Yamaha YZF750R Manuals

Manuals and User Guides for Yamaha YZF750R. We have 1 Yamaha YZF750R manual available for free PDF download: Service Manual

Yamaha YZF750R Service Manual (452 pages)

Brand: Yamaha | Category: Motorcycle | Size: 13.69 MB

Important Features
3
Exploded Diagram
3
Illustrated Symbols
4
Index
5
Contents
6
General Information
13
Motorcycle Identification
13
Vehicle Identification Number
13
Frame Serial Number
13
Engine Serial Number
14
Important Information
15
Preparation for Removal
15
All Replacement Parts
15
Gaskets, Oil Seals, and O-Rings
15
Lock Washers/Plates and Cotter Pins
16
Bearings and Oil Seals
16
Circlips
16
Special Tools for Tune up
17
Special Tools for Engine Service
18
Special Tools for Chassis Service
19
Special Tools for Electrical Components
20
YZF750R General Specifications
21
YZF750R Maintenance Specifications
24
Tightening Torques
31
YZF750R Exclusive Specification
40
YZF750SP General Specifications
43
YZF750SP Maintenance Specifications
46
YZF750SP Exclusive Specification
62
General Torque Specifications
64
Lubrication Point and Grade of Lubricant
65
Coolant Diagrams
67
Lubrication Diagrams
69
Cable Routing
71
Periodic Inspection and Adjustment
75
Periodic Maintenance/Lubrication Intervals
75
Seat Removal
77
Seat Installation
78
Fuel Tank Removal
79
Fuel Tank Installation
80
Cowlings
81
Cowlings Removal
83
Cowlings Installation
84
Engine Valve Clearance Adjustment
85
Intake
90
Exhaust
90
Carburetor Synchronization
93
Idling Speed Adjustment
96
Throttle Cable Adjustment
98
Spark Plug Inspection
100
Ignition Timing Check
101
Compression Pressure Measurement
102
Engine Oil Level Inspection
104
Engine Oil Replacement
106
Clutch Fluid Level Inspection
108
Air Bleeding (Hydraulic Clutch System)
109
Air Filter Cleaning
110
Carburetor Joint Inspection
111
Fuel Line Inspection
112
Crankcase Breather Hose Inspection
112
Exup Cable
113
Exhaust System Inspection
115
Coolant Level Inspection
115
Coolant Replacement
116
Recommended Coolant
118
Handling Notes for Coolant
118
Cooling System Inspection
120
Chassis
121
Front Brake Adjustment
121
Rear Brake Adjustment
121
Brake Fluid Level Inspection
122
Brake Pad Inspection
124
Brake Light Switch Adjustment
124
Brake Hose Inspection
125
Air Bleeding (Hydraulic Brake System)
125
Change Pedal Adjustment
127
Drive Chain Slack Adjustment
127
Drive Chain Lubrication
129
Steering Head Inspection
130
Front Fork Inspection
132
Front Fork Adjustment
133
Spring Preload
133
Rebound Damping (YZF750SP)
134
Compression Damping (YZF750SP)
134
Rear Shock Absorber Adjustment
135
Tire Inspection
137
Wheel Inspection
140
Cable Inspection and Lubrication
140
Lever and Pedal Lubrication
141
Sidestand Lubrication
141
Rear Suspension Lubrication
141
Electrical
142
Battery Inspection
142
Battery Charging Method
142
Charging Method Using a Variable-Current (Voltage) Type Charger
146
Charging Method Using a Constant-Voltage Type Charger
147
Fuse Inspection
148
Headlight Beam Adjustment
150
Headlight Bulb Replacement
150
Engine Overhaul
152
Engine Removal
152
Fuel Tank and Cowlings
152
Engine Oil and Coolant
152
Battery Leads
153
Air Filter Case
153
Carburetor
153
Radiator
153
Hoses and Leads
154
Muffler Assembly
154
Drive Sprocket
156
Engine Disassembly
158
