Covers, Seat, Cowlings and Fuel Tank
110
Engine Oil and Coolant
110
Battery Leads
110
Engine Guard
111
Exhaust Pipes and Muffler
111
Oil Tank
111
Air Filter and Carburetor
112
Radiator
113
Cables and Leads
113
Drive Chain
115
Engine Disassembly
118
Pipes and Hoses
118
Cylinder Head, Cylinder and Pistons
119
Rotor and Starter Drives
122
Clutch
124
Oil Pan, Oil Filter and Oil Strainer
127
Oil Pumps and Timing Chain
128
Balancer Weights
129
Water Pump
131
Crankcase (Lower)
132
Transmission and Shifter
133
Crankshaft
134
Valves and Camshafts
135
Connecting Rods
136
Inspection and Repair Cylinder Head
137
Valve Seat Inspection and Repair
138
Valve and Valve Guide Inspection and Repair
141
Valve Spring Inspection and Repair
142
Camshaft Inspection and Repair
143
Valve Lifter Inspection and Repair
145
Timing Chain, Sprocket and Chain Guide Inspection and Repair
145
Cylinder and Piston Inspection and Repair
145
Piston Ring Inspection and Repair
147
Piston Pin Inspection and Repair
148
Crankshaft and Connecting Rod Inspection and Repair
149
Electric Starter Drive Inspection and Repair
210
Primary Drive Inspection and Repair
211
Clutch Inspection and Repair
211
Transmission and Shifter Inspection and Repair
213
Oil Pump and Strainer Inspection and Repair
215
Oil Delivery Pipes Inspection and Repair
215
Crankcase Inspection and Repair
216
Bearing and Oil Seal Inspection and Repair
216
Circlip and Washer Inspection and Repair
216
Engine Assembly and Adjustment
217
Crankshaft, Piston and Balancer
222
Camshaft, Valve and Timing Chain
223
Transmission
226
Cooling System
253
Radiator Removal
254
Radiator Inspection
254
Radiator Assembly
255
Water Pump Disassembly
257
Water Pump Inspection
258
Water Pump Assembly
258
Thermostat Removal
259
Thermostat Inspection
259
Thermostat Assembly
260
Carburetion
261
Carburetor
262
Section View
263
Carburetor Removal
265
Carburetor Disassembly
266
Carburetor Inspection
268
Carburetor Assembly
270
Carburetor Installation
273
Fuel Level Adjustment
273
Fuel Pump Operation Inspection
274
Fuel Pump Inspection
275
Fuel Pump Assembly
275
Front Wheel
278
Front Wheel Removal
279
Front Wheel Inspection
280
Front Wheel Installation
282
Static Wheel Balance Adjustment
283
Rear Wheel
285
Rear Wheel Removal
286
Rear Wheel Inspection
286
Rear Wheel Installation
287
Front and Rear Brake
289
Brake Pad Replacement
291
Caliper Disassembly
295
Master Cylinder Disassembly
297
Front and Rear Brake Inspection and Repair
298
Air Bleeding
306
Front Fork
307
Front Fork Removal
308
Front Fork Disassembly
309
Front Fork Assembly
312
Front Fork Installation
315
Steering Head and Handlebar
317
Steering Head and Handlebar Removal
318
Steering Head and Handlebar Inspection
321
Rear Shock Absorber and Swingarm
327
Rear Shock Absorber and Swingarm Handling Notes
329
Rear Shock Absorber and Swingarm Notes on Disposal
329
Rear Shock Absorber Removal
330
Swingarm Removal
330
Rear Shock Absorber and Swingarm Inspection
333
Side Clearance Adjustment
335
Rear Shock Absorber Installation
337
Swingarm Installation
337
Drive Chain and Sprockets
341
Drive Chain and Sprockets Removal
342
Drive Chain and Sprockets Inspection
343
Drive Chain and Sprockets Installation
345
XTZ750 Circuit Diagram
348
Electrical Components
350
Checking of Switches
352
Switch Connection as Shown in Manual
352
Checking Switch for Terminal Connection
352
Checking of Bulbs
355
Kinds of Bulbs
355
Checking Bulb Condition
355
Ignition System Circuit Diagram
358
Ignition System Troubleshooting
360
Electrical Starting System Circuit Diagram
368
Starting Circut Operation
370
Electrical Starting System Troubleshooting
371
Starter Motor Does Not Operate
371
Starter Motor
376
Starter Motor Removal
377
Starter Motor Disassembly
377
Starter Motor Inspection and Repair
378
Starter Motor Assembly
379
Starter Motor Installation
380
Charging System Circuit Diagram
382
Charging System Troubleshooting
384
The Battery Is Not Charged
384
Lighting System Circuit Diagram
388
Lighting System Troubleshooting
390
Signal System Circuit Diagram
393
Signal System Troubleshooting
395
Signal System Check
398
Cooling System Circuit Diagram
406
Cooling System Troubleshooting
408
Fan Motor Does Not Move
408
When Engine Is Hot, Temperature Gauge Does Not Move
412
Troubleshooting
415
Starting Failure/Hard Starting
416
Poor Idle Speed Performance
418
Poor Medium and High Speed Performance
418
Faulty Gear Shifting
419
Clutch Slipping/Dragging
419
Overheating or Over-Cooling
420
Faulty Brake
421
Front Fork Oil Leakage and Front Fork Malfunction
421
Instable Handling
422
Faulty Signal and Lighting System
423
XTZ750 Wiring Diagram
425
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Yamaha XTZ750 User Manual (212 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 13.3 MB
Table of Contents
Safety First!
