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Yamaha XS750, Manual, Page: 59 / 154

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Yamaha XS750 Manual Download Page 59

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DAMPER ASS'Y

CIRCLIP
WASHER, plate

(76-95-0.8)

BEARING

WASHER, plate

(69-95-5.4)

SPRING, damper
COLLAR
CIRCLIP
CLUTCH ASS'Y
CLUTCH HOUSING COMP.
SCREW

SPRl NG, compression

PLATE, pressure

PLATE, friction 1

15

16

17

18

19

20

21

22

23

24

25
26

27

28

PLATE, clutch 1
CLUTCH BOSS ASS'Y

PLATE, seat

SPRING, clutch boss

PLATE, clutch

2

CIRCLIP

CIRCLIP

(S-20)

WASHER, plate

(21.2-29-2)

CIRCLIP
GEAR, primary driven

(45T)

WASHER,

plate

(22-36-2.6)

ROD,

push 1

NUT,

hexagon

WASHER,

conical spring

29
30

31

32

33

34

35
36

37

38
39

40

41

42

WASHER,

plate

(25.2-39-1.0)

SPACER
B A L L

(5/16

inch)

ROD,

push

OIL SEAL (SD-8-25-8)

BALL SCREW  ASS'Y

SCREW,

adjusting

NUT,

adjusting

SPRING,

torsion

HOOK,

spring

SCREW, pan head
JOINT

PIN

PIN,

cotter

Summary of Contents for XS750

Page 1: ......

Page 2: ... type Battery dimensions Regulator Rectifier Starting Primary drive Type Teeth ratio Clutch Crystal Silver 2180mm 85 8 in 835mm 32 9 in 1150mm 45 3 in 810mm 31 9 in 1465mm 57 7 in 145mm 5 7 in 27 110mm 4 3 in 229 kg 505 Ibs _ _ _ _ _ _ _ _ D O H C air cooled triple 68mm x 68 6mm x 3 747cc 8 5 1 142 Ibs in 14 Ibs in Pressure lubricated wet sump Trocoid Mikuni BS34 constant velocity 1J701 3 pcs 34mm...

Page 3: ...095 5 955 22 23 0 956 5 201 Shaft drive Spur gear 34 32 1 063 Bevel gear 19 18 1 056 Bevel gear 32 11 2 909 Tubular steel double cradle Telescopic fork 175mm 6 9 in Swing arm 75mm 3 0 in 3 25 H 19 Bridgestone 4 00 H 18 Bridgestone Dual hydraulic disc Single hydraulic disc US gal Regular leaded or unleaded 1 85 x 19 Cast Aluminum 2 15 x 18 Cast Aluminum B MAINTENANCE SPECIFICATIONS 1 Engine Engine ...

Page 4: ...diameter Number of windings 2 8mm 7 75 Valve stem run out maximum Valve seat width standard maximum 03mm 0012 in 1 3mm 050 in 2 0mm 080 in Wear Iimit Camshaft bearingsurface diameter 24 97 24 98mm 0 9830 0 9835 in Camshaft to cap clearance Standard Maximum Camshaft runout limit 020 054mm 0008 002 in 160mm 006in 0 1mm 004 in I Valves I INNER OUTER INTAKE EXHAUST 39 9mm ALLOWABLE TILT FROM VERTICAL ...

Page 5: ...m I EXHAUST CIearance Cold engine 0 2 1 0 25mm A head diameter 31 0 2mm Guide diameter I D 7 019mm Stem to guide clearance 0 035 0 059mm Cylinder and Piston Cylinder material Cylinder liner Standard bore sizehtandard Cylindertaper limit Cylinder out of round limit Piston clearancehtandard maximum maximum Piston Rings Design End gap installed Side clearance Aluminum Pressed in special cast iron 68 ...

Page 6: ...iddle gear case lash 0 022 0 044mm 0009 0017 in 0 032 0 054mm 0013 0021 in 0 03mm 0012 in 090 015mm 0035 0059 in 03 09mm 0011 0035 in 3 0mm 0 12 in 2 8mm 0 11 in 0 05mm 002 in 42 8mm 1 685 in 41 5mm 1 634 in 0 4mm 016in 13 26mm 0 5 1 0 in 08mm 001 in 0 1 0 2mm 004 008 in 2 Carburetion I Manufacturer Model I D No Main jet Needle jet Pilot jet Starter jet Jet needles Clip position Mikuni BS34 1J701 ...

Page 7: ...e length Spring preload length Spring rate 0 45mm travel 45 75mm travel 2 0mm 080 in l 0mm 040 in 1 8 26 p s i 2 0 kg cm2 28 p s i 2 0 kg cm2 28 p s i 2 3 kg cm2 33 p s i DOT No 3 240 C 464 F 5 5mm 0 18 in 0 15mm 006 in 6 5mm 0 26 in 5 0 10 0mm 0 2 0 4 in 5 0 10 0mm 0 2 0 4 in 55 8mm 2 2 in 50 8mm 2 0 in 448 3mm 17 65 in 423 3mm 16 67 in 0 5 kg mm 28 Ibs in 0 6 kg mm 33 6 Ibs in 170cc 5 75 US fl o...

Page 8: ...ng Headlight TaiIIight stopIight License light Flasher Iight Flasher pilot light Meter Iights High beam indicator light Oil pressure warning light Neutral light Mitsuba SM 224C 0 007 ohms 0 01 ohms 12 5mm 0 5 in 5 5mm 0 22 in 620 60g 22 0 2 0 oz 0 5 0 8mm 0 02 0 03 in Yuasa YB 14L 1 4 amps for 10 hours Hitachi Ld 120 02 14 5 0 5V 0 48 0 05 ohms 4 04 0 4 ohms Hitachi TLIZ 80 14 5 0 5V 0 6 1 0mm 024...

Page 9: ... 8mm 8 0 12 0 m kg 58 87 ft lbs 1 5 2 9 m kg 11 21 ft lbs 2 0 m kg 14 ft lbs I 1 10mm Cylinder holding nuts 3 5 m kg 25 ft lbs 2 0 m kg 14 ft lbs Camshaft cap nuts Engine mounting bolts 10mm 1 O m kg 7 ft lbs 5 0 6 0 m kg 36 43 ft lbs Engine oil drain plug Oil filter mounting bolt Middle gear drain plug Front axle nut Front axle holder nuts Rear axle nut Rear axle pinch bolt Chassis 3 9 4 7 m kg 2...

Page 10: ...Componentsshould be room temperature 500 600 ...

Page 11: ...r set Tappet adjusting tool Vacuum gauge Final drive gear holding tool Clutch plate installation tool Middle and final gear holding tool Clutch lock nut wrench Damper special tool Cam chain cutter Rotor puller Slide hammer Gear lash measurement tool middle gear Rotor holding tool Gear lash measurement tool final gear ...

Page 12: ......

Page 13: ...ecrease speed Standard Idle RPM 1 050 1 150rpm g Each gauge will indicate the same reading if the carburetors are synchronized The left and right carburetors are to be synchronized to the center carburetor which has no synchronizing screw Turn the left carburetor synchronizing screw until the gauge reading is the same as for the center carburetor Repeat for the right carburetor B Air Filter 1 Remo...

Page 14: ... a month or every 1 600km 1 000 miles It should be cleaned more often if the machine is operated in extremely dusty areas without the air cleaner element installed Ex cessive oil contamination and engine wear may result NOTE When checking engine oil level with the dip stick let the unscrewed dip stick rest on the case threads Be sure the engine is stopped and the machine is positioned straight up ...