Oil Filter and Oil Cooler
158
Intake Manifold
158
Oil Delivery Hose
159
Water Pump
159
Starter Motor and AC Generator
160
Cylinder Head Cover, Camshaft, Camshaft Case and Cylinder Head
160
Cylinder and Piston
164
Clutch
166
Oil Pan and Oil Strainer
168
Oil Pump and Shift Shaft
169
Crankcase Disassembly
170
Transmission
171
Starter Clutch and Crankshaft
172
Shift Fork and Shift Cam
173
Valve and Camshaft Case
174
Connecting Rod
176
Oil Pump
177
Cylinder Head Inspection and Repair
178
Valve and Valve Guide Inspection and Repair
179
Valve Seat Inspection and Repair
181
Valve Spring Inspection and Repair
184
Camshaft Case Inspection and Repair
185
Valve Lifter Inspection and Repair
185
Camshaft Inspection and Repair
185
Timing Chain, Hy-Vo Chain, Sprocket and Chain Guide
187
Timing Chain Tensioner Inspection and Repair
188
Cylinder and Piston Inspection and Repair
188
Piston Ring Inspection and Repair
189
Piston Pin Inspection and Repair
190
Crankshaft and Connecting Rod Inspection and Repair
191
Oil Pump Inspection and Repair
196
Primary Drive Inspection and Repair
197
Starter Drives Inspection and Repair
197
Clutch Operation Checking Steps
197
AC Generator Shaft Inspection and Repair
198
Clutch Inspection and Repair
198
Transmission and Shifter Inspection and Repair
200
Shift Shaft and Stopper Lever Inspection and Repair
202
Oil-Jet Nozzle Inspection and Repair
202
Relief Valve, Oil Pipe and Strainer Inspection and Repair
202
Oil Cooler Inspection and Repair
203
Crankcase Inspection and Repair
203
Bearing and Oil Seal Inspection and Repair
204
Circlip and Washer Inspection and Repair
204
Engine Assembly and Adjustment
205
Connecting Rod and Crankshaft
206
Lower Crankcase
212
Upper Crankcase
214
Crankcase Assembly
217
Shift Shaft and Oil Pump
220
Piston and Cylinder
227
Cylinder Head
230
Camshaft
231
Cylinder Head and Camshaft
232
AC Generator and Starter Motor
237
Oil Cooler and Oil Filter
239
Engine Remounting
240
Cooling System
245
Radiator/Oil Cooler
245
Radiator Removal
246
Radiator Inspection
248
Radiator Installation
249
Oil Cooler Removal
251
Oil Cooler Inspection
251
Oil Cooler Installation
252
Thermostatic Valve/Water Pump
254
Thermostatic Valve Removal
255
Thermostatic Valve Inspection
256
Thermostatic Valve Installation
257
Water Pump Removal
259
Water Pump Inspection
260
Water Pump Installation
263
Carburetor (YZF750R)
266
Carburetor (YZF750SP)
267
Carburetor Removal
268
Carburetor Disassembly
270
Carburetor Inspection
276
Carburetor Assembly
278
Carburetor Installation
282
Fuel Level Adjustment
284
Throttle Sensor Adjustment and Inspection (YZF750SP)
285
Front Wheel
288
Front Wheel Removal
289
Front Wheel Inspection
290
Front Wheel Installation
291
Static Wheel Balance Adjustment
292
Rear Wheel
294
Rear Wheel Removal
295
Rear Wheel Inspection
296
Rear Wheel Installation
296
Front and Rear Brake
298
Brake Pad Replacement
300
Caliper Disassembly
304
Front Brake
305
Rear Brake
306
Master Cylinder Disassembly
307
Caliper Assembly
312
Master Cylinder Assembly
317
Hydraulic Clutch
323
Hydraulic Clutch Disassembly
324
Clutch Release Cylinder
324
Master Cylinder
325
Hydraulic Clutch Inspection and Repair
326
Hydraulic Clutch Assembly
327
Front Fork YZF750R
332
Front Fork YZF750SP
333
Front Fork Removal
334