1
Remember
1
Frame and Engine Numbers
2
Identification Numbers
2
Buying Spare Parts
2
Daily (Pre-Ride) Checks
4
Engine/Transmission Oil Level Check
4
TDM850 (1991 to 1995) and XTZ750 Models
4
TDM850 (1996-On) and TRX Models
5
Brake Fluid Level Checks
6
Front Brake Fluid Level
6
Before You Start
6
Rear Brake Fluid Level
7
Coolant Level Check
8
Tyre Tread Depth
9
Tyre Care
9
The Correct Pressures
9
Tyre Checks
9
Routine Maintenance and Servicing
10
Contents
10
Routine Maintenance
11
Specifications
11
Torque Settings
12
Recommended Lubricants and Fluids
12
Component Locations
13
Component Locations
15
Maintenance Schedule
16
Introduction
17
Every 300 Miles (500 Km)
17
Lubrication
18
Hint
18
Every 4000 Miles (6000 Km) or 6 Months
19
Spark Plugs - Check and Adjustment
19
Idle Speed - Check and Adjustment
20
Carburettors - Synchronisation
20
Air Filter - Cleaning
21
Fuel System - Check
22
Engine - Oil Change
22
Filter Cleaning
22
Brake Pads - Wear Check
23
Brake System - Check
23
Clutch - Check and Adjustment
25
Battery - Check
25
Wheels and Tyres - General Check
26
Wheel Bearings - Check
26
Sidestand and Cut-Off Switches - Check
26
Nuts and Bolts - Tightness Check
26
Cooling System - Check
27
Throttle and Choke Cables - Check
27
Throttle Cables
27
Pivot Points
28
Stand, Lever Pivots and Cables - Lubrication
28
Choke Cable
28
Swingarm and Suspension Bearings (XTZ Models) - Re-Greasing
28
Suspension - Check
29
Steering Head Bearings - Freeplay Check and Adjustment
29
Front Suspension
29
Rear Suspension
29
Every 8000 Miles (12,000 Km) or 12 Months
31
Engine - Oil and Filter Change
31
Every 16,000 Miles (24,000 Km) or Two Years
32
Fuel Filter - Renewal (1999 TDM Models)
32
Swingarm and Suspension Bearings (TDM and TRX Models) - Re-Greasing
32
Steering Head Bearings - Lubrication
32
Cooling System - Draining, Flushing and Refilling
33
Refilling
34
Valve Clearances - Check and Adjustment
34
Every 28,000 Miles (42,000 Km)
34
Shim Selection Chart - Inlet Valves
36
Shim Selection Chart - Exhaust Valves
36
Every Four Years
37
Non-Scheduled Maintenance
37
Brake Hoses - Renewal
37
Headlight Aim - Check and Adjustment
37
Cylinder Compression - Check
38
Engine - Oil Pressure Check
38
Front Forks - Oil Change
39
TDM, Trxand 1995 XTZ Models
39
1989 To 1994 XTZ Models
39
Engine, Clutch and Transmission
40
Degrees of Difficulty
40
Cylinder Head
41
Cylinder Block
41
Oil Pump
43
General Information
45
Operations Possible with the Engine in the Frame
45
Operations Requiring Engine Removal
45
Major Engine Repair - General Note
45
Engine Disassembly and Reassembly - General Information
49
Valve Cover - Removal and Installation
50
Camshafts and Followers - Removal, Inspection and Installation
51
Cam Chain Tensioner - Removal, Inspection and Installation
56
Cylinder Head - Removal and Installation
57
Valves/Valve Seats/Valve Guides - Overhaul
59
Cylinder Head and Valves - Disassembly, Inspection and Reassembly
59
Cylinder Block-Removal, Inspection and Installation
62
Pistons - Removal, Inspection and Installation
64
Piston Rings - Inspection and Installation
66
Clutch - Removal, Inspection and Installation
67
Clutch Assembly
69
Clutch Cable - Removal and Installation
73
Starter Clutch and Idle/Reduction Gear - Removal, Inspection and Installation
74
Gearchange Mechanism External Components - Removal, Inspection and Installation
74