Page 15: ...he oil pressure indicator lightshould go off after the engine is started CAUTION If the Oil indicator light remains on immediately stop the engine Refer to lubrication information in Sec 3 5 D Middle Gear Final Gear Oil 1 Oil level measurement a Place the machine on a level surface and place it on the center stand The engine should be cool at atmospheric temperature Allow 2 minutes for oil to drai...

Page 16: ...OTE After initial 250 mile oil change it is normally not necessary to change middle and final gear oil more frequently than the indicated service interval of 6 000 miles E Clutch Adjustment This model has a clutch cable length adjustor and a clutch mechanism adjustor The cable lengthadjustor5 are used to take up slack from cable stretch and to provide sufficient free play for properclutch operatio...

Page 17: ...ustment must be checked because heat and clutch wear will affect this free play possibly enough to cause improper clutch operation Recheck clutch cable adjustment a t handlebar after adjusting F Cam Chain Adjustment The cam chain becomesstretchedwith use resulting in improper valve timing and engine noise To prevent this the cam chain tensioner must be adjusted regularly Loosen the tensioner stopp...

Page 18: ... the valve lifter Adjusting pads are available in 25 thicknesses ranging from No 200 2 00mm to No 320 3 20mm in steps of 0 05mm The thickness of each pad is marked on the pad face that contacts the valve lifter notthe cam Adjustment of valve clearance is accomplished as follows 1 Determine valve clearance feeler gauge measurement 2 Remove adjusting pad and note number 3 Select proper pad from appr...

Page 19: ...measured valve clearance from step 1 on chart Read across c A t the intersection of installed pad number down and measured clearance across is a new pad number 7 8 9 EXAMPLE Exhaust valve installed pad No 250 read down Measured clearance 0 32mm read across New pad number No 260 intersection of down across NOTE The new pad number is to be used as a guide only Verify the correctness of this choice i...

Page 20: ...Intake i I CLEARANCE Exhaust ...

Page 21: ...ank and position it so that fuel will not spill when the petcock is removed 2 Remove petcock and inspect filter screen Replace filter if seriously contaminated 3 Remove 4 screws on front and rear of petcock and remove plate gaskets lever anddiaphragm 2 4 CHASSIS 4 Inspect all components and replace any that are damaged I f the diaphragm is in any way A Fuel Petcock Cleaning damaged or the petcock ...

Page 22: ... 2 Brake pad check To check pad wear open the wear indicator cap If any pad is worn to the red line replace both pads in the caliper 3 Check the brake fluid level Insufficient brake fluid rnay allow air to enter the brake system possibly causing the brake to become ineffective Check the brake fluid level and replenish when necessary and observe these precautions a Use only the designated quality b...

Page 23: ...uminum wheels are NOT de signed for use with tubeless tires b Raise the wheel off the ground Spin Rim runout limits Vertical 2mm 0 08 in Lateral 1mm 0 04 in Front axle nut torque 7 0 10 0 m kg 50 72ft lb 12 18 m kg 87 130 ft lb Rear axle nut torque b Check axle holder nuts right side I Front axle holder nuts 1 3 2 3 m kg 9 17ft lbs 1 CAUTION First tighten the nut on the front end of the axle holde...

Page 24: ...tube CAUTION Do not allow oil to contact disc brake components 5 When most of the oil has drained slowly raise and lower the outer tubes to pump the remaining oil It may be necessary to remove the spring seat and top spring to keep them from falling out when raising fork tubes 6 Inspectdrain screwgasket Replace ifdamaged Reinstall drain screw 7 Pour specified amount of oil into the fork inner tube...

Page 25: ...aker Point Adjustment 1 Remove breaker point cover 2 Each cylinder has a set of breaker points The No 1 left cylinder set is marked with a 1 on the backing plate The No 2 center cylinder set is marked with a 2 and the No 3 cylinder set is marked 3 The spark plug wires are also numbered 3 Check contact breaker point gap at largest gap with feeler gauge Contact Breaker Gap 0 3 0 4mm 012 016 in If ne...

Page 26: ...tructed NOTE The battery must be charged before using to insure maximum performance Failure to properly charge the battery before first use or a low electrolyte level will cause premature failure of the battery Charging current 1 4 Amps Charging hours 10 hrs 5 Retighten screw Check timing again for the No 1 cylinder 6 Rev the engineto above 3 000 rpm The pointer should indicate the area of the two...

Page 27: ...ark plug properly Champion N 7 Y Tightening Torque 1 5 2 5 m kg 10 8 18 1 ft lb F Headlight 1 Headlight beam adjustment When necessary adjust the headlight beam as follows a Adjust horizontally by tightening or loosening the adjust screw To adjust to the right Tighten the screw To adjust to the left Loosen the screw b Adjust vertically as follows 1 Loosen adjusting screw under headlight body Adjus...

Page 28: ...ill speed assembly time and help insure correct reinstallation o f all engine parts 4 Place machine on center stand Start engine and allow it t o warm up Stop engine and drain engine transmission oil 5 Remove oil filter element t o drain oil filter 6 If middle gear case is t o be removed drain middle gear oil 7 Remove air scoop from cylinder head cover B Fuel Tank Removal 1 Turn fuel petcocks t o ...

Page 29: ...lencers 3 Loosen clamps holdingcarburetors t o air clean er case and intake manifolds Loosen breather hose clamp a t air cleaner case junction 5 Pull air cleaner case to the rear Remove clutch cable from holder attached to the left carbu retor Lift carburetors back and to the left Remove throttle cable from carburetors 6 Remove air cleaner case E Wiring and Cables 1 Pull back rubber cover on clutc...

Page 30: ...so that they can be safe ly removed F Drive Shaft Joint 1 Pull rubber boot from drive shaft coupling to expose four 4 bolts 2 Remove four 4 bolts on drive shaft coupling G Removal 1 Remove three 3 engine mounting bolts from frame Remove footrests with the two 2 rear engine mounting bolts 2 Slide engine forward Remove engine t o the right Position a box or other support to the right of the machine ...

Page 31: ...clockwise from L H end See illustra tion EXHAUST INTAKE 4 Remove cam chain guide stopper 5 Remove the cam caps CAUTION To avoid damage to the camshaft caps observe thefollowing a Position cams as described in step 3 b The camshaft caps are numbered left t o right 1 2 3 4 and E or I for intake or ex haust Damage will result if the caps are in correctly removed or installed c Remove camshaft caps fr...

Page 32: ...ssembly 1 Remove valve lifters and pads Place each lifter in a box that identifies the location of each lifter CAUTION in their original locations Lifters must always be installed 2 Install the valve spring compressor special tool Remove the valve keepers by usinga mag net Remove the retainer and valve springs NOTE The valve springs are progressively wound The more tightly wound end is placed down...

Page 33: ... washer and lock washer from the rotor Use the rotor holding tool and bolt special tools to remove rotor 5 Remove the crankcase cover bolts and remove the cover 6 Remove oil pressurewarning switch D Generator 1 Remove generator wiring harness from mount ing clips Remove oil pressure warning switch wire E Bearing Housing Remove four 4 bearing housing securing bolts and remove bearing housing 2 Remo...

Page 34: ... larger circlip 3 Remove clutch damper 4 Remove primary driven gear and chain 5 Remove clutch housing NOTE If the clutch plates are stuck to the housing thread in the clutch adjuster screw on the left side of the engine This will push off the housing 6 Remove washer and circlip in front of pressure plate ...

Page 35: ...h boss Use deep 32mm socket to remove clutch boss nut Remove nut spring washer clutch boss plate washer and spacer G Kick Gear Removal 1 Remove circlip holding the kick idlegear 2 Install the kick crank on the kick shaft Pull the kick starter assembly and the kick idle gear out together Remove bearing and washer 3 Remove the circlip holding kick gear 4 Re move the washer and gear ...

