INDEX GENERAL INFORMATION 3 GEN INFO SPECIFICATIONS @ m 0 |*O ~ N L PERIODIC INSPECTION AND ADJUSTMENT Bi 1B = | > Oo lc ENGINE OVERHAUL ENG COOLING SYSTEM COOL CARBURETION A a elad else Ee TROUBLESHOOTING CARB CHASSIS IcHas — > ELECTRICAL — ELECe ? TRELWe a S IG)GEN INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER ENGINE SERIAL NUMBER IMPORTANT INFORMATION ce ceeee este entre eeT2 PREPARATION FOR REMOVAL.............. ceveeeeeees 1.2 ALL REPLACEMENT PARTS ..........002.0002000eeeeee cee VD GASKET, OIL SEALS, AND O-RINGS .........20000e00eee es 4 LOCK WASHER/PLATES AND COTTER PINS 213 BEARINGS AND OIL SEALS ... 213 CIRCLIPS.. 2... 13 SPECIAL TOOLS ...... FOR TUNE UP ..... FOR ENGINE SERVICE FOR CHASSIS SERVICE FOR ELECTRICAL COMPONENTSMOTORCYCLE IDENTIFICATION GEN ous GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number (4) is stamped into the right side of the steering head. Starting serial number: 3LD-000101 3SC-000101 (E) 3TD-000101 (CH) ENGINE SERIAL NUMBER The engine serial number (7) is stamped into the right side of the engine. Starting serial number: 3LD-000101 3SC-000101 (E) 3TD-000101 (CH) WOT *The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. * Designs and specifications are subject to change without notice.IMPORTANT INFORMATION ES dus IMPORTANT INFORMATION PREPARATION FOR REMOVAL 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. Refer to “SPECIAL TOOL”. 3. When disassembling the machine, keep mat- ed parts together. This includes gears, cylinders, pistons, and other mated parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced 4. During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly rein- stalled 5. Keep away from fire. ALL REPLACEMENT PARTS 1, Use only genuine Yamaha parts for all replace- ments. Use oil and/or grease recommended by Yamaha for assembly and adjustment. Other brands may be similar in function and appearance, but inferior in quality. GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings dur- ing reassembly. Apply grease to the oil seal lips. 12IMPORTANT INFORMATION LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/plates (@) and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened. BEARINGS AND OIL SEALS 1. Install the bearing|s) and oil seal(s) with their manufacturer's marks or numbers facing out- ward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light-weight lithium base grease to the seal lip(s). Oil the bearings liberally when installing. © Oil seal ACAUTION: Do not use compressed air to spin the bear- ings dry. This causes damage to the bearing surfaces. @ Bearing CIRCLIPS 1, All circlips should be inspected carefully be- fore reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip (), make sure that the sharp edged corner (2) is positioned op- posite to the thrust @) it receives. See the sectional view. @ ShaftSPECIAL TOOLS a dus SPECIAL TOOLS The proper special tools are necessary for com- plete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. FOR TUNE UP 1, Inductive tachometer P/N 90890-03113 This tool is needed for detecting engine rpm. 2. Inductive timing light P/N 90890-03109 This tool is necessary for checking ignition timing. 3. Compression gauge P/N 90890-03081 This gauge is used to measure the engine com- pression. 4, Fuel level gauge P/N 90890-01312 This gauge is used to measure the fuel level in the float chamber. 14SPECIAL TOOLS 5. Vacuum gauge P/N 90890-03094 This gauge is needed for carburetor synchroni- zation. FOR ENGINE SERVICE 1. Hexagon wrench (6 mm) P/N 90890-01395 This tool is used to loosen or tighten the cylinder head securing nut. 2. Piston pin puller P/N 90890-01304 This tool is used to remove the piston pin. 3. Universal clutch holder P/N 90890-04086 This tool is used to hold the clutch when remov- ing or installing the clutch boss locknut. 4. Torx wrench (T30) P/N 90890-05245 This tool is used to loosen or tighten the main axle bearing retainer bolt. 1.5SPECIAL TOOLS ee os 5. Rotor holder P/N 90890-01701 This tool is used to hold the rotor. 6. Rotor puller P/N 90890-01362 D Adapter P/N 90890-01382 @ These tools are used to remove the rotor. 7. Valve spring compressor P/N 90890-04019 aoe -@ Attachment P/N 90890-04114 ce -@® These tools are used to remove and install the valve assemblies. 8. Valve guide remover and installer set (5.5 mm) P/N 90890-04016 These tools are used to remove, install and re- bore the valve guide. 9. Valve seat cutter P/N YM-91043 This tool is used to adjust the valve clearance.7 GEN INFO. 10. Plastigage® set “Green” P/N YU-33210 SPECIAL TOOLS This gauge is needed to measure the clearance for the connecting rod bearing and the crankshaft bearing. 11. YAMAHA bond No. 1215 P/N 90890-85505 This sealant (bond) is used for crankcase mating surfaces, etc. 12, Piston ring compressor P/N 90890-04121 This tool is used to compress piston rings when installing the cylinder. 13. Radiator cap tester P/N 90890-01325 . ® Adapter P/N 90890-01352 ........