Yamaha XS750-2D User manual

SUPPLEMENT
XS750 - 2D
Note: This section only covers those points which are
different from the
XS 750 D.
If the subject does not appear in this section,
please refer to the Contents page.
SPECIFICATIONS
(XS750-2D Only)
A. GENERAL SPECIFICATIONS
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimumground clearance
Caster (steeringhead angle)
Trail
Weight:
Net
Engine:
Type
Bore x stroke x cylinders
Displacement
Compressionratio
Lubrication:
Lubrication system
Delivery pumptype
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, triple
68 mmx68.6 mm x 3
747 cc
8.5 : 1
Pressure lubricated, wet sump
Trocoid pump
Mikuni
BS34, Constant velocity, 1J701,3pcs
34 mm mm

Air filter:
Type
Type
Ignition:
Spark plug
Charging:
Type
Manufacture, I.D. No.
Maximumoutput
Battery type
Battery dimensions
Regulator
Rectifier
Starting
Primary deive
Type
Teeth, ratio
Clutch
Transmission:
Type
Teeth. ratio, overall 1st
2nd
3rd
4th
5th
Secondary Drive:
Type
Transmission Output:
Middlegear case
Final gear
case
Type. teeth, ratio
Type. teeth, ratio
Type, teeth, ratio
Chassis:
Frame
Suspension:
Front (type,
travel)
Rear (type, travel)
Front
Rear
Brakes:
Front
Rear
Fuel tank
Wheels:
Front
Rear
Tires:
Dry foam rubber
Battery/coil
NGK BP-7ES 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 ElectricSM
- 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
Shaft drive
Spur gear, 34/32, 1.063
Bevelgear, 19/18, 1.056
Bevel
gear. 32/11,2.909
Tubular steel double cradle
Telescopicfork, 175 mm (6.9 in)
Swing arm,80 mm (3.2 in)
3.25 H 19
- 4PR Bridgestone
4.00 H 18
- 4PR Bridgestone
Dual hydraulic disc
Single hydraulicdisc
17.0 lit (4.5 USgal) Regular leaded or unleaded
1.85 x 19 Cast Aluminum
2.15 x 18 Cast Aluminum

B. MAINTENANCESPECIFICATIONS
Engine/Transmission oil capacity
Total amount
Oil and filter change
Oil change
2. Carburetion
Manufacturer Mikuni
Model, I.D.No. BS34.1J701
Main jet
No. 145
Needle
jet
Y - 2
Pilot
jet
No. 17.5
Starter
jet
No.25
Jet needlelclip position 4H 11/3
1. Engine
3,800 cc (4.0
US qt)
3,500 cc (3.7
US qt)
3,000 cc (3.2 US qt)
Float level
Pilot screw 2-1/4 turns
Air jet, Main 1.0 mm
Air
jet, Pilot 1.6 mm
Throttle valve, No. 140
Inlet valve size
2.0 mm
Engine idlespeed 1,050 - 1,150 rpm
26.5 ± 2.5mm (from gasket surface)
Brakes
Recommendedfluid
Minimumboiling point
Pad thickness wear limit
Brake disc maximumdeflection
Brake disc minimumthickness
Front brake freeplay (endof lever)
Rear brakefreeplay (end
of pedal)
Front forks
Spring
free length
Spring preload length
Spring rate
(0~100 mmtravel)
Fork oil capacity (eachside)
(100~175 mmtravel)
Rear shock absorbers
Spring free length
Spring preload length
Spring rate (0~45mmtravel)
(45~
80 mmtravel)
4. Electrical
Ignitiontiming retarded
advanced
advance
starts
Spark plug cap resistance
Regulator type
Lighting
Regulated voltage
Headlight
Tai
I I ight/stoplight
Flasher light
Flasher pilot light
Meter lights
High beam indicator light
Oil pressurewarning light
Neutral light
DOT No.3
240°C (464°F)
6.0 mm (0.24 in)
0.15 mm
(0.006 in)
6.5 mm (0.26 in)
5 - 8 mm (0.2 - 0.3 in)
10
mm (0.40 in)
503.2 mm (19.81
in)
473.2 mm (18.63 in)
0.5 kg/mm (28Ib/in)
0.648 kg/mm (36.3 Ib/in)
200 cc (6.76 USfl.oz.)
256 mm(10.08 in)
228 mm (9.0 in)
1.9 kg/mm (106 Ib/in)
2.52 kg/mm 1141.1 Ib/in)
10°@1.100 rpm
28.5°±1.5°@3.050±150rpm
1,800±100 rpm
4.25~6.0 K ohms
National RD1143
14.5±0.3V
Sealed beam 12V, 50/40W
12V. 8/27W (two bulbs)
12V. 27W (four bulbs)
12V. 3.4W (twobulbs)
12V. 3.4W (two bulbs)
12v.3.4
w
12v. 3.4w
12v. 3.4w