Page 36: ... hammer to remove the holder 1 Remove clip holding shift lever two 2 Re move the lever 2 Remove clip holding shift shaft lever Remove shift shaft I Governor Assembly Removal 5 Remove the kick shaft assembly 1 Remove bolt holding crankshaft turning nut from L H end of crankshaft ...

Page 37: ...and remove breaker assembly 3 Remove governor assembly 4 Remove starter clutch assembly J Electric Starter Removal Remove L H crankcase cover 2 Remove idler gear 1 and shaft 5 Remove oil delivery pipe 3 Place a folded rag between the kick idler gear two 2 and pump drive gear as shown Remove pump drive gear nut and gear Re move cam chain ...

Page 38: ...or securing bolts L Transmission Bearing Housing Removal Remove starter motor Remove the transmission bearing housing bolts Re move housing K Middle Gear Removal M Breather Removal Remove seven 7 middle gear case securing bolts Re Remove six 6 breather securing bolts Remove move the middle gear case drive cam and spring breather ...

Page 39: ...bolt This bolt is located near the transmission drive axle as shown This bolt must be located before proceeding with crankcase disassembly 3 Remove oil pump driven gear 5 Remove pressure relief valve remove circlip washer spring and plunger 6 Remove oil pump check valve remove cir clip plug spring and plunger 2 Remove oil pump ...

Page 40: ...mer to carefully separate the crankcases The crankshaft and transmission shafts should stay in the bottom crankcase 1 3 Remove crankshaft Note location of special main bearing A bearing This is a combina tion side thrust bearing and main bearing P Transmission Disassembly 1 Removemiddle driven gear 2 Remove shift fork guide bar circlip E clip Remove guide bar 3 Remove main axle assembly 4 Remove c...

Page 41: ...gear Push drive axle up at the bearing and out so that the middle drive gear can be removed Remove drive axle 9 Remove shift cam detent and shaft cam se curing bolt 10 Remove circlip on shift cam stopper plate Remove stopper plate and shift cam Further disassembly of the transmission shafts can be undertaken after study of the transmis sion illustration ...

Page 42: ... WASHER plate 30 2 40 2 0 CIRCLIP GEAR 4th wheel 23T SHIM GEAR 3rd wheel 26T GEAR 5th wheel 22T GEAR 2nd wheel 27T CIRCLIP S 30 SHIM drive axle 24 2 33 1 6 BEARING WASHER plate 30 2 40 2 0 BEARING B5206 special CIRCLlP GEAR middle drive 32T WASHER plate 30 31 32 33 34 35 36 37 38 39 40 41 42 43 WASHER spring BOLT hexagon socket head MIDDLE DRIVEN GEAR COMP 34T COLLAR 35 40 16 BEARING B6207 special...

Page 43: ...3 SCREW 23 SHAFT shift lever BEARING 14 B OLT 24 SCREW flat head ClRCLlP 34 ø special PLATE side SCREW flat head 15 16 17 WASHER lock BAR shift fork guide 1 FORK shift 2 25 26 27 LEVER shift 2 ClRCLlP E 9 SPRING torsion PLATE stopper 18 PIN cam follower 28 LEVER shift 3 ClRCLlP S 30 STOPPER cam 19 20 WASHER plate 12 22 1 0 ClRCLlP E 10 29 ClRCLlP E 7 ...

Page 44: ...ither or both valve and guide as necessary Intake 020 041mm 0 10mm 0008 0016 004 Exhaust 035 059mm 0 12mm 0014 0023 005 2 Valve stem end Inspect end of valve stem I f the end appears to be mushroomed or has a larger diameter than the rest of the stem the valve valve guide and oil seal should be replaced 3 Turn valve on a V block and measure the amount of stem runout with a dial gauge If it exceeds...

Page 45: ...ean off all grinding compound and check valve seat width The valve seat will have re moved the bluing wherever it contacted the valve face Measure the seat width with vernier calipers It should measure approximately 1 3mm 05 Also the seat should be uniform in contact area If valve seat width varies or if pits still exist then continue to cut with the 45 cutter Remove just enough material to achiev...

Page 46: ... engine uses two springs of different sizes to prevent valve float or surging The chart below shows the basic value characteristics b Even though the spring is constructed of dur able spring steel it gradually loses some of it s tension This is evidenced by a gradual short ening of free length Use a vernier caliper to measure spring free length If the free length of any spring has decreased more t...

Page 47: ...ts d Install the camshaft on the cylinder head Place a strip of Plastigauge between camshaft and camshaft cap as illustrated lengthwise along camshaft Tighten the nuts with specified torque Remove the camshaft cap and determine the clearance by measuring the width of the flattened Plastigauge I PLASTIGAUGE I CAMSHAFT CYLINDER HEAD STUDS FOR CAMSHAFT CAP Cap Nut Tightening Torque 0 8 1 0 m kg 5 8 7...

Page 48: ...r Limit 68 00 68 02mm 68 10mm 2 677 2 678 in 2 681 in 0 05mm 0 002 in 0 05mm 0 002 in G F Cylinder 1 Inspect the cylinder walls for scratches If vertical scratches are evident the cylinder wall should be rebored or the cylinder should be replaced 2 Measure cylinder wall wear as shown If wear is excessive compression pressure will de crease Rebore the cylinder wall and replace the piston and piston...

Page 49: ...e color mark is painted on the expander spacer Size Color Oversize 1 Brown Oversize 2 Oversize 3 Black Oversize 4 Yellow c Push the ring into the bore and check end gap clearance with a feeler gauge NOTE The end gap on the expander spacer of the oil control ring is unmeasureable If the oil control ring rails show excessive gap all three components should be replaced Top 2nd ring 0 2 0 4mm 0 80mm 0...

Page 50: ...ve bolts in reverse assembly order 10 9 8 etc h Carefully remove lower crankcase Measure width of Plastigauge on crankshaft journals to determine clearance Main bearing oil clearance 022 044mm 0008 0017 in 4 Crankshaft Main Bearing Selection a Numbers used to indicate crankshaft journal sizes are stamped on the L H crank web The first four 4 are mainbearingjournal numbers starting with the left jo...

Page 51: ...bearing clearance is similar to mainbearingclearance measurement a Clean all bearing surfaces b Place a piece of Plastigauge on connecting rod cap Place cap on crankshaft journal Do not allow the cap to move Install special bolts and apply molybdenum grease to the threads Install rod cap and nuts Tighten rod caps evenly to specified torque Rod cap torque 3 8 kg m 27 ft lbs I Oil clearance rod I 03...

Page 52: ...oil pump assembly Check the plungers for scratches and wear L PRIMARY DRIVE 1 Hy Vo Chain And Primary Gears The Hy Vo primary chain is a plate and pin type that does not use rollers as in the case of a conventional motorcycle drive chain The plates of the chain form a mating surface for the primary gear teeth That is the primary gears actually mesh with the chain plates This chain is extremely dur...

Page 53: ...ion and Clutch Plates Check clutch steel plates and friction plates for heat damage Measure friction plate thick ness at 3 or 4 points Measure clutch plates for warpage with a dial gauge and stand Re place clutch plate or friction plates as a set if any is faulty or beyond wear limits Friction plate thickness Standard Wear Limit 3 0mm 2 8mm 0 12 in 0 11 in I I Clutch plate 0 05mm warp limit 0 002 ...

Page 54: ...d of bolts in oil pump driven gear 1 Starter clutch bolt torque 2 8 3 2 m kg 20 23 ft lbs 2 Kick Starter a Kick Gears 1 Check the kick gears for wear or scratches on teeth particularly in the chamfered area of each gear b Kick Clip Spring 1 The kick clip is fitted to kick gear 5 and slides in the groove A too tight or loose fitting clip may result in improper operation If too loose bend the kick c...