-.022200--@ This tester is used for checking the cooling system. FOR CHASSIS SERVICE 1. T-handle P/N 90890-01326 a se ® Fork damper rod holder (30 mm) P/N 90890-01327 . ae) These tools are used to loosen and tighten the front fork damper rod holding bolt.EN SPECIAL TOOLS nea oS 18 2. Front fork seal driver (weight) P/N 90890-01367 .........06002e ee @D Adapter (43 mm) P/N 90890-01374 0.0.0... seeeeeree ® These tools are used when installing the fork oil seal. 3. Ring nut wrench P/N 90890-01268 ....... wee @D P/N 90890-01403 .. 2 @ This too! is used to loosen and tighten the steer- ing ring nut. FOR ELECTRICAL COMPONENTS 1. Dynamic spark tester P/N 90890-03144 This instrument is necessary for checking the ig- nition system components. 2. Pocket tester P/N 90890-03112 This instrument is invaluable for checking the elec- trical system.GEN INFO ousCHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS MAINTENANCE SPECIFIGATIONS ..... ENGINE . ce CHASSIS... ELECTRICAL...... GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS ........... : 7 seers 220 LUBRICATION POINT AND GRADE OF LUBRICANT...............2-21 LUBRICATION DIAGRAM ........... 2-23 COOLANT DIAGRAM... : See eeee eee eeer eer 2:20) CABLE ROUTING eee eee eee etree eeeet ent 2:25)GENERAL SPECIFICATIONS | SPEC p SPECIFICATIONS GENERAL SPECIFICATIONS Model XTZ750 Model Code Number: 3LD 3SC (E) 3TD (CH) Frame Starting Number: 3L.D-000101 3SC-000101 (E) STD-000101 (CH) Engine Starting Number: | 3LD-000101 | 3SC-000101 (E) 3TD-000101 (CH) Dimensions: Overall Length 2,285 mm (90.0 in) (B)F)(GBNLMED(!) 2,365 mm (92.7 in) (DSKDK)(SFN)(CH) Overall Width 815 mm (32.1 in) Overall Height 1,355 mm (53.3 in) Seat Height 865 mm (34.1 in) Wheelbase 1,505 mm (59.3 in) Minimum Ground Cleararice 240 mm (9.5 in) Basic Weight: | With Oil and Full Fuel Tank 226 kg (498 Ib) Minimum Turning Radius: 2,400 mm (94.5 in) Engine: Engine Type Liquid cooled 4-stroke, DOHC Cylinder Arrangement Forward inclined parallel 2-cylinder Displacement 749 cm* Bore x Stroke 87x63 mm (3.43 x 2.48 in) Compression Ratio 95:1 Compression Pressure 950 kPa (9°5 kg/cm’, 135 psi) Starting System Electric starter Lubrication System: Dry sump Engine Oil Type or Grade: i er ee |.—t SAE 20W40 type SE motor oil SAE 10W30 type SE motor oil —f 0 5 10 18°C 24SPEC GENERAL SPECIFICATIONS Model Engine Oil Capacity: Periodic Oil Change: With Oil Filter Replacement Total Amount Coolant Total Amount: (Including All Routes) Air Filter: Fuel: Type Tank Capacity Reserve Amount XT2750 4.0 L (3.5 Imp qt, 4.2 US qt) 4.1 L (3.6 Imp qt, 4.3 US qt) 4.4 L (3.9 Imp qt, 4.7 US qv) | 1.7L (1.5 Imp at, Dry type element 1.8 US at) | Regular gasoline 26 L (5.7 Imp qt, 6.9 US gal) 5 L (1.1 Imp qt, 1.3 US gal) Carburetor: Type x Quantity Manufacturer Spark Plug: Type Manufacturer Gap Clutch Typ Transmission: Primary Reduction System Primary Reduction Ratio Secondary Reduction System Secondary Reduction Ratio Transmission Type | BDST 38x2 | MIKUNI | DPR8EA-9/X24EPRU-9 NGK/NIPPON DENSO. 0.8~0.9 mm (0.031 ~ 0.035 in) Wet, multiple-dise Spur gear 67/39 (1.718) Chain Drive 46/16 (2.875) Constant mesh 5-speed Manufacturer (Type) Operation Left foot operation Gear Ratio Ist 37/13 (2.846) 2nd . 37/20 (1.850) 3rd 30/21 (1.429) 4th 27/23 (1.174) Sth 28/27 (1.037) Chassis: Frame Type Double cradle Caster Angle 26.5° Trail 101 mm (3.98 in) o = | Tire: Front Rear Type j With tube | With tube Size 90/90-21 54H | 140/80-17 69H BRIDGESTONE «Twa7) BRIDGESTONE (Twas) 22GENERAL SPECIFICATIONS | SPEC PF Model Tire Pressure (Cold Tire): Maximum load” Cold tire pressure Up to 90 kg (198 Ib) load* 90 kg (198 Ib)~ Maximum load* High speed riding “Load is total weight of cargo, rider, passeng xTZ750 184 kg (406 Ib) Front Rear 225 kPa 225 kPa (2.25 kg/em?, 33 psi) | (2.25 kg/om’, 33 psi) 225 kPa 250 kPa (2.25 kg/cm”, 33 psi) (2.5 kg/cm?, 36 psi) 225 kPa 250 kPa (2.25 kg/em®, 33 psi) | (2.5 kg/cm*, 36 psi) fer, and accessories. Brake: Front Brake Type Dual disc brake Operation Right hand operation Rear Brake Type Single disc brake Operation Right foot operation Suspension: Front Suspension Rear Suspension Telescopic fork ‘Swingarm (Link suspention) Shock Absorber: Front Shock Absorber Rear Shock Absorber Coil-Air spring/Oil damper Coil-Gas spring/Oil damper Wheel Travel: Front Wheel Travel Rear Wheel Travel 235 mm (9.25 in) 215 mm (8.46 in) Electrical Ignition System Generator System Battery Type or Model Battery Capacity T.C.1. (Digital) A.C. magneto generator YBI4L-A 12V, 144H Headlight Type: Bulb Wattage x Quantity: Headlight Auxiliary Light Tail/ Brake Light Flasher Light Quartz bulb (Halogen) 12V 55W + 12V 60/55W (D, F, B, S) 12V 45/40W x2 (SF, NL, E, DK, N) 12V 35/35W x2 (I, GB) 12V 4W x1 (D, F, B, S, SF, NL) 12V 4W x2 (E, DK, N) 12V 3W x2 (I) 12V 3.4W x2 (GB) 12V BW/21W x1 12V 21Wx4GENERAL spEciFications | SPEC | Model XTZ750 Indicator Light: Wattage x Quantity “METER LIGHT” | 12V 3.4Wx2 “NEUTRAL” 12V 3.4Wx1 “HIGH BEAM” 12V 3.4Wx1 “TURN” 12V 3.4W x2 24MAINTENANCE SPECIFICATIONS SPEC a MAINTENANCE SPECIFICATIONS ENGINE Model Cylinder Head Warp Limit x Cylinder: Bore Size/Measureing Point x Camshaft: Drive Method Camshaft Outside Diameter Shaft-to-cap Clearance Cam Dimensions: Intake “cH Exhaust “A” — 8 ra Camshaft Runout Limit Timing Chain: Chain Type/No. of Links Chain Adjustment Method XTZ750 0.03 mm (0.0012 in) % Lines indicate straightedge measurement. 