Oil Pumps - Removal and Installation
76
Oil Tank - Removal and Installation (1996-On TDM Models and All TRX Models)
79
Balancer Shafts - Removal, Inspection and Installation
81
Cam Chain and Guides - Removal, Inspection and Installation
84
Crankcase Halves - Separation and Reassembly
84
Crankcase Bolts - 1991 to 1995 TDM Models and XTZ Models
85
Crankcase Bolts - 1996-On TDM Models and TRX Models
85
Crankcase Halves - Inspection and Servicing
87
Main and Connecting Rod Bearings - General Information
87
Connecting Rods - Removal, Inspection and Installation
88
Oil Clearance Check
88
Bearing Shell Selection
89
Main Bearing Shell Selection
91
Transmission Shafts and Bearings - Removal and Installation
92
Transmission Shafts - Disassembly, Inspection and Reassembly
93
Input Shaft Reassembly
94
Output Shaft Disassembly
95
Output Shaft Inspection
95
Output Shaft Reassembly
95
Selector Drum and Forks Removal, Inspection and Installation
96
Initial Start-Up after Overhaul
98
Recommended Running-In Procedure
98
Cooling System
99
Radiator Pressure Cap - Check
100
Coolant Reservoir - Removal and Installation
100
Cooling Fan and Cooling Fan Switch - Check and Renewal
101
Coolant Temperature Gauge/Warning Light and Sender - Check and Renewal
102
Coolant Temperature Warning Light (1999 TDM Models)
102
Coolant Temperature Gauge (XTZ, TRX and 1991-98 TDM Models)
102
Sender Check (All Models)
102
All Models
103
Thermostat Housing and Thermostat - Removal, Check and Installation
103
Radiator - Removal and Installation
104
Water Pump - Check, Removal, and Installation
105
Coolant Hoses - Removal and Installation
106
Fuel and Exhaust Systems
107
Fuel Tank and Fuel Tap(S) - Removal and Installation
109
General Information and Precautions
109
Fuel Tank - TDM Models
109
Fuel Tank - TRX Models
110
Fuel Tank - XTZ Models
110
Fuel Tap(S)
110
Fuel Tank - Cleaning and Repair
112
Air Filter Housing - Removal and Installation
112
Idle Fuel/Air Mixture Adjustment - General Information
112
Carburettors - Removal and Installation
113
Carburettor Overhaul - General Information
113
Carburettors Cleaning and Inspection
114
1991 To 1998 TDM Models, All TRX and XTZ Models
114
Ignition System
116
Ignition HT Coils - Check, Removal and Installation
118
Ignitor Unit - Check, Removal and Installation
119
Ignition Timing - General Information and Check
120
Throttle Position Sensor (1996- % on TDM and TRX)- Check, Adjustment and Replacement
120
Frame, Suspension and Final Drive
122
Frame - Inspection and Repair
124
Footrests, Brake Pedal and Gearchange Lever - Removal and Installation
124
Brake Pedal
125
Gearchange Lever
125
Sidestand - Removal and Installation
126
Handlebars and Levers - Removal and Installation
126
Handlebars
126
Forks - Removal and Installation
128
Front Brake Lever
128
Clutch Lever
128
Forks - Disassembly, Inspection and Reassembly
130
1991 To 199S TDM Models
130
1996-On TDM Models and TRX Models
134
XTZ Models
135
Front Fork Components - XTZ Models
136
Steering Stem - Removal and Installation
137
Steering Head Bearings - Inspection and Replacement
139
Rear Shock Absorber - Removal, Inspection and Installation
140
Rear Suspension Linkage (TRX and XTZ Models) - Removal, Inspection and Installation
141
Suspension Linkage and Swingarm Assembly - TRX Models
142
Suspension - Adjustments
143
Front Forks
143
Suspension Linkage and Swingarm Assembly - XTZ Models
143