Page 55: ...hauled All gasket surfacesmust be cleaned 2 Properly oil all mating engineand trans mission parts during assembly 3 All circlips should be inspected before assembly Replace distorted cir clips Always replace cotter pins and piston pin clips after one use A Shift Cam Install shift cam stopper plate and circlip Tighten shift cam locating bolt and bend over the lock tab Install and tighten detent ass...

Page 56: ...ned next to the bearing cap Install the circlip E clip on the shaft to hold the plate washer next to the bearingcap NOTE When installing shift forks make sure cam follower pins are correctly positioned in the shift cam 5 Install main shaft and clutch push rod seal 6 Install shift fork guide bar and shift fork 1 Install circlips E clips 7 Install middle driven gear Make sure circlip halves are prop...

Page 57: ...shers on bolts 5 6 7 8 b Bolt threads must be oiled c Tighten bolts in two stages in proper torque sequence Start with bolt number one Tighten the unnumbered bolt as number 24 Stage 1 8mm bolts 1 0 m kg 7 ft lb 2 0 m kg 14 ft lb Stage 2 8mm bolts 2 0 m kg 14 ft lb 10mm bolts 3 7 m kg 27 ft lb 10mm bolts D Oil Pump 1 Reassemble oil pump in reverse disassembly order Lubricate the oil pump well durin...

Page 58: ...ASHER plate 20 2 30 1 0 ClRCLlP S 20 COVER kick spring SPACER SPRING torsion KICK SHAFT ASS Y 22T 16 17 18 19 20 21 22 23 24 25 26 27 28 29 SHIM kick shaft 1 40 3 54 0 8 BEARING KICK IDLE GEAR ASS Y 38 30T SHIM kick shaft 2 35 3 54 0 8 CIRCLIP S 35 CIRCLIP S 17 GEAR kick 4 20T HOLDER kick gear PIN dowel 4 10 BOLT hexagon socket head CLIP special GEAR kick 5 21T SHAFT kick 2 SHIM ...

Page 59: ...5 26 27 28 PLATE clutch 1 CLUTCH BOSS ASS Y PLATE seat SPRING clutch boss PLATE clutch 2 CIRCLIP CIRCLIP S 20 WASHER plate 21 2 29 2 CIRCLIP GEAR primary driven 45T WASHER plate 22 36 2 6 ROD push 1 NUT hexagon WASHER conical spring 29 30 31 32 33 34 35 36 37 38 39 40 41 42 WASHER plate 25 2 39 1 0 SPACER BA L L 5 16 inch ROD push OIL SEAL SD 8 25 8 BALL SCREW ASS Y SCREW adjusting NUT adjusting S...

Page 60: ...o idler shaft Oil the bearing 5 Install the kick starter shaft and kick idle gear assembly together Use the kick crank to help install the kick shaft assembly Install the torsion spring on the boss Install the washer and circlip on the kick shaft Check the move ment of the kick shaft with the kick crank Remove the kick crank 2 Install kick gear holder 3 Install kick gear 4 shim and circlip G Clutc...

Page 61: ... tern clockwise around the clutch boss until all friction and steel clutch plates are installed 3 Install push rod 1 intotheslot in the main axle 4 Install plate washer onto main axle Install pressure plate with the arrows matching the arrows on the clutch boss 5 Install two clutch springs and screws lightly so that the clutch plates can be moved 6 Install the clutch alignment tool special tool to...

Page 62: ...er on kick shaft Install a new gasket and the right crankcase cover Do not use all cover screws until rotor and generator cover are installed Install rotor plate washer spring washer and bolt Hold rotor with special rotor holding tool and tighten bolt Rotor bolt torque 3 0 4 0 m kg 22 29 ft lbs I 4 Install generator assembly Connect oil pres sure warning wire to the switch Install all generator co...

Page 63: ...sprocket Connect wire to each end of cam chain 5 Install oil pump drive gear Place a ragbetween oil pump drive gear and driven gear to lock the gears Install plate washer and nut Tighten nut L Left Crankcase Cover 1 Oil Delivery Pipe Oil the threads of the oil delivery pipe union bolts Install new washers on each side of each bolt and tighten bolts I gear nut torque 8 0 12 0 m kg 58 87 ft lbs Oil ...

Page 64: ...mps provided 3 Attach neutral light wire 4 Install crankshaft turning nut on crankshaft Tighten securing bolt Crankshaft turning nut bolt torque 1 5 2 9 m kg 11 21 ft lb I N Pistons and Cylinder 1 Install pistons on rods The arrow on the pis tons must point to the front of the engine NOTE Always install new piston pin circlips 2 Install a new cylinder base gasket Install new cylinder seal 2 with f...

Page 65: ... threads before tightening Tight en in two 2 stages of one half torque each Tighten according to the proper sequence No 1 2 3 etc CYLINDER HEAD TORQUE SEQUENCE Stage 1 l0mm nut No 1 8 1 5 m kg 11 ft lbs 8mm bolt No 9 10 1 m kg 7 ft lbs Stage 2 10mm nut No 1 8 3 5m kg 25 ft lbs 8mm bolt No 9 10 2 0 m kg 14ft lbs 5 Install two 2 cylinder head holding nuts with washers on left side of cylinder a CYLI...

Page 66: ...the cams must be aligned with the arrows on the No 1 cam caps The No 1 cylinder must be a t T D C The No 1 T mark on the gov ernor aligned with the stationary timingmark 3 Install a new cam chain tensioner Remove the tensioner cover Loosen the adjuster bolt Turn the crankshaft until the cam chain ten sioner rod moves to i t s inner most position Tighten the adjuster bolt and lock nut Install tensi...

Page 67: ...rain plug Torque Engine oil drain plug 3 9 4 7 m kg 28 34ft lbs Oil filter mounting bolt 3 0 3 4 m kg 22 25 ft lbs Middle gear drain plug 3 9 4 7 m ka 28 34 ft lbs 5 Add oil to engine and middle gear case Engine oil 3 0 lit 3 2 US qt Middle gear oil 360cc 12 oz I NOTE These oil quantities are for an over hauled engine Observe oil filter filling proce dure CAUTION If oil pressure warning light red ...

Page 68: ...ET starter body BODY starter PLUNGER starter SPRING plunger WASHER CAP plunger COVER plunger cap BUSHING starter plunger CLIP RING WASHER LEVER starter 1 WASHER SPRING starter lever WASHER spring SCREW pan head SPRING pilot screw SCREW pilot I 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 CAP pilot screw NUT WASHER COLLAR spring LEVER throttle SPRING throttle SEAL 8 ø SCREW throttle stop SPRING thr...

Page 69: ...e T NOTE The low speed mixture screw settings are adjusted at the factory with the use of specialized equipment Do not attempt to change these set tings C Disassembly 1 Prepare to separate carburetors separationnot necessary if only float level adjustment or throttle slide inspection is to be done Re move starter lever 1 Loosen starter lever 2 securing screws and remove starter lever rod Remove up...

Page 70: ... 8 Reassemble in reverse order Pay close atten tion to the installation of the vacuum piston diaphragm E Adjustments D Inspection 1 Examine carburetor body and fuel passages If contaminated wash carburetor in petroleum based solvent Do not use caustic carburetor cleaning solutions Blow out all passages and jets with compressed air 2 Examine condition of floats If floats are leaking or damaged they...

Page 71: ...osition of the needle in the needle jet If it is necessary to alter the mid range air fuel mixture characteristics of the machine the jet needle position may be changed Move the jet needle up for a leaner condition or toward the bottom position for a richer condition I Jet needle ...