87.000 ~ 87.005 mm (3.4252 ~3.4254 in) 40 mm (1.6 in) 87.1 mm (3.429 in} Chain drive (Right) 24.967 ~ 24.980 mm (0.9830 — 0.9835 in) 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) 35.7 ~35.8 mm (1.4055 ~ 1.4094 in) 35.6 mm (1.4 in) 27.95 ~ 28.05 mm (1.1004 ~ 1.1043 in) 27.85 mm (1.1 in) 7.65 ~7.85 mm (0,3012~0.3091 in) 35.95 ~ 36.05 mm (1.4154 ~ 1.4193 in) 35.85 mm (1.41 in} 27.95 ~ 28.05 mm (1.1004 ~ 1.1043 in) 27.85 mm (1.1 in) 7.9~8.1 mm (0.3110 ~ 0.3189 in) 0.03 mm (0.0012 in) 82 RH 2015/138 Links [ Automatic —MAINTENANCE SPECIFICATIONS | SPEC p Model Valve, Valve Seat, Valve Guide: Valve Clearance (Cold): XTZ750 IN, 0.15~0.20 mm (0.006 ~ 0.008 in) EX. 0.25~0.30 mm (0.010 ~ 0.012 in) Valve Dimensions: iro , Fe Head Dia Face Width Seat Width Margin Thickness “A” Head Dia. IN. 25.9~26.1 mm (1.020 ~ 1.028 in) EX. 27.9~28.1 mm (1.098 ~ 1.106 in) “B" Face Width IN. 2.06~2.46 mm (0.081 ~ 0.097 in) EX. 2.06 ~ 2.46 mm (0.081 ~0.097 in} “C" Seat Limit Width IN 0.9~ 1.1 mm (0,035 ~ 0.043 in) EX, 0.9~ 1.1 mm (0.035 ~ 0.043 in) “D" Margin Thickness Limit IN. 0.8~ 1.2 mm (0.032 ~0.047 in) EX. 0.8~ 1.2 mm (0.032—0.047 in) Stem Outside Diameter IN 5.475 ~5.490 mm (0.2156~0.2161 in} EX. 5.460 ~ 5.475 mm (0.2150 ~ 0.2156 in) IN 5.45 mm (0.214 in) EX, 5.43 mm (0.214 in) Guide Inside Diameter IN 5.50~5.51 mm (0.216~0.217 in) EX. 5.50~5.51 mm (0.216~0.217 in) IN 5.55 mm (0.219 in) EX. 5.55 mm (0.219 in) Stem-to-Guide Clearance IN 0.01 ~0.04 mm (0.0004 ~ 0.0015 in) EX. 0.03 ~0.05 mm (0.001 ~ 0.002 in) IN, 0.08 mm (0.003 in) EX. 0.1 mm (0.004 in) Stem Runout Limit 0.01 mm (0.004 in) ira Valve Seat Width IN. 0.9~ 1.1 mm (0.035 ~ 0.043 in) EX. + 0.9~ 1.1 mm (0.035 ~ 0.043 in) 26MAINTENANCE SPECIFICATIONS | SPEC | XTZ750 Model | Valve Spring: Free Length IN. 37.29 mm (1.47 in) EX. 37.29 mm (1.47 in) Set Length (Valve Closed) _ IN. 30.39 mm (1.2 in) EX. 30.39 mm (1.2 in) Compressed Pressure IN. 10.00 ~ 11.60 kg (22.05~22.57 tb) at 30.39 mm (Valve Closed) EX. 10.00 ~ 11.60 kg (22.05 ~22.57 tb) at 30.39 mm Tilt Limit IN 2.5°/1.7 mm (2.5°/0.067 in) EX. 2.5°/1.7 mm (2.5°/0.067 in) Direction of Winding IN. | Clockwise (Top View) EX Clockwise Piston: Piston Size “D”" Measuring Point Piston Off-set Piston Off-set Direction Piston-to-Cylinder Clearance 86.920 ~ 86.935 mm (3.422 ~ 3.423 in) 4.7 mm (0.185 in) 1mm (0.04 in) INSIDE 0.065 ~ 0.085 mm (0.0026 ~ 0.0033 in} <0.15 mm (0.0059 in) > Piston Ring: Top Ring: Type Barrel Dimensions (B x T) End Gap (installed) E23? [_\ fe bert Side Clearance (Installed) 2nd Ring: ‘Type Dimensions (8 xT) End Gap (Installed) Side Clearance Oil Ring: Dimensions (B xT) End Gap (Installed) = Ts hol 1.03.3 mim (0.039 x 0.130 in) 0.3~0.5 mm (0.012~0.020 in) | 0.03 0.07 mm (0.0012~0.0028 in) Taper 1.03.3 mm (0.039 x 0.130 in) 0.3~0.5 mm (0.012~0.020 in) | 0.02~0.06 mm (0.0008~0.0024 in) 2.02.8 mm (0.079 x 0.110 in} 0.2~0.7 mm (0.008 ~ 0.028 in)MAINTENANCE SPECIFICATIONS spec] Sg | Model X1Z750 Connecting Rod: Oil Clearance 0.026 ~ 0.050 mm (0,001 ~ 0.002 in) Bearing Color Code 1. Blue 2. Black 3. Brown 4. Green Crankshaft: Crank Width “A” Runout Limit "C" Big End Side Clearance “D" ‘Small End Free Play “F 2 ie 64.75 ~ 65.25 mm (2.549 ~ 2.569 in) 0.02 mm (0.0008 in} 0.16~0.27 mm (0.006 ~0.011 in) 0.8~ 1.0 mm (0.0315 ~ 0.0394 in) Oil Clearance 0.020 ~ 0.038 mm (0.0007 ~ 0.0015 in) Bearing Color Code + D 1. Blue 2. Black 3. Brown, 4. Green 5. Yellow A a4 | 6. Pink 7. Red 7 | Balancer: Drive Method Spur gear Clutch: Friction Plate: Thickness Quantity Wear Limit Clutch Plate: Thickness Quantity Warp Limit Clutch Plate: Thickness Quantity Warp Limit Clutch Spring Free Length Quantity Minimum Free Length Clutch Release Method 2.9~3.1 mm (0.114~0.122 in) 8 pcs. 2.8 mm (0.11 in) 2.2~2.4 mm (0.087 ~ 0.094 in) | 1 pc. 0.1 mm (0.004 in) 1.9~2.1 mm (0.075 ~ 0.083 in) 7 pes. 0.1 mm (0.004 in) | 51.8 mm (2.04 in) 6 pes. 50 mm (1.97 in} Outer pull, rack & pinion pull Transmission: Main Axle Runout Limit Drive Axle Runout Limit 0.08 mm (0.003 in) 0.08 mm (0.003 in) Shifter: Type Guide bar 28MAINTENANCE SPECIFICATIONS | SPEC PF Engine Idling Speed Vacuum Pressure at Idling Speed Lubrication System: Oil Filter Type Oil Pump Type Tip Clearance Side Clearance Bypass Valve Setting Pressure Relief Valve Operating Pressure Cooling System: Radiator Core Size Width Height Thickness Radiator Cap Opening Pressure Reservoir Tank Capacity Water Pump Type Reduction Ratio Thermostat Opening Temperature Model XTZ750. Carburetor: 1.0. Mark 3LD 00, 3TD 00 (CH) Main Jet (M.J.) | #142.5, #140 (CH) Main Air Jet (MAJ) | #60 Jet Needle (J.N.) 5C19-3, 5C20-3 (CH) Needle Jet (NJ) Y-4 (611) Throttle Valve Size (Thy) #130 Pilot Jet (Pd) #42.5, #35 (CH) Pilot Air Jet (PAS) #60 Bypass 1 (B.P.1) | 00.8 2 (B.P.2) 90.8 3 (B.P.3) 60.8 Pilot Screw {P.S.) 2 turns out Valve Seat (V.S.) O17 Starter Jet 1 {G.S.1) #70 2 {G.S.2) 90.8 Pilot Outlet (P.0.) 