Valve Timing (XS750D, XS750-2D)
OVER LAP
77 "
BDC
Specifications in parentheses ( ) are for XS
750
- 2D. Specifications without parentheses
are for
XS750D.
Close
Intake
Exhaust
60°
BBDC
(64° ) (40°)

Page numbers shown in brackets correspond to page numbers of the XS750D Service Manual.
(PAGE 19 - 20)
A.
Maintenance Intervals For New Machines (XS750D, XS750-2D)
Initial 400Km (250miles):
Cam chain adjustment
Spark plug inspection
Wheel, tire inspection
Fuel petcock cleaning
Battery maintenance
Lights, signals check
Fittings, fasteners tightening
Brake system inspection
Initial 800km (500miles):
Carburetor adjustment
Brake system inspection
Wheel, tire inspection
Battery maintenance
Ignition timing check
Lights, signals check
Fittings, fasteners tightening
Clutch adjustment
Steering head adjustment
Initial 1,600km (1,000miles):
Air filter cleaning
Brake system inspection
Wheel, tire inspection
Fuel petcock cleaning
Battery maintenance
Lights. signals check
Fittings, fastenerstightening
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,
tire inspection
Battery maintenance
Ignition timing adjustment
Lights, signals check
Fittings, fastenerstightening
B. Routine Maintenance intervals (XS750D, XS750-2D)
Every 1 ,600km (1,000miles):
Air filter cleaning
Brake system inspection
Wheel, tire inspection
Battery maintenance
Lights, signalscheck
Fittings, fastenerstightening
Every 3,200km (2,000miles):
Spark plug inspection
Carburetor adjustment
Fuel petcock cleaning
Ignition timing check and adjustment
Clutchadjustment
~
Every 6,400km (4,000miles):
Cylinder compression check
Valve clearance check and adjustment
(9,600km
or 6,000miles)
Cylinder head torque check
Cam chain adjustment
(4,800km or 3,000miles)
Steering head adjustment
Swing arm bearing adjustment

C. Lubrication Intervals For New Machines (XS750D, XS750-2D)
Middle/Final (rear) gear
Initial 400km (250miles):
Replaceengine/transmissionoil
Replace
oil filter
Replace middle/final(rear)gear
oil
Lubricatethrottle griplhousing
Check brake fluid
Initial800km (500miles):
Check brake fluid
Initial 1,600km (1,000miles)
Check brake fluid
3. SAE 80
, API "GL-4"Hypoidgear oil, for use below 15°C (41°F)
Initial 3,200km (2,000miles):
Replaceengine/transmission oil
(2,400km or 1,500miles)
Lubricate control/meter cables
Lubricate throttle grip/housing
Check brake fluid
Replacefront fork oil
Replace
oil filter (4,800km or 3,000miles)
Replacesteering bearing grease
Lubricate speedometer gear housing
D. Routine Lubrication Intervals (XS750D, XS750-2D)
Every 1,600km (1,000miles):
Check brake fluid
Every 3,200km (2,000miles):
Lubricate control/meter cables
Lubricate point cam lubricationwicks
Every 4,800km (3,000miles):
Replace engine/transmission oil
Every 6,400km (4,000miles):
Lubricate throttlegrip/housing
Replacefront fork oil
Lubricatespeedometer gear housing
Every 9,600km (6,000miles):
Replaceoilfilter
Replacemiddle/final (rear)gear oil
Every 12,800km (8,000miles):
Replacesteering bearing grease
Replacerear arm pivot bearing grease
Replacewheel bearing grease
NOTE:
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace and bleed the air from
the brake fluid. Normally check the brake fluid
level and add the fluid as required.
2. Replacethe master cylinder and caliper cylinder internal seals every two years.
3. Replacethe brake hoses every four years, or if cracked or damaged.
E. Recommended Lubricants (XS750D, XS750-2D)