Page 72: ...ngine 5 Remove the front wheel axle by simulta neously twisting and pulling out on the axle Then remove the wheel assembly The speedo meter gear unit housing must be removed B Front Axle Inspection Remove any corrosion from axle with emery cloth Place the axle on a surface plate and check for bends If bent replace axle Rim run out limits Vertical 2mm 0 08 in Lateral lmm 0 04 in 3 Check wheel balan...

Page 73: ...ly with the outer race E Installing Front Wheel When installing front wheel reverse the removal pro cedure Note the following points 1 Lightly grease lips of front wheel oil seals and gear teeth of speedometer drive and driven gears Use lightweight lithiumsoap basegrease 2 Make sure there is enough gap between disc pads 3 Check for proper engagement of the boss on the outer fork tube with the loca...

Page 74: ... SEAL dust 11 COVER plate dust 12 SCREW pan head 13 WASHER spring 14 WASHER plate 15 BEARING B6304Z 9 OIL SEAL SD 25 47 7 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 OIL SEAL SO 27 52 5 COLLAR shaft COVER dust COLLAR PLATE stopper torque SHAFT wheel PIN cotter WASHER plate NUT shaft SPACER WASHER plain WASHER spring NUT hexagon PIN cotter BALANCER wheel ...

Page 75: ... rear brake 2 WASHER lock 3 BOLT hexagon 4 CALIPER ASS Y rear 5 CALIPER PAD KIT 6 BUSHING boot 7 SLEEVE 8 BOLT support 9 SCREW bleed with cap 10 CALIPER SEAL KIT 11 NUT crown 12 WASHER spring 13 WASHER plate ...

Page 76: ...SCREW 13 NUT adjusting 14 MASTER CYLINDER ASS Y rear 15 CYLINDER KIT master 16 CAP reservoir 17 DIAPHRAGM reservoir 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 BUSHING diaphragm BOLT cap BOLT plug GASKET BOOT master cylinder BOLT hexagon WASHER spring HOSE rear brake BOLT union WASHER plain CLAMP 1 CLAMP 2 SCREW pan head WASHER spring BOLT WASHER lock ...

Page 77: ... pin on the axle nut Torque Axle nut 12 18 m kg 87 130 ft lb Axle pinch bolt 0 45 0 75 m kg 3 5 ft lb 5 3 BRAKES CAUTION Disc brake components rarely require disassembly Do not disassemble com ponents unless absolutely necessary If any hydraulic connection in the system is opened theentiresystemshouldbedisassembled drained cleaned and then properly filled and bled upon reassembly CAUTION D o not u...

Page 78: ...voir 19 BUSHING diaphragm 20 BRACKET master cylinder 21 BOLT hexagon 22 WASHER spring 23 LEVER right 24 SCREW 25 NUT 26 SPRING 27 BOLT 28 NUT BOLT union WASHER HOSE brake 1 BOOT master cylinder JOINT BOLT hexagon WASHER spring WASHER plate HOSE brake 2 BOLT union HOLDER brake hose right HOLDER brake hose left FRONT STOP SWITCH ASS Y ...

Page 79: ... DISK front brake WASHER lock BOLT hexagon FRONT CALIPER ASS Y right FRONT CALIPER ASS Y left CALIPER PAD KIT BUSHING boot with grease SLEEVE BOLT support SCREW bleed with cap CALIPER SEAL K I T BOLT hexagon WASHER spring WASHER plate ...

Page 80: ...d dust seal 6 Carefully force the piston out of the caliper cylinder with compressed air Never try to pry out the piston CAUTION Cover the piston with a rag Use care so th at piston does not cause injury as it is expelled from the cylinder 7 Remove piston seal d Remove master cylinder from handlebars Re move cap and drain remaining fluid 2 Rear a Remove brake hose b Remove two 2 bolts holding mast...

Page 81: ...and dust seals if damaged Re place seals every two years 4 Inspect master cylinder body Replace if scratched Clean all passages with new brake fluid 5 Inspect brake hoses Replace every four years or if cracked frayed or damaged Maximum deflection 0 15mm 006 in Minimum disc thickness 6 5mm 0 26 in If disc is worn beyond minimum thickness or deflection exceeds specified amount replace disc E Brake R...

Page 82: ...ir from the brake fluid If the brake fluid level is very low or brake operation is incorrect bleed the brake system 1 Add proper brake fluid to the reservoir In stall the diaphragm being careful not to spill or overflow the reservoir 2 Connect the clear plastic tube tightly to the caliper bleed screw Put the end of the tube into a container 3 Attach brake hoses front and rear Brake hosetorque 2 3 ...

Page 83: ...e pushing it back out of the rim hole NOTE If you are changing the tire itself then finish the removal by working the second beadoff the rim 1 Disconnect speedometer cable Disconnect brake calipers and remove front wheel Place wooden wedge or other object into caliper assemblies to keep brake pads from falling out Remove front fender 2 Loosen pinch bolts on steering stem and crown and remove fork ...

Page 84: ... front fork piston 24 12 CYLINDER COMP front fork 25 13 SPRING front fork 26 SEAL dust GASKET GUIDE cover under GUIDE cover upper SEAT spring upper SPRING O RING SEAT spring RING stopper CAP front fork UNDER BRACKET COMP BOLT WASHER spring 27 28 29 30 31 32 33 34 35 HOLDER axle WASHER plate NUT nylon BOLT hexagon socket head SCREW drain COVER upper left COVER upper right REFLECTOR WASHER spring WA...

Page 85: ...re all components are clean before assembly 2 Apply oil to the fork seal and install the seal spacer and seal by pressing in with a large socket Install retaining clip 3 Install inner tube into outer tube Install dust cover Install and tighten Allen bolt and washer Assembly procedure is the reverse of the disassembly procedure NOTE When installing fork springs the greater pitch should be at the bo...

Page 86: ...ndle 6 WASHER plate 7 BOLT stem 8 BOLT pinch 9 BOLT pinch 10 WASHER plain 11 NUT crown 12 13 14 15 BOLT hexagon socket head cap CAP bolt HOLDER handle upper HOLDER handle under 16 WASHER 17 BUSHING rubber 18 WASHER plate 19 NUT hexagon 20 CLIP 21 PLUG 22 GUIDE wire ...

Page 87: ...ly Grease bearings and races with wheel bearing grease 2 Install steering stem underbracket and bear ings 3 Install bottom fitting nut Tighten to approx imately 1 0 1 2 m kg 7 9 ft lbs Do not over tighten Tighten top fitting nut 4 Continue reassemblyin reverseassemblyorder 5 When assembly is complete check steering stem by turning it from lock to lock If there is any binding or looseness readjust ...

Page 88: ...EAL SD 25 40 5 COLLAR 17 25 7 SHAFT pivot NUT pivot shaft PLUG BOOT rubber SPRING tension SPRING tension 11 12 13 14 15 16 17 19 18 BOLT hexagon WASHER spring REAR CUSHION ASS Y left REAR CUSHION ASS Y right NUT cap WASHER plate 10 25 2 0 BOLT WASHER spring WASHER ...

Page 89: ...eft and right gaps differ by more than the limit adjust as follows a Loosen both the left and right pivot shaft nuts b Loosen pivot shaft on the side of the greater swing gap Loosen only slightly counterclockwise approximately one half turn After loosening tighten the opposite pivot shaft clockwise to 0 5 0 6 43 52 c Measure gap again between frame and swing arm If the left and right gaps are not ...