90.85, 40.9 (CH) Fuel Level | 5.1~6.1 mm (0.2~0.24 in) | Above from the float chamber line 1,100 ~ 1,200 r/min 31.9~34.6 kPa {240 ~ 260 mmHg, 8.1 ~8.8 inHg) | Paper type Trochoid pump type 0~0.12 mm (0 ~0.005 in) 0.03 ~ 0.08 mm (0.001 ~ 0.003 in} 40~80 kPa (0.4 ~0.8 kg/cm’, 5.69~ 11.38 psi) 350 ~ 450 kPa (3.5~ 4.5 kg/cm’, 49.77 ~ 63.99 psi) 380 mm (15 in} 147.8 mm (5.82 in) 32 mm (1.26 in) | 95~ 125 kPa (0.95 ~ 1.25 kg/em?, 13.51 ~17.77 ps 0.45 L (0.40 Imp at, 0.47 US qt) <0.15 L (0.13 Imp at, 0.16 US qt)> Single-suction centrifugal pump 44/44 x 38/27 (1.407) 80 ~ 84°C (176 ~ 183°F)MAINTENANCE sPEciFicaTions | SPEC| © TIGHTENING TORQUE Part name Thread O'ty Taghtening eats Remarks size Nm |mekg| ftelb Cylinder head (exhaust pipe) stud bot | mea] 4 [is [18 {11 | —@ Cylinder head (camshaft cap) JFlange bot} m6 | 16 | 10 | 1.0] 7.2 Cylinder head Nut | M10 6 40 | 4.0 | 29 | —© Cylinder head cover + Bolt |; M6 4 10 1.0 | 7.2 | Cylinder body drain bolt Flange bolt} M 6 1 10 1.0 | 7.2 Spark plug - M12 2 417.5) 1.75 | 12.5 Connecting rod Nut m9| 4 | 48 | 48 | 35 Flywheel magneto Flange bolt] M12 1 130 13 94 Timing chain sprocket Flange bolt] M 7 4 24 24 7 Timing chain tensioner Bot [m6] 1 | 10 | 1.0 | 7.2 Thermostat Flange bolt} Mie | 1 | 13 | 1.3 | 9.4 Hose clamp (thermostat-radiator) | Panhead |M5| 2 | 2 10.2] 1.4 | screw (cylinder-thermostat) | Panhead |MS| 2 | 2 | 0.2 | 1.4 screw | | (radiator-water pump) | Panhead | M 5 2 2 02) 1.4 screw Radiator protector Panhead |M5/ 4 | 5 | 05 | 36 screw Radiator Flange bolt] M 6 2 7 07 | 51) Delivery hose (crankcase-cylinder) Bolt mio} 2 | 21} 21] 15 | Oil pump assembly Panhead |M6| 6 | 6 | 06 | 43 screw | Oil buffle plate Flange bolt] M 6 2 10 1.0 | 7.2 Drain plug (oil pan) | mia] 1 | 35 | 35 | 25 Oil strainer Panhead |M6] 4 | 7 10.7] 5 | Stake CJ screw | Relief valve stay Flange bolt| M6 | 1 | 10 | 1.0] 7.2] K€] Drain bolt {oil strainer case) Flange bolt) M10 1 30 | 3.0 2 Carburetor joint Bolt M6 4 10 1.0 | 7.2 Air cleaner Flange bolt| M6 | 1 | 7 |0.7 | 51 Muffler protector Screw |m6| 8 | 4 |o4 | 29 Exhaust pipe (CO test) sot |mM6| 2 | 10 | 1.0 | 7.2 Exhaust pipe Nut |M8] 4 | 20) 20] 14 | Exhaust pipe protector Screw |mM6| 3 | 4 |o4| 29 Exhaust pipe and muffler Bolt M8 2 20 2.0 14 Muffler Bot [ma] 2 | 24 | 24] 7 Crankcase Flange bolt} M10 | 6 | 40 | 4.0 | 29 —@ Crankcase Flange bolt} M6 | 10 | 12 | 1.2 | &7 —=© Crankcase Flange bolt! M 8 W 24 24 7 —i€) Balancer shaft Screw M6 2 12 1.2 | 87 Holder Flange bolt} M6 | 4 | 10 | 1.0 | 7.2 Chain cover Flange bot| M6 | 2 | 5 | 05 | 36 Crankcase cover (left-rear) Flange bolt| M6} 5 | 5 | 05 | 36 2.10MAINTENANCE SPECIFICATIONS spec| OF Tightening torque | Part to be tightened Part name |!) gry ; Remarks ig Nm |m+kgj ftelb Crankcase cover (left-front) Panhead |M5| 2 | 4 | 04 | 29 | Stake -4GJ | screw Starter clutch | Bolt M6 3 | 10 | 1.0 | 7.2 Clutch spring Screw M6 6 8 08 | 58 Clutch boss Nut | m20} 1 | 7 | 0.7 | 5.1 [Use lock washer Main axle bearing stopper Screw [m6| 3 | 12 | 1.2 | 87 Drive sprocket Nut | mig] 1 | 70 | 7.0 | 51 [Use lock washer| Drive axle cover plate sot |ms6}] 5 | 7 | 70} 5.1 Shift cam Screw M5 1 4 04 | 29 Shift cam stopper lever Bolt M6 1 12 1.2) 87 Shift fork guide Flange bot} M6 | 2 | 12 | 1.2 | 87 Shift arm Flange bolt} M6]. 1 | 12 | 1.2 | 87 Shift rod nut |me| 2! 8 }o8| 58 Stopper lever Bot | M8 1 | 22 | 22) 16 —G) Crankcase Screw |M6) 1 | 12 | 1.2 | 87 Stator Screw |m6] 3 | 7 |07]5.1) —@ Stator assembly sensor Screw | M5 2 4/04/29 —@ Ignition coil Screw | M6} 2 | 10 | 1.0 | 7.2 Neutral switch Screw |mé6] 2 | 4 | 04 | 29 Starter motor {Flange bolt} M 6 2 10 1.0 | 7.2 Thermo switch = m6] 1 | 28 | 28] 20 Thermo switch housing - IPT 1/8] 1 15 1.5 WV Other engine part Flange bolt} M6 | — | 10 | 1.0 | 7.2 Screw M6 - 7 07 5 Flange boit| M8 - 20 2.0 14MAINTENANCE sPEcIFicaTIons |SPEC| 9 Model XTZ750 a Lubrication Chart: Pressured feed smb Splashed Oi tank EX] Send pump [2 Check valve = —)[ Main axle famp[clstch HH J Drive axle, ay | rere i [Doe ney ch} u Connecting 10d f= i [cemecina a Hh Front balancer pasp[ Water pump i i Bypass Rear balancer i WW #2 Crank E> a! Hi 2 | == u tt it J i Oil strainer Oil pan Crankcase Tightening Sequence: Crankcase (Upper! 