Torque Specifications
Front axle nut
Front axle holder nuts
Rear axle nut
Rear axle pinch bolt
Rear shock absorber
(Top)
(Bottom)
Brakes
Caliper support bolt
Caliper mounting bolt
Brake hose union bolt
Disc mounting bolt
Front fork pinch bolt
Steering stem top bolt
Swing arm pivot lock nut
Rear shock absorber nut
Engine:
10.7 m - kg (77 ft - lb)
2.0 m - kg (14ft - lb)
15.0 m
- kg (108ft-lb)
0.6 m - kg ( 4 ft - lb)
3.5 m
- kg (25ft - lb)
4.0 m
- kg (29ft-lb)
1.8 m - kg (13ft - lb)
3.5 m
- kg (25ft - lb)
2.6 m-kg (19ft-lb)
2.0 m - kg (14ft - lb)
1.8 m
- kg (13ft-lb)
8.6 m - kg (62 ft - lb)
10.0 m
- kg (72ft - lb)
3.0 m
- kg (22ft - lb)
Spark plug
Cam cap nut
Rod cap
Starter clutch bolt
Shift cam locating bolt
Detent assembly
Transmission bearing caps
Crankshaft 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 nuts
Chassis
2.0 m
- kg (14ft - lb)
0.9 m
- kg
3.8 m
- kg
3.0 m
- kg
1.7 m
- kg
4.3 m
- kg
2.0 m
- kg
2.0 m
- kg
3.7 m
- kg
12.0 m
- kg
0.9 m - kg
2.3 m
- kg
3.5 m
- kg
2.2 m - kg
2.1 m
- kg
10.0 m
- kg
2.3 m
- kg
2.0 m
- kg
3.5 m
- kg
2.0 m
- kg
1
.O m - kg
5.5 m
- kg
9.5 m - kg
4.3 m
- kg
3.2 m- kg
4.3 m - kg
4.0 m-kg
( 7 ft - lb)
(27 ft
- lb)
(22ft
- lb)
(12ft
- lb)
(31ft
- lb)
(14
ft - lb)
(14
ft - lb)
(27 ft - lb)
(87
ft - lb)
( 7 ft - lb)
(17ft
- lb)
(25
ft - lb)
(16ft - lb)
(1
5 ft - lb)
(72
ft - lb)
(17 ft
- lb)
(14ft-lb)
(25ft - lb)
(14ft
- lb)
( 7 ft
- lb)
(40
ft - lb)
(69 ft - lb)
(31ft
- lb)
(23ft
- lb)
(31ft
- lb)
(29 ft - lb)