Page 90: ...re removed 3 Examine rubber boot for damage Replace if damaged E Installation Installation of the swing arm can be accomplished by reversing the removal procedure Observe adjustment procedures for obtaining equal arm spacing 5 8 REAR SHOCK ABSORBER A Removal 1 Remove one rear shock absorber at a time inspect and reinstall before removingthe other B Inspection 1 2 3 4 Check the rod If it isbentorda...

Page 91: ...lder on gear Tighten holder to stud bolt with nut Check for free movement of cable within its housing If movement is obstructed check for fraying or kinking of cable strands If damage is evident cable assembly To lubricate cable hold in vertical position lubricant to uppermost end of cable Leave in vertical position until lubricant appears at bottom Allow excess to drain and reinstall NOTE Choice ...

Page 92: ...ngagement to engagement Note ment from gear engagement to gear engage the lash measurement on the dial gauge ment as the gear coupling is rotated The measurement point on the tool is from the surface of the gear coupling Final gear lash in If lash is not within tolerance refer to Shaft Drive Section for adjustment and repairpage ...

Page 93: ...XS750 Power Flow Schematic ...

Page 94: ...wo geared shafts the drive pinion shaft and gear and the driven pinion gear A flange rides on the driven pinion spline and is bolted to the ball joint The ball joint acts like the universal joints in an auto mobile drive shaft The ball joint is permanent ly lubricated and rarely requires replacement The swing arm rear arm serves as both a suspension component and a housing for the drive shaft Powe...

Page 95: ...ed by shimming resistance of the driven pinion bearings I t 2 Tooth Patterns The locations and is usually adjusted by replacing the terns of contact that are made on the gear Expansion Spacer and very carefully teeth This can be adjusted by shimming adjusting the torque on the special nut 3 Bearing Clearance The distance between a bearing and its bearing housing cap This is an extremely small clea...

Page 96: ...dentification Some component assemblies such as the Middle Gear Case assembly may contain components of more than one type These different types will be identified in the text as Type 1 or Type 2 Precise serial number identification of applicable machines is not available Middle Gear Case Final Gear Case Identifying Feature Housing cap The application of parts of the individual types will be discu...

Page 97: ...nal gear holding tool P No 90890 01229 Ring gear holding tool P No 90890 01254 Dial gauge stand P No 90890 01232 P No 90890 05147 Torque wrench 0 30 cm kg In addition t o these tools and common hand tools the following are required 1 t on press Universal bearing puller Feeler gauges Loctite or similar thread sealant Contact pattern paint See Section 6 2 Bearing installation collars Torque wrench 0...

Page 98: ...lable but can be constructed for shaft drive component disassembly and assembly Press Tool No 1 For final gear guide coller removal see page126 Press Tool No 2 For final gear roller bearing and oil seal installation see page Final Gear Stand ...

Page 99: ...UREMENT A Place the machine on a level surface and place it on the center stand The engine should be cool at atmospheric tempera ture Allow 2 minutes for oil to drain to bottom of cases B Remove the oil filler cap Check the oil level with level gauge from tool kit as shown The correct oil level is between the two marks on each end of the level gauge Use end of gauge marked REAR for measuring the r...

Page 100: ...gear case Do not allow the gear oil to contact the tire and wheel C Reinstall the middle and or final drain plug s MIDDLE GEAR DRAIN BOLTTORQUE 4 3 m kg 31 ft lb FINAL GEAR DRAIN BOLT TORQUE 2 3 m kg 17 ft lb D Fill the gear case s up to specified level Oil Capacity Middle Gear Case 375 cc 13 0 U S fl oz Final Gear Case 300 cc 10 0 U S fl Recommended oil See page 9 E Reinstall the filler cap s sec...

Page 101: ...th I J Driven cam seized to middle gear drive pinion shaft Seizure due to lack of lubrication Small foreign object lodged between moving parts 2 A rolling rumble noticeabte at low speed a high pitched whine a clunk from a shaft drive component or area A Damage to bearings B C Gear tooth damage D Drive flange ball joint bolts loose Improper gear lash improper gear tooth contact NOTE Damage areas A ...

Page 102: ...stop riding immediately This condition could lead to locking up of the shaft drive assembly and result in harm to a rider 4 If the drive flange ball joint bolts are slightly loose a clunk may be felt when slowly taking off or when changing from slow acceleration to slow deceleration At high speed this will result in vibration WARNING Do not continue riding a machine suspected of having loose flang...

Page 103: ...d by road debris or an accident or a gasket or seal may be cracked or broken However on new or nearly new machines an apparent oil leak may be the result of a rust preventive coating or excess assembly lubrication of seals Always clean the machine and recheck the suspected location of any apparent leakage Oil Seals and Gaskets Rubber seal Drive shaft housing in swing arm contains no oil E Checking...

Page 104: ...ven 7 middle gear case securing bolts Remove the meddle gear case drive cam and spring B Final Gear Removal 1 Remove rear axle and left shock absorber Remove rear wheel See XS750D Service Manual for procedures 2 Remove 4 nuts holding Final Drive unit to swing arm NOTE Keep the Final Drive pinion bearing housing attached to the Final Drive assembly I t may tend to separate from the Final Gear for T...

Page 105: ...al drive case stud bolt Place gear holder Special Tool over ring gear surface and stud bolt Tighten holder to stud bolt with nut I 5 Install final gear lash measurement tool on gear coupling input side 1 Gear lash measurement tool 6 Mount a dial gauge against the lash measurement tool at the scribed mark 60 mm 2 36 in from the center of the shaft 7 Use special wrench to gently rotate gear coupling...

Page 106: ...sh measurement tool on the input shaft as shown 1 Gear lash measurement tool 2 Mount a dial gauge against the lash measurement tool a t the scribed mark 34 mm 1 34 in from the center of the shaft 1 Middle and final gear holding tool 4 Check this engagement at 4 positions Rotate the driven pinion shaft 90 each time and repeat the gear lash check Hold the gear case and rotate the input shaft back an...

Page 107: ...must be replaced during reassembly By removing only the drive pinion it is possible to perform a thorough inspection of the middle gear assembly By removing the drive pinion shaft only the following can be inspected 1 Drive Pinion Bearing page 117 118 2 Driven Pinion Bearings page 118 119 3 Drive Pinion Bearing Housing Cap clearance page 120 4 Condition of gear teeth page 117 5 Tooth contact patte...

Page 108: ...earing movement for damage to balls rough spots bearing looseness Inspect gear teeth If any gear tooth is damaged the gear set must be replaced Driven Pinion Assembly Inspection Leave driven pinion installed Spin the shaft to check for bearing damage Inspect gear teeth Drive Pinion Bearing Removal for re placement only Bend down locking collar of the nut 2 Use special tool to hold splined end of s...

Page 109: ...housing F Driven Pinion Disassembly for replace ment only NOTE The following driven pinion disassembly should be performed only if the bearings are to be replaced Do not re use bearings or races that have been installed and removed 1 Remove bearing housing screws Remove bearing housing from case 4 Small bearing rear Remove bearing housing oil seal and bearing inner race ...

Page 110: ... requires an oven Heat bearing housing to 100 C 212 F If necessary tap the races out with a punch 6 Large bearing front Use a universal type bearing puller to remove the bearing from the driven pinion 4 5 Install bearing housing onto drive pinion Install remaining bearing inner race half Use middle gear holding tool to lock drive pinion shaft and install nut Tighten to specified torque Drive Pinio...

Page 111: ...ces must be clean to obtain an accurate measure ment 2 Hold the housing cap in position Insert a feeler gauge between the cap and the case If necessary select an appropriate thrust shim to achieve specified gap Cap to housing gap no gasket 0 2 0 25 mm 0 0079 0 0098 in 3 When gap is adjusted properly remove cap Install new housing cap gasket Reinstall cap and tighten screws to specified torque C Ge...