212MAINTENANCE sPEciFicaTions | SPEC CHASSIS Model | XTZ750 Steering System: | Steering Bearing Type Taper Roller Bearing Front Suspension: Front Fork Travel 235 mm (9.25 in) Front Spring Free Length | 844.5 mm (21.4 in) <517 mm (20.4 in) > Spring Rate: KI 4.5 N/mm (0.45 kg/mm, 25.2 Ib/in} Stroke KI 0.0~235 mm (0.0~9.25 in) Optional Spring No Oil Capacity 669 cm? (23.5 Imp oz, 22.6 US oz) Oil Level 130 mm (5.12 in) From top of inner tube fully compressed without spring Oil Grade Fork oil 10W or equivalent Enclosed Air Pressure: 4 Standard | 100 kPa (1 kg/cm’, 14.2 psi) Rear Suspension: Shock Absorber Travel 82 mm (3.23 in) Spring Free Length 240 mm (9.45 in) Fitting Length 457 mm (18 in} Spring Rate KI 140 N/mm (14.0 kg/mm, 784 tb/in) Stroke K1 0.0 ~82.0 mm (0.0~3.2 in) Optional Spring No Enclosed Gas Pressure: Standard 2,000 kPa (20 kg/cm’, 284 psi) Swingarm: | Free Play Limit | 1.0 mm (0.039 in) at swingarm end Move swingarm end side to side Side Clearance 0.3 mm (0.012 in} at swingarm pivot Front Wheel: Type Spoke wheel Rim Size 1.85% 21 Rim Material Aluminuth Rim Runout Limit Radial 1.0 mm {0.039 in) Lateral 0.5 mm (0.020 in} Rear Whee! Type Spoke wheel Rim Size | 73.00 x17 Rim Material | Aluminum Rim Runout Limit Radial 1.0 mm (0.039 in) Lateral 0.5 mm (0.020 in) Drive Chain: Type/Manutacturer 520VL2/DAIDO No. of Links 112 Chain Free Play 25~35 mm (0.98 ~ 1.38 in) 213MAINTENANCE SPECIFICATIONS | SPEC Model Front Disc Brake Type Disc Outside Diameter x Thickness — a Master Cylinder Inside Diameter Caliper Cylinder Inside Diameter Brake Fluid Type Rear Disc Brake: Type Disc Outside Diameter x Thickness exc « Master Cylinder Inside Diameter Caliper Cylinder Inside Diameter Brake Fluid Type Brake Lever and Brake Pedal: Brake Lever Free Play Brake Pedal Position Pad Thickness Inner 5.2 mm (0.21 in) * | <1.5 mm (0.06 in)> Pad Thickness Outer 5.2 mm (0.21 in) ¥ | <1.5 mm (0.06 in)> Pad Thickness Inner | 5.2 mm (0.21 in) ¥ | <1.5 mm (0.06 in) > Pad Thickness Outer 5.2 mm (0.21 in) * | <1.5 mm (0.06 in) > XTZ750 | Dual | 245 x4 mm (9.65 x0.16 in) | 14 mm (0.55 in} | 27 mm (1.06 in) DOT #4 If DOT #4 is not available, DOT #3 can be used| Single | 245 x5 mm (9.65 x 0.20 in) 14 mm (0.55 in} 21 mm (1.06 in) DOT #4 2~5 mm (0.08~0.20 in) At brake lever end. 5~25 mm (0.20 ~0.98 in) Below top of footrest. 244MAINTENANCE SPECIFICATIONS. SPEC PF TIGHTENING TORQUE 4 Part to be tightened Thread | Tightening 1orave_| Remarks size | Nm | mekg | ftelb Handle crown and inner tube ms | 2 | 23 | 17 Handle crown and steering shaft mia | 80 | 80 | 58 Handlebar holder (upper) and ms | 20 | 20] 14 handlebar holder (under) | | Steering shaft and ring nut M25) 5.5 | 0.55 | 4 | See Note Cowling stay and frame me | 6 115] 1 Cowling stay and cowling (front) m6 | 7 | 07 | 5.1 Cowling stay and ignitor unit m6 | 7 | o7 | 51 Frame and rectifier/regulator m6 | 7 | 07 | 51 Cowling stay and conduction unit m6 | 7 | 07 | 61 Cowling stay and horn m6 | 7 | 07 | 61 Cowling (front) and side cowling (left and right) | MS | 5 | 05 | 36 Side cowiing (left and right) and fuel tank ms | 5 | 05 | 36 Under bracket and joint me | 7 |o7 | 61 Front master cylinder and master cylinder cap M4 | 15 | 015) 1 Speedometer and cowling stay m6 | 7 | o7 | 51 Handle crown and main switch m6 | 7 | o7 | 51 Handlebar holder (under) and nut mio | 27 | 27 | 19 Engine mounting and frame mio | $3 | 58 | 42 Frame and down tube (front) me | 23 | 23 | 17 Frame and down tube (rear-left) mio | 32 | 32 | 23 Frame and down tube (rear-right) me | 23 | 23 | 17 Engine protector and frame me | 7 | 07 | 54 Pivot shaft and frame mis | 90 | 90 | 65 Swingarm and relay arm ma | 60 | 50 | 36 | Relay arm and connecting rod mia | 50 | 50 | 36 Connecting rod and rear arm mia | 50 | 5.0 | 36 Rear shock absorber and frame mio | 35 | 35 | 25 Rear shock absorber and relay arm mio | 35 | 36 | 25 Chain tensioner me | 23 | 23 | 17 Chain case and swingarm me | 4 | 04 | 29 Chain protector and swingarm M6 7 |) 07) 51 Chain guide and swingarm me | 7 | o7 | 51 Fuel tank bracket and fuel tank m6 | 7 | 07 | 54 Fuel tank bracket and frame me | 15) 15 | 11 Fuel tank and frame m6 | 7 | o7 | 51 Fuel pump and frame me | 7 | o7 | 54 Ignition coil and frame m6 | 7 | 07 | 51 Rear carrier (front) and frame ms | 20 | 20 | 1 | Rear carrier (rear) and frame m6 | 10 | 10 | 7.2 Rear side cover and rear carrier ms | 4 | 04 | 29 Rear carrier and flasher bracket me | 7 | 07 | 54 Helmet holder and flasher bracket me | 7 | o7 | 51 Seat and frame m6 | 7 | 07 | 51 Fuel cock and fuel tank m6 | 5 | 05 | 36 Frame and battery box me | 7 | 07 | 51MAINTENANCE SPECIFICATIONS [spec 97 Part to be tightened Mud guard and frame Oil tank and frame Side cover and frame Recovery tank and frame License bracket and frame License bracket and tail/brake light Rear reflector and stay License bracket number plate stay Front wheel axle and nut Rear wheel axle and nut Brake caliper (front) and front fork Brake caliper (rear) and bracket Sidestand and frame Footrest bracket and frame Footrest (for passenger) and frame Master cylinder (rear brake) and frame Reservoir tank (rear brake) and frame Sidestand switch and frame Brake hose (union bolt) Brake hose and brake hose holder Thread size Zezzzez=e M10 M10 Tightening torque Nm T mekg | ftelb 07 | 54 07 | 5.1 04 | 29 | 06 | 43 os | 58 } 07 | 51 o4 | 29 04 | 29 10.0 | 72 90 | 65 | 35 | 25 35 | 25 40 | 29 45 | 32 20 | 14 20 | 14 04 | 29 04 | 29 25 ) 18 [ts | 33 Remarks NOTE: 1. First, tighten the ring nut approximately 38 Nm (3.8 m-kg, 27 ftelb) by using the torque wrench, then loosen the ring nut one turn 2. Retighten the ring nut to specification. 