Front Fork Disassembly
335
Front Fork Assembly
338
Front Fork Installation
344
Steering Head and Handlebar
346
Steering Head and Handlebar Removal
347
Steering Head and Handlebar Inspection
350
Steering Head and Handlebar Installation
351
Rear Shock Absorber and Swingarm
355
Rear Shock Absorber and Swingarm Handling Notes
356
Rear Shock Absorber and Swingarm Notes on Disposal
356
Rear Shock Absorber Removal
356
Rear Shock Absorber Inspection
361
Swingarm Inspection
361
Rear Shock Absorber Installation
363
Swingarm Installation
364
Drive Chain and Sprockets
366
Drive Chain and Sprockets Removal
367
Drive Chain and Sprockets Inspection
368
Drive Chain and Sprockets Installation
370
Electrical Components
372
Checking of Switches
374
Switch Connection as Shown in Manual
374
Checking Switch for Terminal Connection
375
Checking of Bulbs
378
Kinds of Bulbs
378
Checking Bulb Condition
378
Checking of Connections
380
Ignition System Circuit Diagram
381
Ignition System Troubleshooting
382
Electric Starting System Circuit Diagram
388
Starting Circuit Operation
389
Electric Starting System Troubleshooting
390
Starter Motor Does Not Operate
390
Charging System Circuit Diagram
401
Charging System Troubleshooting
402
The Battery Is Not Charged
402
Lighting System Circuit Diagram
406
Lighting System Troubleshooting
407
Headlight "High Beam" Indicator Light, Taillight, And/Or Meter Light Do Not Come on
407
Main Switch
408
Light Switch/Lights (Dimmer) Switch
408
"PASS" Switch
409
Lighting System Check
410
Headlight and "HIGH BEAM" Indicator Light Does Not Come on
410
Meter Light Does Not Come on
411
Taillight Does Not Come on
411
Auxiliary Light Does Not Come on
412
Front Position Light Does Not Come on
413
Signal System Circuit Diagram
414
Signal System Troubleshooting
416
Flasher Light, Brake Light And/Or Indicator Light Do Not Come on
416
Horn Does Not Sound
416
Signal System Check
418
Horn Switch
418
Flasher Light And/Or "TURN" Indicator Light Does Not Blink
421
"Neutral" Indicator Light Does Not Come on
423
"Oil Level" Indicator Light Does Not Come On, When Engine Oil Level Is Low
425
"Fuel" Level Indicator Light Does Not Come On, When Fuel Level Is Low
427
Cooling System Circuit Diagram
428
Cooling System Troubleshooting
429
Fan Motor Does Not Move
429
Water Temperature Meter Does Not Move, When Engine Is Warm from Cool
429
Fuel Pump System Circuit Diagram
433
Fuel Pump Circuit Operation
434
Fuel Pump System Troubleshooting
435
Fuel Pump Fails to Operate
435
Fuel Pump Test
438
Exup System Circuit Diagram
439
Exup System Troubleshooting
440
When Engine Revolution Is Changed, Exup Servomotor Does Not Operate
440
Starting Failure/Hard Starting Troubleshooting
445
Pool Idle Speed Performance
446
Poor Medium and High Speed Performance
446
Faulty Gear Shifting
447
Clutch Slipping/Dragging
447
Hard Shifting
447
Shift Pedal Does Not Move
447
Overheating
448
Faulty Brake
448
Front Fork Oil Leakage and Front Fork Malfunction
448
Instable Handling
448
Faulty Lighting and Signal System
449
Headlight Dark
449
Flasher Does Not Light
449
Flasher Keeps on
449
Faulty Exup
450
Wiring Diagram
451

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Yamaha YZF750R Service Manual (452 pages)

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