Page 112: ...evolutions 4 Remove the bearing housing cap and tap out the drive pinion shaft Inspect the gear tooth patterns Example 1 Correct pattern NOTE The pattern should be centered in the tooth drive surface However wear and drive forces tend to move the contact area to the out side Therefore the correct pattern can be slightly toward the inside or heel of the gear tooth 5 To correct an incorrect tooth pa...

Page 113: ...iven shaft using a press and a collar of the proper size Oil the bearing 3 Install smaller bearing inner race into bearing housing Oil the bearing 4 Install a new oil seal into the bearing housing Use a press if necessary 5 Install the washer and a new expan sion spacer on the driven pinion shaft 6 Install the driven pinion assembly into the bearing housing assembly 7 Grease the inside surfaceof t...

Page 114: ...m kg 72 108ft lb d Repeat steps a b and c until proper preload is reached NOTE Early type 1 units used a slightly greater preload however use the above specification for all types 9 Apply tooth pattern checking paint to drive pinion gear Check pattern and adjust if necessary Use procedure for checking drive pinion 10 Install driven pinion assembly into middle gear case as shown Clean bearing housi...

Page 115: ... 0 5 A Purpose of Ring Gear Removal By removing the ring gear assembly only the following inspections can be made I Drive pinion bearings page 117 118 125 2 Ring gear bearings 3 Gear teeth condition 4 Tooth contact pattern page 121 128 129 5 Drive pinion bearing preload page 128 128 ...

Page 116: ...e page 128 for basic procedure Drive Pinion Removal Use two slied weights and 6 mm shafts to remove bearing housing NOTE On Type 2 Final Gear assemblies remove bearing housing securing screw before removing bearing housing E Drive Pinion Disassembly replacement bearings or races after removal 1 Hold gear coupling with special tool Remove self locking nut from drive pinion Tap lightly with a soft h...

Page 117: ...housing to 150 C 302 F Use appro priately shaped punch to remove the roller bearing outer race Remove inner race from the drive pinion 7 2 Reassembly and Adjustment A Drive Pinion Assembly 1 Install 2 new bearing outer races into the drive pinion bearing housing 2 Install the inner race of the smaller bearing to drive pinion shaft Oil the bearing 3 Install the inner race of the smaller bearing int...

Page 118: ...ive pinion shoulder b c Choose spacers that will reduce clearance at c in the illustration to 0 02 mm 0008 in that is the thickness of the spacers must be 0 02 mm less than the c dimen sion d Install the spacers plate washer and nut Tighten nut to specified torque and check preload Specified torque 7 5 8 5 m kg 54 61 ft lb Preload 10 12 cm kg 9 10 in lb e If the preload is less than specified redu...

Page 119: ...dure a Lash too large Install one size smaller ring gear shim b Lash too small Install one size larger ring gear shim Recheck gearlash B Tooth Contact pattern andGear Lash 1 Remove drive pinion assembly from final gear housing The ring gear must be assembled for this check 2 Apply contact pattern checking paint to ring gear See Section 6 2 D for basic contact pattern checking proce dure Page 121 3...

Page 120: ...ease ring gear shim To increase gear lash reduce ring gear shim If it is necessary t o increase ring gear shim by more than 0 1 mm reduce the thrust washer thickness by 0 1 mm for each 0 1 mm of ring gear shim increase and i f it is necessary to reduce shim b y more than 0 1 mm reverse above procedure 114 Section 5 2 5 Final assembly a Remove drive pinion bearing hous ing assembly and apply a smal...

Page 121: ...0 1 mm Old thrust shim b Choose New thrust shim b 0 1 mm 2 Roller bearing replacement a Remove original roller bearing 3 If undamaged reinstall ring gear ball assembly 2 pieces Remove thrust bearing and original shim If bearing washer and assemble the inner and is replaced use a new shim of the outer races of the bearing for same size Continue reassembly in the measurement Use a micrometer to reve...

Page 122: ... drive shaft lubri cate splines and oil seal with light coat of lithium soap base grease 8 2 Ball Joint inspection A Removal Remove middle gear and final gear cases Remove drive shaft The ball joint can now be easily removed from the swing arm cavity NOTE The ball joint cannot be disassembled If damaged it must be replaced Inspection Inspect ball joint for leakage The ball joint should move freely...

Page 123: ...segments should be 0 5 0 8mm 0 02 0 03 below the segment level If not scrape to pro per limits with appropriately shaped tool A hack saw blade can be ground to fit COMMUTATOR MICA UNDERCUT 0 5 0 8mm 0 02 0 03 in c Check the armature and field coil for shorting and insulation Replace armature as required I Coil Resistance Armature coil 0 007 20 C Field Coil I 0 01 20 C d Check the front and rear co...

Page 124: ...battery red white blue white Turn ignition off Use ohms x 1 scale on tester The resistance between these wires should be no more than 3 5 ohms If there is more resistance the relay should be replaced 6 2 CHARGING SYSTEM A Charging Circuit Diagram M AI N A C GENERATOR REGULATOR B A C Generator 1 Checking method a Connect D C voltmeter to the battery termi nals b Start engine c Accelerate engine to ...

Page 125: ...netic field that producesa charging voltage in the three stator windings RECTIFIER 1 I 1 When adjusting the regulator a D C voltmeter ammeter and tachometer are necessary They are connected as illustrated and adjustment should be made in the following sequence a Remove the regulator from the frame and check the contact points If the point surfaces are rough they should be smoothed with sand paper ...

Page 126: ...orted the rectifier could be damaged After the adjustment the generated voltage shows slight fluctuations as illustrated below When the generator speed increases from low the lower contact is in operation to high the upper contact is in operation thevoltage fluctuates slightly but this is a normal pheno menon If the voltageshowsa 0 5volt increase the adjustment is considered to be correct If the v...

Page 127: ...fe of a battery is usually 2 to 3 years but lack of care as described below will shorten the life of the battery a Negligence in keeping battery topped off with distilled water b Battery being left discharged c Over chargingwith heavy charge d Freezing e Filling with water or sulfuric acid containing impurities f Improper charging voltage or current on new battery Battery I 12V 14AH Specific gravi...

Page 128: ...ture 2 Stop engine and connect tester as shown SPARK PLUG 3 Start engine and increase spark gap until mis fire occurs Test at various rpm s between idle and red line I Minimum spark gap 6mm 0 24 in D IgnitionCoil 1 Coil spark gap test a Remove fuel tank and disconnect ignition coil from wire harness and spark plug b Connect Electro Tester as shown IGNITION COIL ORANGE ELECTRO TESTER c Connect full...

Page 129: ...type accordingly It is actually economical to install new plugs often since it will tend to keeptheengine in good condition and prevent excessive fuel consumption A How To Read A Spark Plug Condition 1 Best condition When the porcelain around the center electrode is a light tan color 2 If the electrodes and porcelain are black and somewhat oily replace the plug with a hotter type for low speed rid...

Page 130: ... Flasher light s do not work a Check bulb b Right circuit 1 Check for 12V on dark green wire to light 2 Check for ground on black wire to light assembIy c Left circuit 1 Check for 12V on dark brown wire to light 2 Check for ground on black wire to light assembly d Right and left circuits do not work 1 Check for 12V on brown white wire to flasher switch on left handlebar 5 Neutral light does not wo...

Page 131: ...ition 1 Flasher unit 2 Bulb 3 Lighting circuit 4 Handle switch light circuit If 1 through 4 are in good condition the following may be faulty 1 Flasher canceling unit 2 Handle switch reset circuit 3 Speedometer sensor circuit b Pull off the 6 pin connector from the flasher canceling unit and connect a tester ohms x 100 range across the white green and the black lead wires on the wire harness side ...