2.16MAINTENANCE SPECIFICATIONS. SPEC PF ELECTRICAL Model Voltage Ignition System: Ignition Timing (B.T.D.C.) Advanced Timing (B.T.D.C.) Advancer Type XTZ750 12 10° at 1,150 r/min 43° at 6,000 r/min Electrical type Model/Manufacturer Minimum Spark Gap Primary Winding Resistance Secondary Winding Resistance Spark Plug Cap Type Resistance Charging System: Type “4 : e 30} —}—|- Af} 4} 4+} 4 E | Es -- 1 §a 20 j— ae | - 10 | LI | 0 2 4 6 8 10 Engine Speed (x 10° r/min) TCA: Pickup Coil Resistance 184 ~ 2762 at 20°C (68°F) (Color) | (Blue/Yellow— Green/White) T.C.1. Unit/Mi TNDFO6/NIPPON DENSO Ignition Coil | JO246/NIPPON DENSO 6 mm (0.24 in) 2.38 ~ 3.220 at 20°C (68°F) 12~18 k@ at 20°C (68°F) Resin type 10 kf at 20°C (68°F)MAINTENANCE SPECIFICATIONS | SPEC Model XTZ750 A.C. Generator Model/Manufacturer | TLNZ29/NIPPON DENSO Nominal Output | 14V 25A at 5,000 r/min 2 @ — 20 >t Ss L 44 8 tofY~4+ + —|- 7 9 | A~Att fot. | tt i 1 o 2 4 6 8 10 Engine Speed (x 10° r/min) Stator Coil Resistance 0.20~ 0.309 at 20°C (68°F) (White—Whit Rectifier/ Regulator: | Model/Manufacturer . ‘SH569/SINDENGEN Type ‘Semi conductor— Short circuit type Voltage Regulator No load Regulated Voltage 14.3~15.3V Rectifier | Capacity 258 Withstand Voltage 240V Battery: Specific Gravity 1.280 Electrical Starter System: Type Constant mesh type Starter Motor: Model/ Manufacturer SM-13/MITSUBA Output 0.8 kW Brush— Overall Length | 12.5 mm (0.49 in) <5 mm (0.20 in} > Commutator Dia: 28.0 mm (1.10 in) Wear Limit 27.0 mmm (1.06 in) Mica Undercut 0.7 mm (0.028 in) Starter Relay: Model/Manufacturer MS5D-191/HITACHI Amperage Rating 1004 Horn: Type/ Quantity Plane type/1 pe Model/Manufacturer YE-12/NIKKO Maximum Amperage 2.58 218MAINTENANCE SPECIFICATIONS SPEC PF Model Flasher Relay (Relay Assembly): Type Model/ Manufacturer Self Cancelling Device Flasher Frequency Wattage Starting Circuit Cut-Off Relay: Model/Manufacturer Coil Winding Resistance Diode XTZ750 Condenser type FZ249SD/NIPPON DENSO No 60 ~ 120 cyl/ 21Wx4+3.4W. G8MS/OMRON 90 ~ 1102 Yes Headlight Relay (F): Model/Manufacturer ACAI211-9/MATUSHITA Model/Manufacturer Thermostat Switch: Model/Manufacturer | Function Temperature Thermo Unit Model/ Manufacturer Coil Winding Resistance Circuit Breaker: Type Amperage for Individual Circuit x Quantity: MAIN RESERVE Coll Winding Resistance 72~882 Diode No . Electric Fan: NAAF48/NIPPON DENSO VFI0SA/N. THERMOSTAT 102 ~ 108°C (215.6 ~ 226.4°F): ON 98°C (208.4°F): OFF 11H/NIPPON SEIKI 153.99 at 50°C (122°F) 47.5 ~ 52.812 at 80°C (176°F) 26.2~ 29.32 at 100°C (212°F) 16.1 at 120°C (248°F) Fuse 30/1 pe. 30/1 pe.GENERAL TORQUE SPECIFICATIONS/ DEFINITION OF UNITS | SPEC a GENERAL TORQUE o SPECIFICATIONS This chart specifies torque for standard fasteners fsaneraifsorail with standard I.S.O. pitch threads. Torque specifi- hn ea specifications cations for special components or assemblies are (Nut) | (Bolt) AT mnekg | ftelb included in the applicable sections of this book. ; 6} 06 | 43 To avoid warpage, tighten multi-fastener assem- a | blies in a crisscross fashion, in progressive stages, 3} 30 1 Until full torque is reached. Unless otherwise Tamia} eto ss 14 ecification: r oon te specified, torque specifications call for clean, dry 3g sm | t@mm | 88 | 8S a threads. Components should be at room tem- ee 2mm | mm | 130 | 13.0 34 perature, I) A: Distance across flats B: Outside thread diameter DEFINITION OF UNITS Unit Read Definition = Measure | millimeter 70 7 meter Length centimeter 10 * meter Length kilogram 10" gram_ _| Newton 1 kg x m/sec | Newton meter Nxm ~ Torque ” Meter kilogram mxkg Torque Pa Pascal Nim? - ressure N/mm Newton per millimeter _| N/mm Spring rate L Liter - 7 Volume cm? Cubic centimeter or capacity r/min Rotation per minute Engine speed 2-20LUBRICATION POINT AND GRADE OF LUBRICANT | SPEC p LUBRICATION POINT AND GRADE OF LUBRICANT ENGINE Lubrication Point Oil seal lips Bearing Piston surface Piston pin Lubricant Type Connecting rod bolt Crankshaft journal | Balancer 1 (Bearing/shatt) | Camshaft cam lobe/journal Valve stem (IN. EX.) Valve stem end | Water pump impeller shaft, {oi pump rotor inner/outer) shaft | oir strainer assembly | Crankease cover (Push rod) Starter clutch ball Primary driver gear | Transmission gear (Wheel/pinion) Axle (Main/drive) Shift cam | Shift fork/guide bar | Shitt shatt assembly Shift boss (Inner) Matching surface {Cylinder head and cylinder head cover) Crankcase matching surface Yamaha Bond No. 1215 Yamaha Bond No, 1215 221LUBRICATION POINT AND GRADE OF LUBRICANT SPEC SF CHASSIS. Lubrication Point Lubricant Type Gear unit (Speedometer) - on Front wheel oil seal lips ~ - _siSe 7 Rear wheel cil seal lips : - | Se Bush (Swingarm) and thrust cover : Se Oil seal lips (Swingarm) and bearing —ad Ses Pivot shaft (Swingarm) —silSe Bearing (Relay arm and rear shock absorber) fe _ site | Bearing (Relay arm and frame) ite Bearing (Relay arm and