1989–1997 Yamaha XTZ750 Super Tenere Service Manual (P/N 3LD-28197-21)

This Yamaha factory workshop manual covers the XTZ750 Super Tenere identified by model codes 3LD, 3SC (E), and 3TD (CH). Both frame and engine numbering begin at 3LD-000101, 3SC-000101, and 3TD-000101. Its core subject is the 749 cc liquid-cooled, DOHC parallel-twin with dry-sump lubrication and a constant-mesh five-speed transmission. The 425-page PDF contains a repeated 57-page scan block and one additional duplicate page, leaving 367 distinct page images; confirm fit from the model code and starting number rather than model year alone. Because the material assumes measuring equipment, Yamaha service tools, and a working knowledge of motorcycle repair, it is suited to experienced mechanics and technicians rather than first-time owners.

• Engine overhaul: Documents engine removal, complete disassembly, inspection and repair, bearing selection, and reassembly of the cylinder head, valves and camshafts, crankshaft and connecting rods, pistons and cylinders, twin balancers, clutch, oil pumps, transmission, shifter, rotor, and starter drive.

• Carburetion and cooling: Breaks down the twin Mikuni BDST carburetors for removal, disassembly, inspection, assembly, synchronization, fuel-level adjustment, and fuel-pump testing. Separate 3LD00 and 3TD00 (CH) calibration data help prevent the Swiss-market carburetor setup from being treated as the base specification. Radiator, cap, water-pump, thermostat, coolant-replacement, and leak-testing work is covered as well.

• Chassis repair: Follows front- and rear-wheel removal, bearing inspection, static balancing, brake-pad service, caliper and master-cylinder rebuilding, hydraulic bleeding, fork teardown and seal replacement, steering-head service, swingarm and linkage inspection, rear-shock adjustment, and drive-chain and sprocket work.

• Electrical diagnosis: Maps the digital TCI ignition, electric starting, starter motor, AC-magneto charging, lighting, signal, and cooling-fan systems. Circuit-specific fault tracing is paired with switch and bulb checks, component locations, continuity and resistance tests, charging-output checks, and the related electrical specifications.

• Maintenance and adjustment: Uses the factory interval chart and covers valve-clearance shim work, carburetor synchronization, ignition-timing and compression checks, oil and coolant service, clutch and throttle-cable adjustment, brake inspection, drive-chain adjustment, steering-head setup, suspension checks, spoke inspection, battery service, and headlight aiming.

• Troubleshooting and reference data: Symptom charts address hard starting, poor idle or higher-speed performance, faulty shifting, clutch slip or drag, overheating or overcooling, weak braking, fork leakage or malfunction, unstable handling, and lighting or signal faults. Engine and chassis torque tables, general torque guidance, capacities, lubricant grades, wear limits, clearances, and electrical test values support the repair chapters.

For engine rebuild work, the data tables go past ordinary service intervals. They cover crankpin and main-journal bearing selection, cylinder and piston wear checks, valve, guide, and seat dimensions, camshaft and transmission inspection limits, lubrication routing, and assembly-specific tightening references. These are the measurements needed to decide whether components can be reused, refinished, or replaced.

Diagrams and Factory Tooling

The visual references are tied directly to workshop tasks: an engine lubrication-route diagram, coolant-flow diagram, cable-routing plates, a carburetor section view, the complete XTZ750 wiring diagram, and separate circuit diagrams for ignition, starting, charging, lighting, signals, and the cooling fan. Exploded assembly views identify part order and lubrication points before major teardown.

The special-tool section identifies the equipment by Yamaha number. Examples include the vacuum gauge P/N 90890-03094, rotor puller P/N 90890-01362 with adapter 90890-01382, and valve-spring compressor P/N 90890-04019 with attachment 90890-04114. Chassis and electrical repair references call for the fork damper-rod holder P/N 90890-01327, dynamic spark tester P/N 90890-03144, and pocket tester P/N 90890-03112.

Several manual-specific cautions deserve attention. Solvent can swell and distort the hydraulic-brake seals, while turning the crankshaft during camshaft installation can cause damage or incorrect valve timing. The rear shock is a sealed, nitrogen-pressurized unit that must not be opened, heated, or deformed. Secure the motorcycle and engine before major removal work, allow the cooling system to depressurize, and keep ignition sources away from fuel.