(PAGE 24)
C. Engine/Transmission oil (XS750-2D)
2. Engine/Transmission oil and oil filter
replacement.
g. Add oil through the dip stick hole.
Specifications should be changed
as
follows:
3.0 liter (3.3 US qt)
With oil filter change
(PAGE 25)
D. Middle Gear/Final Gear Oil (XS750D,
2. Gear oil replacement
XS750-2D)
d. Fill the gear case(s) upto specified level.
Specifications should be changed as fol -
lows:
Oil Capacity:
Middle gear case:
375cc(12.7 U.S. fl oz)
Final gear case: 300cc(10.0 U.S. fl oz)
1 I
(PAGE 26)
F. Cam Chain Adjustment (XS750-2D)
The cam chain tensioner stopper bolt is
located on the right (inboard)side of the
tensioner
boss.
(PAGE 28)
H. Compression Pressure Measurement (XS
750D, XS750-2D)
Procedure 5.
Specifications should be changed as fol -
lows:
Compression pressure:
(at sea level)
Standard:
10 kg/cm² (142 psi)
Minimum:
9 kg/cm² (128 psi)
Maximum:
11 kg/cm² (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 at the lever end is
5 ~ 8 mm (0.2 ~ 0.3 in) before
the adjustor contacts the master
cylinder piston.
3) After adjusting, tighten the lock
-
nut.
NOTE:
Check for correct play and make
it
is working properly.
Free play: 5 ~ 8mm (0.2 ~ 0.3 in)
1. Adjustor 2. Locknut
a. 5 ~ 8 mm (.02 ~ 0.3in)
b. Rear brake pedal free play
CAUTION:
Proper pedal free play is essential to
avoid excessive brake drag.
1) Loosen the adjustor locknut (for
pedal height).
2) By turning the adjustor bolt clock -
wise or counterclockwise, adjust
the brake pedal position
as shown
in the illustration.
3) Secure the adjustor locknut.
4) Loosen the brake rod adjustor lock -
nut.
5) Turn in the brake rod until it
lightly touches the master cylinder,
then turn
it out by approx. 1-½ ~
1-¾ turns.

NOTE:
See that the punched mark on the
brake rod
is not above the top
surface of the adjustor locknut in
securing the brake rod adjustor
locknut.
(PAGE 86~90)
5-3. BRAKES (XS750D, XS750 - 2D)
The shim inthe caliper is no longer used,
and
a set of two pad springs has been
changed into
a one piece type.
(PAGE 37)
C.
Muffler, Footrest, Brake Pedal (XS750-
2D Only)
The muffler has been changed from 3
into 1 to 3 into 2.
1. Brake rod
4. Footrest
2. Adjustor bolt (for pedal height) 5. Brake pedal
3. Locknut 6. Joint
7. Locknut
(PAGE 68)
XS750D, XS750-2D
1 Damper assembly
3 Plate washer ( 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. S crew
13. Pressure p late
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 s
pring
17. S eat plate
20. Circlip
21. Circlip (S-20)
22. Plate washer ( 21.2-29.2)
23. Circlip
24. Primary
driven gear ( 45T)
25. Plate washer ( 22-36-2.6)
26. Push rod 1
28. Lock washer
29. Conical spring washer
30. Plate washer ( 25.2-39-1.0)
27. Hexagon
31. Spacer
32. Ball ( 5/16 inch)
33. Push rod
34. Oil seal ( SD-8-25.8)
35. Ball screw assembly
36. Adjusting screw
37. Adjusting nut
38. T orsion spring
39. Spring hook
40. Pan head screw
41. Joint
42. Pin
43. C otter pin