connecting rod) om Bearing (Connecting rod and swingarm) gee _ ‘Brake pedal shaft _ ; ise | Bearing (Steering head) — ie Tube guide (Throttle grip) inner surface - - - sae: Brake lever, sliding surface . _ _ aS Clutch lever, sliding surface | Se Clutch cable end oo : — aa Side stand bolt, sliding surface - - Ses | Bush (Chain tensioner) - — : aS Grease nipple (Swingarm) aS _ Grease nipple (Relay arm) | ste Grease nipple (Relay arm and connecting rod) _ ads Grease nipple (Connecting rod and swingarm) 7 a —aa Sei - Brake pedal and rear master cylinder a aa Se 2.22LUBRICATION DIAGRAM SPEC £9] LUBRICATION DIAGRAM @ Oil tank {el FiLUBRICATION DIAGRAM | SPEC pF Balancer {B} To oil tank Oil strainer 3) Oil pump Rotor Crankshaft A] Pressured feed 2.24IB] To piston IC} To shift fork shaft [D) To cylinder head LUBRICATION DIAGRAM | SPEC PF ba|. LUBRICATION DIAGRAM SPEC P9| [B| From crankcase IC) To crankcase 0) ToD Main axle Drive axle @ Shift fork shaft LUBRICATION DIAGRAM - | SPEC {B) From drain bolt Pressured feedcootant piacraAm =| SPEC COOLANT DIAGRAM @ Radiator @ Water pump @ Thermostat housing ® Themes Radiator cap a d > 4 q © s yy S Oo . 5 4 s © S S y O a— «KC 2.28CABLE ROUTING SPEC p9| CABLE ROUTING Q g 3 @) 6) © ® ® i Headtight ead (©) Atter ciamping the front flasher Be 1) Front flasher light lead left) light leads, pass them into the Front brake svich load Soasdamear ble hole oft fe feaher sa Throttle cable NYO Brake hose [Dl Pass the speedometer cable panel (ig) Front flasher light lead (right) through the guide. Handlebar switch lead (left) (5 Flasher relay IE] To the flasher relay. aeeeretleed {Al Clamp the headlight lead and Se the front flasher light leads Guide {B) To the auxiliary light @@ Handlebar switch lead (left! 2) Clutch switch lead 3) Starter cable Fuel hose @® Starting circuit cut-off relay lead @ Neutral switch lead (9 A.C. magneto lead GD Battery negative lead caste Routine |SPEC| Battery positive lead g Breather hose Starter relay lead Vacuum hose Wireharess Rear flasher light lead 4 Fes carer Air ventilation hose ® Regulator plate 9 Rectifier/regulator @ Coolant reservoir tank hose Starting circuit cut-off relay Sidestand switch 2:30CABLE ROUTING | SPEC 9 | Spark plug lead {| To oil tank. HI Pass the wireharness in front Holder [D] Clamp the starting motor lead, _of the regulator plate. @ Brake hose the neutral switch lead and [1] Pas the rear flasher light lead, @ Speedometer cable A.C. magneto lead, start on the inside of the hole Thermo unit lead E] Connect the neutral switch of the license bracket and pass Headlight lead lead to the wireharness. on its outside, and connect it f) Auxiliary light (El Connect the A.C. magneto to the wireharness. Meter light lead lead to the wireharness. (G] Connect the wireharness to the starter relay. Al Pass the wireharness through the guide. (B) Clamp the air ventilation hoses. 2.31CABLE ROUTING SPEC PF | (0) Pass the wirehamess and the tear flasher light leads (left and right) outside of the license bracket. {KJ Pass the air ventilation hose inside of the regulator plate and clamp it by band [Ul Pass the coolant reservoir tank hose through the hole of the battery box. Do not pinch the sidestand switch lead with the rear footrest {M] Clamp the sidestand switch lead. [] Pass the breather hoses between the left side "of the relay arm and in front of the swingarm. [P] Pass the breather hose through the hole of the bracket [left side! [Q] Pass the fuel hose through the clamp. IB] Pass the spark plug lead over the regulator hose, Be sure both spark plug leads do not contact the cooling fan. 2:32CABLE ROUTING SPEC PF [S] Pass the coolant reservoir hose over the side cowling bracket. [1] Pass the thermo unit leads outside of the regulator hose and then connect to the thermo unit. @ Connect the headlight lead and the thermo unit lead outside of the regulator hose. [U Pass the meter light lead outside of the meter.CABLE ROUTING SPEC | §5 @ Fan motor lead Cooling fan Band 4) Coolant reservoir tank hose & Starter cable © Clutch cable D) Clamp @) Air ventilation hose 0 @ Oil tank Rear flasher light lead (right) @) Tail/brake light lead @® Rear carrier @ Fuel pump assembly 3 Rear flasher light lead (left) 14) Fuel hose (from fuel tank) ( Wireharness Spring @ Battery box @ Vacuum hose (from carburetor B Starting motor lead joint) @ Air ventilation hose Neutral switch lead A.C. magneto lead Spark plug lead Fuel hose (from carburetor) @ Clip 2:34SPEC 99 | CABLE ROUTING {A] Clamp the starter cable and reservoir tank hose in front of the cross pipe. [6] Pass the coolant reservoir tank hose and starter cable through the guide {C) Pass the clutch cable through the guide. (Oj Clamp the fan motor leads over the frame. {E) Pass the air ventilation hose through the hole of the bracket (F) Clamp the wireharness, air ventilation hose, coolant reservoir tank hose and starter motor lead with the former two on the upper side and the latter two on the lower side. {G) Connect the rear flasher light lead (right) to the wireharness HI Connect the tail/brake light lead to the wireharness.