Page 132: ...NCTION 1 HEAD INDICATOR BULB DOES NOT GLOW Voltage on LG Wire to Reserve INDICATOR LIGHT DOES NOT LIGHT WHEN LOW BEAM COMES ON HIGH BEAM IS Reserve Unit Indicator Light and or Wiring is Defective NOT FUNCTION Headlight Ground ...

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Page 135: ...0 rnm Formula for determining new shim Original shim new case number original case number Example 0 10 79 73 79 93 0 10 0 2 0 10 0 20 0 30 new shim Notice that the subtraction of a negative number 0 20 is the same operation as adding that amount as a positive number Use this shim and the normal instructions for installation of middle gear components described in Page 119 Section 6 2 C Final Inspec...

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Page 137: ...I Parts No Parts Name Type 1 Type 2 Middle gear housing YG4 11011 00 1G 1J7 17511 Y0 Bearing housing YG4 11011 10 0G 1J7 17521 Y0 Pinion shim Housing cap gasket YG4 11710 70 0G 1J7 17531 Y0 YG4 11005 40 0G 1J7 17519 Y0 Housing cap 1J7 17538 01 1J7 17538 Y1 B Final Gear Parts Name Drive shaft housing camp Bearing housing Gear coupling Expansion spacer Parts No Type 1 Type 2 YG4 11011 50 0G 1J7 4615...

Page 138: ...OIL SCAVENGE Return ...

Page 139: ...Minimum ground clearance Caster steering head angle Trail Weight Net Engine Type Bore x stroke x cylinders Displacement Compressionratio Lubrication Lubrication system Delivery pump type Carburetion Manufacture Type I D No Quantity Rated venturi size 2 160 mm 85 0 in 895 mm 35 2 in 1 150 mm 45 3 in 820 mm 32 3 in 1 470 mm 57 9 in 140 mm 5 5 in 27 110 mm 4 3 in 232 kg 512 Ib D O H C air cooled trip...

Page 140: ... or CHAMPION N 7Y Three phase regulated alternator Hitachi LD120 02 14 5 V 18A 12V 14A Hr 134 x 166 x 89 mm National RD1143 IC Regulator National RD1143 Silicon full wave Transmission Coupled kick Mitsuba Electric SM 224C Hy Vo silent chain 45 27 1 666 Wet multiple disc Constant mesh 5 peed drum shifter 32 13 2 461 13 285 27 17 1 588 8 636 26 20 1 300 7 069 23 21 1 095 5 955 22 23 0 956 5 201 Shaf...

Page 141: ...load length Spring rate 0 100 mm travel Fork oil capacity each side 100 175 m m travel Rear shock absorbers Spring free length Spring preload length Spring rate 0 45 mm travel 45 80 mm travel 4 Electrical Ignition timing retarded advanced advance starts Spark plug cap resistance Regulator type Lighting Regulated voltage Headlight TaiIIight stoplight Flasher light Flasher pilot light Meter lights H...

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Page 143: ...htening Initial 3 200km 2 000miles Clutch adjustment Cylinder cornpression check Valve clearance check Cylinder head torque check Cam chain adjustment 4 800km or 3 000miles Spark plugs inspection and cleaning Carburetor adjustment Brake system inspection Wheel t i r e inspection Battery maintenance Ignition timing adjustment Lights signals check Fittings fasteners tightening B Routine Maintenance ...

Page 144: ... XS750 2D Every 1 600km 1 000miles Check brake fluid Every 3 200km 2 000miles Lubricate control meter cables Lubricate point cam lubrication wicks Every 4 800km 3 000miles Replace engine transmission oil Every 6 400km 4 000miles Lubricate throttle grip housing Replace front fork oil Lubricate speedometer gear housing Every 9 600km 6 000miles Replace oil filter Replace middle final rear gear oil Ev...

Page 145: ...shaft bolts 8 mm 10 mm Clutch holding nut Clutch spring screws Middle gear case mounting screws Rotor holding bolt Bearing housing bolt Oil pipe union bolt Oil pump drive gear nut Crankshaft turning nut Cylinder head 8 mm 10 mm Cylinder holding nuts Camshaft cap nuts Engine mounting bolts 10 mm 12mm Engine oil drain plug Oil filter mounting bolt Middle gear drain plug Final gear assembly mounting ...

Page 146: ...mum 11 kg cm 156 psi E 30 C Front And Rear Brake XS750D XS 750 2D 1 Brake adjustment a Front brake lever free play The front brake lever should be so adjusted that it has a free play 5 8mm 0 2 0 3 in at the lever end 1 Loosen the locknut on the brake lever 2 Turn the adjustor so that the brake lever movement a t the lever end is 5 8 mm 0 2 0 3 in before the adjustor contacts the master cylinder pi...

Page 147: ...her 76 95 0 8 2 Circlip 4 Bearing 5 Plate washer 69 95 5 4 6 Damper spring 7 Collar 8 Circlip 9 Clutch assembly 10 Clutch housing complete 11 Screw 13 Pressure plate 14 Friction plate 14 1 Friction plate cork lining 15 Clutch plate 1 16 Clutch boss assembly 18 Clutch boss spring 19 Clutch plate 2 12 Compression spring 17 Seat plate 20 Circlip 21 Circlip S 20 22 Plate washer 21 2 29 2 23 Circlip 24...

Page 148: ...xt to one dot Position the next steel plate next t o the next dot on the clutch boss Follow this pattern clockwise around the clutch boss until all friction and steel clutch plates are installed In this case the friction plate with cork lining should be installed on the extreme outside PAGE 73 N Piston and Cylinder XS750D XS750 2D 4 Position piston rings as shown NOTE 1 Make sure ends of oil ring ...

Page 149: ...e left cylin der No 1 cylinder Lock the timing plate setting screw with paint 5 For the subsequent operations follow the procedure described 2 5 C Igni tion Timing gauge PAGE 78 4 1 CARBURETOR XS750 2D B Specifications Specification should be cha follow as Starter jet 25 PAGE 82 5 2 REAR WHEEL XS750 2D Only A Removal 1 Place machine on side stand and remove left rear shock absorber NOTE When reins...

Page 150: ...ar fender 1 Installation bolts 6 Remove the axle nut cotter pin and the axle nut 7 Loosen the rear axle pinch bolt 9 Hold up the brake caliper assembly and place it on the hook of the rear arm 10 Move the wheel to the right side t o separate it from the final gear case and remove the rear wheel NOTE Do not depress the brake pedal when the wheel is off the machine so that the caliper piston is not ...

Page 151: ... 2D Only The regulator has been changed from a mechanical point type t o an IC Integrated Circuit type The IC Voltage Regulator is a small and normally very reliable component Due to its construction it is lightweight and free from the wear and misadjustment asso ciated with mechanical voltage regulators If the following inspection reveals that the regulator is faulty it cannot be adjusted and mus...

Page 152: ...en the engine is started and its revolutions go up 7 Make sure that V1 keeps the level of 14 2 14 8V even when engine revo lutions increase 0 0 X 0 0 X 0 0 X U 01 X 0 X X 0 X X 0 X Engine revolutions 8 If these levels are not maintained the regulator is defective and must be re placed Checking Silicon Rectifier 1 Check silicon rectifier as specified using Yamaha pocket tester F Green U White ...

Page 153: ...aged if subject to overcharging Special care should be taken to avoid a short circuit and or incorrect connection of the posi tive and negative leads at the battery Never connect the rectifier directly to the battery to make a continuity check ...

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