(PAGE 69)
G. Clutch and Primary Drive (XS750D,
XS750-2D)
1. Install clutch spacer, plate washer, and
clutch boss. Install the spring washer,
lock washer and locknut. Use the clutch
holding tool and special 32mm deep
socket (special tool) to tighten the
clutch nut.
Top (LOWER RAIL1
NOTE:
Bend over locking tab after locknut is
tightened.
~~~
Clutch nuttorque:
12.0 m-kg (87 ft-lb) 1
, Main axle
Locknut
Lock wash
Conical
spring
washer
2. Install a clutch friction plate, then a
steel clutch plate. Install clutch friction
plates and steel plates alternately.
NOTE:
Each steel clutch plate has a tab. There
is a dot on the clutch boss to correspond
to each tab.
Install a clutch plate tab
next to one dot. Position the next steel
plate next to the next dot onthe 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 expan -
ders are not overlapped.
2) Manufacturer's marks or numbers
stamped on the rings are
on the top
side of the rings. Coat pistons and
rings well with oil.
2ND
I
OILRING '
(UPPER RAIL)
5. Install the cylinder. A ring compressor
is usually not necessary.
(PAGE 74)
P. Camshaft installation (XS750D)
Deletethe following sentences.
NOTE:
Manufacturer's marks or numbers
stamped on the rings are on the topside
of
the rings. Coat pistons and rings well
with
oil.

5. Install the cylinder.
A ringcompressor is
usually not necessary.
3-6. TIMING PLATE SETTING (XS750D,
A. Timing plate setting
XS750-2D)
Adjustments required when the fol -
lowing parts are replaced; crankcase,
crankcase cover (left side) governor
assembly and/or crankshaft.
1. Install the governor and breaker plate
assembly on the crankcase cover (left
side).
2. Install the dial gauge in the spark plug
hole in the left cylinder
(No.1 cylinder).
The dial gauge stand (special tool)
is
required.
3. By turning the crankshaft counter -
clockwise slowly, locate T.D.C. on the
power stroke in the left cylinder
(No. 1
cylinder).
4. Align the timing plate tip with the " T "
mark on the governor for the 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 " .
1. 0181 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 reinstalling rear shock absorber,
tighten to following torque:
Top mount: 3.5 m
- kg (25 ft-lb)
Bottom mount: 4.0 m - kg (29 ft - lb)
2. Hook one end of the wire tool to the
hook attached to the frame.
3. Apply your weight to the rear part of
the
seat, and contract the rear shock
absorber by pulling up the right side of
the swing arm with your hand, then
connect the
free end of the wire tool
tothe swing arm
as shown.
4. With the wire tool in this position, pull
machineonto center stand.

5.
Raise the seat and unscrew the rear fen -
der installation bolts untiltheir threaded
8. While supporting the brake caliper, pull
out the rear axle.
portion
is completely out. Reinsert those
bolts as stoppers while holding the rear
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 to
separate
it from the final gear case and
removethe rear wheel.
NOTE:
Do not depress the brake pedal when
the wheel
is off the machine so that
the caliper piston
is not forced out
of the cylinder.

11. To install the rear wheel, reverse the
removal procedure.
NOTE:
When installing the rear wheel, be
sure
the splines on the wheel hub fit intothe
final gear case. Make sure there
is an
enough gap between the disc pads for
the brakedisc.
CAUTION:
Always use a new cotter pin when re-
assembling rear axle nut.
Axle nut: 15.0 m-kg (108 ft-lb)
Axle pinch bolt: 0.60 m-kg (4 ft-lb)
1 Rear wheel hub splines 2. Final gear case splines
6-2. CHARGING SYSTEM (XS750-2D Only)
A. Charging Circuit Diagram
NOTE:
Rectifier
is combined with the Voltage
Requlator
in the same housing.
IC Voltage Regulator with Rectifier
m
/ \
Field coil
/ A.C. Generator
(PAGE 137)
C. Voltage Regulator (XS750-2D Only)
The regulator has been changed from a
mechanical - point type to 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
must be replaced.
Checking IC Voltage Regulator
1. Measure the specific gravity of the bat -
tery fluid. If it is less than 1.26, remove
the battery and recharge
until it is more
than 1.26.
2. Remove the left hand side cover.
3. Check the battery terminals and couplers
for looseness.
4. Connect two Yamaha pocket testers to
the regulator coupler as illustrated.
CAUTION:
Beware of short-circuiting when con-
necting tester lead wires to the coupler.

5. Turn the main switch on. Make sure that
V2
is less than1.8V.
connecting
Good
element
NOTE:
Do not turn on lights or signals.
Replace Replace
lelement lelement
shorted1 opened)
6. Make sure that V2 gradually increases
up
to 9 ~ 11 V when 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.
01 u 0 0 X
B1 v 0 0 X
61 w 0 0 X
U 01 X 0 X
D1
D2
v 61 X 0 X
D3
w B, 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

0: Continuity X: Discontinuity (=-)
Even of one of elements is broken,
replace assembly.
CAUTION:
The silicon rectifier can be damaged 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.

XS750-2D Circuit Diagram