[1] Connect the rear flasher light lead (left) to the wireharness, [i] Pass the coolant reservoir tank hose right side of the starter relay. IK) Clamp the wireharness and the air ventilation hose. {L] Pass the leads under the frame. Mi Clamp the coolant reservoir tank hose (outside) and the spark plug lead (inside) {MJ Pass the fuel hose over the vacuum hose. [Q] Pass the vacuum hose under the fuel hose. caste RouTING | SPEC oF ®E 2:36CABLE ROUTING | SPEC 9§ | @® Ignitor unit 3 Master cylinder reservoir tank @ Holder (1G Oil tank breather hose @ Horn 9 Wireharness @ Fan motor lead 18 Ignition coit Spark plug lead Band © Spark plug cap @ Clutch cable @ Rear brake switch Brake hose ® Clamp @® Throttle cable @ Rear brake switch lead @) Front brake switch lead (® Master cylinder (rear brake) @) Handlebar switch lead (right) g Rear brake hose 3 Main switch tead D Master cylinder reservoir hose, rc a 0 ®8@®CABLE ROUTING | SPEC 9 | {Al Connect the wireharness to ignitor unit [B] Clamp the rear brake switch lead. {C] Pass the rear brake hose through the guide. [D) Clamp the master cylinder reservoir hose. {E] Connect the rear brake switch leads to the wireharness under the clamp: {E] Pass the oil tank breather hose on the inside of the down tube {G] Pass the clutch cable through the guide. IH] Pass the brake hose through the guide. » ® D 238SPEC 99]INSP ADJ CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION... PERIODIC MAINTENANCE/LUBRICATION . SEAT, FUEL TANK AND COVER REMOVAL . INSTALLATION ENGINE peer VALVE CLEARANCE ADJUSTMENT CARBURETOR SYNCHRONIZATION TIMING CHAIN ADJUSTMENT IDLE SPEED ADJUSTMENT . THROTTLE CABLE FREE PLAY ADJUSTMENT SPARK PLUG INSPECTION IGNITION TIMING CHECK....... COMPRESSION PRESSURE MEASUREMENT ENGINE OIL LEVEL INSPECTION ENGINE OIL REPLACEMENT CLUTCH ADJUSTMENT AIR FILTER CLEANING CARBURETOR JOINT INSPECTION FUEL LINE INSPECTION EXHAUST SYSTEM INSPECTION ..... COOLANT LEVEL INSPECTION COOLANT REPLACEMENT: COOLING SYSTEM INSPECTION CHASSIS ........ : FRONT BRAKE ADJUSTMENT REAR BRAKE ADJUSTMENT BRAKE FLUID LEVEL INSPECTION BRAKE PAD INSPECTION. BRAKE LIGHT SWITCH ADJUSTMENT. AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) CHANGE PEDAL ADJUSTMENT .... DRIVE CHAIN SLACK ADJUSTMENT DRIVE CHAIN LUBRICATION. .. STEERING HEAD ADJUSTMENT FRONT FORK INSPECTION REAR SHOCK ABSORBER ADJUSTMENT TIRE INSPECTION WHEEL INSPECTION SPOKES INSPECTION AND TIGHTENING CABLE INSPECTION AND LUBRICATION LEVER AND PEDAL LUBRICATION SIDESTAND LUBRICATION REAR SUSPENSION LUBRICATION 3d 3-1 33 33 34 35 35 3.13 3-15 315 3-16 3-18 3-19 3-20 3-22 3-23 3-25 3.26 3.27 3.28 3.28 3.29 3-30 3-33 3-34 3-34 3-35 3.36 3.37 3:37 3-38 3-39 3-39 3-41 3-41 23-43 344 «3-45 3-47 3.48 3-48 3-48 3-49 3.49)INSP ADJ ELECTRICAL eo - 3-50 BATTERY INSPECTION 3-50 FUSE INSPECTION 3-53 HEADLIGHT BEAM ADJUSTMENT 3.54 HEADLIGHT BULB REPLACEMENT 3-55INTRODUCTION/ | INSP EF'a PERIODIC MAINTENANCE/LUBRICATION INTERVALS | ADJ PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information ap- plies to vehicles already in service as well as new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter PERIODIC MAINTENANCE/LUBRICATION INTERVALS Unit: km (mill EVERY BREAK.IN| ITEM | REMARKS '6,000 (4,000)]12,000 (8,000) {1,000 (6001 or 6 months Jor 12 months Vata Gheck valve deorance. Adjust it necessary EVERY 42,000 2,000 Spark pluglel | Chock condition. Clean or replace i necessary Ai fer -Giean. Replace if necessary Check idle speed/starter operation. acme Adjust if necessary, Check fuel hose for cracks or damage. ieee Replace if necessary. cine of _| Replace (Warm engine before draining! / _| See NOTE Engine oil fiter” | Replace y } Check operation/fluid leakage/ See NOTE. Correct if necessary. Clutch: Check operation. Adjust if necessary. t | ) Engine oil Brake" nivot® | Check swingarm assembiy for looseness. | Swingarm pivot | Correct if necessary. Moderately repack | Rear suspension fae | Check operation. Moderately repack.*** ots" Check balance/damage/runout/spoke tightness. Repair if necessary. Check beatings assembly for looseness/ | _ i Wheels* Wheel bearings’ | damaged. Replace if damaged | Check bearings assembly for looseness. Correct if necessary Moderately repack every 24,000 (16,000) or 24 months, ** Steering bearing” Check operation/oil leakage Front forks Ropair if necessary. Rear shock | Check operation/oil leakage. | absorber | Repair i necessary, | | Check coolant leakage. Repair if necessary. | Cooling system | Replace coolant every 24,000 (16,000) or | | 24\months | 7 Check chain slack/alignmeni. Adjust i Drive chain eee aa EVERY 500 (300) ; sae] Check al! chassis fittings and fasto ] Fiitinga/Fasteners* Correct if necessary. Sidestand™ Check operation. Repair W necessary | Sidestand switch" | Check operation. Clean or replace it necessary Check specific gravity. Battery* Check breather hose for proper operation Correct if necessary a1