Bearing Replacement - XTZ Models
146
Bearing Replacement - TDM and TRX Models
146
Swingarm - Inspection and Bearing Replacement
146
Drive Chain - Removal, Cleaning and Installation
147
Endless Type Chain
147
Riveted Link Type Chain
148
Sprockets - Check and Replacement
148
Rear Sprocket Coupling/Rubber Dampers - Check and Replacement
150
Table of Contents
151
Brakes, Wheels and Tyre
151
Brake Pads - Replacement
153
Brake Calipers - Removal, Overhaul and Installation
156
Overhaul
157
Brake Discs - Inspection, Removal and Installation
158
Front Brake Master Cylinder - Removal, Overhaul and Installation
158
Rear Brake Master Cylinder - Removal, Overhaul and Installation
160
Brake Hoses, Pipes and Unions - Inspectionand Replacement
162
Brake System - Bleeding
163
Wheels - Inspection and Repair
163
Front Wheel-Removal and Installation
164
Wheels - Alignment Check
164
Rear Wheel - Removal and Installation
166
Wheel Bearings - Removal, Inspection and Installation
167
Front Wheel Bearings
167
Rear Wheel Bearings
168
Sprocket Coupling Bearing
169
Tyres - General Information and Fitting
169
Common Tyre Sidewall Markings
170
Bodywork
171
Seat - Removal and Installation
172
1996-On TDM Models
172
1991 To 1995 TDM Models
172
TRX Models
172
TDM Models
173
Fainng - Removal and Installation
176
Engine Bashplate (1991-95 TDM and All XTZ) - Removal and Installation
178
Electrical System
179
Starter Motor
180
Battery-Removal, Installation, Inspection and Maintenance
181
Electrical System - Fault Finding
181
Torque Settings
181
Battery - Charging
182
Inspection and Maintenance
182
Fuses - Check and Renewal
183
Lighting System - Check
183
Headlight
183
Tail Light
183
Headlight Bulb and Auxiliary Light Bulb - Renewal
184
Auxiliary Light
184
Brake Light
184
Headlight Assembly - Removal and Installation
185
Brake/Tail Light Bulb - Renewal
185
Hazard Relay (1999 TDM Models)
186
Flasher Relay
186
Tail Light Assembly - Removal and Installation
186
Turn Signal Circuit - Check
186
Turn Signal Bulbs - Renewal
187
Turn Signal Assemblies - Removal and Installation
187
Brake Light Switches - Check and Replacement
188
Circuit Check
188
Switch Replacement
188
Front Brake Lever Switch
188
Instrument Cluster and Speedometer Cable - Removal and Installation
189
Instrument Cluster
189
Speedometer Cable (TRX, XTZ Andterminal and 1991 to 1998 TDM Models)
190
Instruments - Check, Replacement and Bulbs
190
Tachometer
191
Coolant Temperature Gauge (TRX, XTZ and 1991 to 1998 TDM Models)
191
Bulb Renewal
192
Ignition (Main) Switch - Check, Removal and Installation
192
Fuel Gauge (1999 TDM Models)
192
Fuel Gauge and Sender Unit - Check and Replacement (1999 TDM Models)
192
Handlebar Switches - Check
193
Handlebar Switches - Removal and Installation
193
Neutral Switch - Check, Removal and Installation
194
Chock
194
Sidestand Switch - Check and Replacement
195
Clutch Switch - Check and Replacement
195
Diode (XTZ Models) - Check and Replacement
195
Horn - Check and Replacement
197
Starter Relay - Check and Replacement
197
Starter Motor - Removal and Installation
198
Starter Motor - Disassembly, Inspection and Reassembly
199
Charging System Testing - General Information and Precautions
202
Charging System - Leakage and Output Test
202
Output Test
203
Regulator/Rectifier - Check and Replacement
206
Wiring Diagrams
207
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