Yamaha XZ550RJ 1982 Service Manual
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Yamaha XZ550RJ 1982 Service Manual

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YAMAHA
XZ550RJ
SERVICE MANUAL
11H-28197-10
1

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Summary of Contents for Yamaha XZ550RJ 1982

  • Page 1 YAMAHA XZ550RJ SERVICE MANUAL 11H-28197-10...
  • Page 2 FEATURES XZ550RJ Liquid-cooled V-Twin The 70° V-Twin engine is liquid-cooled to maintain the best operating temperature range. The cooling system features an aluminum-corrugate radiator which is extremely light and exhibits excellent heat-dissipating char- acteristics. An automatically activated electric fan pulls air through the radiator in heavy-traffic situations. The system has an automotive-type expansion and recovery tank which makes airspace in the radiator unneces- sary and virtually eliminates coolant loss on even the hottest days.
  • Page 3 YICS To increase fuel economy through more efficient combustion, the engine is equipped with the patented Ya- maha Induction Control System (YICS). In this configuration, the YICS consists of a chamber linked to the in- take manifold by a tube. Upon intake, the vacuum in the manifold creates a vacuum in the chamber; when the intake valve closes, the chamber draws in some air-fuel mixture.
  • Page 4 LIQUID COOLING SYSTEM Downdraft carb The induction system on this motorcycle features downdraft carburetion. The 34 mm (1.34 in) Venturis are positioned so that the incoming air takes a virtually straight path through the carbs and the intake manifolds to the combustion chambers;...
  • Page 5 The axle placement helps to maintain a short wheelbase, allowing quick, sporty handling. Yamaha's proven Monoshock rear suspension provides the excellent handling and comfort charac- teristics for which it is famous. The spring preload is adjustable to five settings.
  • Page 6 Proper service with the correct tools is necessary to ensure that the motorcycle will oper- ate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the cus- tomer with the most satisfaction from his motorcycle and to conform with federal environmental quality objec- tives.

  • Page 7: Table Of Contents

    CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION………………………………………………………………………………..Frame serial number……………………………………………………………………………………….. Engine serial number………………………………………………………………………………………. Vehicle identification number…………………………………………………………………………….. SPECIAL TOOLS……………………………………………………………………………………………………... For tune-up…………………………………………………………………………………………………… For engine service………………………………………………………………………………………….. For chassis service…………………………………………………………………………………………. For middle gear service……………………………………………………………………………………. For shaft drive service……………………………………………………………………………………... For electrical components…………………………………………………………………………………...

  • Page 8: Chapter 1. General Information

    GENERAL INFORMATION MOTORCYCLE IDENTIFICATION Frame serial number The frame serial number is stamped into the right side of the steering head pipe. 1. Engine serial number Vehicle identification number The vehicle identification number is on the left side of the steering head pipe. 1.

  • Page 9: Special Tools

    SPECIAL TOOLS The proper special tools are necessary for complete Tappet adjusting tool (P/N YM-28899) and accurate tune-up and assembly. Using the cor- rect special tool will help prevent damage caused by the use of improper tools or improvised techniques. For tune-up Inductive tachometer (P/N YU-08036) Inductive timing light (P/N YU-08037)
  • Page 10 Valve guide reamer Flywheel puller (P/N YM-04066) (P/N YU-33270) This must be used when replacing the valve guide. This tool is used for removing the flywheel Valve guide installer 8mm (0,3 in) wrench adapter (P/N YM-04065) (P/N YM-28897) This tool is needed for proper installation of the This tool is used to loosen or tighten the cylinder valve guides.
  • Page 11 Piston pin puller 46 mm (1.8 in) offset wrench (P/N YU-01304) (P/N YM-04045A) This tool is used to loosen and tighten the primary This tool is used to remove the piston pin. drive gear/balancer drive gear securing nut. #30 Torx driver Plain bearing driver/installer (P/N YU-29843-6) (P/N YM-28898)

  • Page 12: For Chassis Service

    Plastigauge set “Green” For middle gear service (P/N YU-33210) Universal joint holder (P/N YM-04062) This gauge is needed when measuring clearance for connecting rod bearing. This tool is used when adjusting gear lash, in the For chassis service middle gear. T-handle (P/N YU-01268) and damper rod holder (P/N YM-33256) Middle drive gear holder...

  • Page 13: For Shaft Drive Service

    Bearing retainer wrench For shaft drive service Damper spring compressor (P/N YM-33214) (P/N YM-04011) This tool is used to loosen or tighten the bearing retainer. This tool is needed to disassemble and reassemble the middle gear damper. For electrical components The uses of these tools are described in Chapter 6.
  • Page 14 CHAPTER 2. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION…………………………………………………………………………………………………….. MAINTENANCE INTERVALS CHARTS…………………………………………………………………………. PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM………………………………………………… GENERAL MAINTENANCE/LUBRICATION……………………………………………………………………. ENGINE………………………………………………………………………………………………………………. Valve clearance adjustment………………………………………………………………………………… Spark plug……………………………………………………………………………………………………… Crankcase ventilation system……………………………………………………………………………… Fuel line………………………………………………………………………………………………………… Exhaust system………………………………………………………………………………………………. Carburetor synchronization………………………………………………………………………………… Idle speed……………………………………………………………………………………………………… Engine oil………………………………………………………………………………………………………. Coolant…………………………………………………………………………………………………………. Clutch adjustment……………………………………………………………………………………………. Checking ignition timing……………………………………………………………………………………. Compression pressure measurement…………………………………………………………………….

  • Page 15: Periodic Inspections And Adjustments

    PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION MAINTENANCE INTERVALS CHARTS Proper periodic maintenance is important. Espe- This chapter includes all information necessary to cially important are the maintenance services re- perform recommended inspections and adjust- lated to emissions control. These controls not only ments.

  • Page 16: General Maintenance/Lubrication

    GENERAL MAINTENANCE/LUBRICATION...

  • Page 17: Engine

    ENGINE Valve clearance adjustment Adjust the valve clearance as follows: NOTE: Valve clearance must be measured when the en- gine is cool to the touch. 1. Remove the seat, and remove the side cov- ers, fuel tank, air filter assembly, and crank- case ventilation pipes.
  • Page 18 The flywheel is marked as follows: 1. Emblem plate 2. Timing plug 7. Align the "T" mark (for the front cylin-der)Vpn the flywheel with the stationary pointer on the crankcase cover. The pointer can be viewed through the timing window in the crankcase cover.
  • Page 19 a. There is a slot in each valve lifter. The slots d. Remove the pads from the lifters. There is a must be positioned opposite of each other on slot in each lifter. Use an air gun or a small the exhaust and intake side before the tappet screwdriver and a magnetic rod to remove adjusting tool is installed.
  • Page 20 NOTE: The new pad number is to be used as a guide only. Verify the correctness of this choice in the following step(s). At the intersection of installed pad number (down) and measured clear- ance (across) is a new pad number. EXAMPLE: Intake valve, installed pad: No.250 (read down)
  • Page 22 10. Install the new pad in the lifter. Install the pad with the number down. 11. Turn the crankshaft to remove the adjusting tool from the camshaft. 12. Turn the crankshaft to rotate cam several ro- tations. This will set the pad in the lifter. 13.

  • Page 23: Spark Plug

    Spark plug N OTE: 1. Check electrode condition and wear, insula- tor color, and electrode gap. Valve clearance must be set properly before syn- 2. Clean the spark plug with spark plug cleaner chronizing the carburetors. if necessary. Use a wire gauge to adjust the plug gap to specification.

  • Page 24: Idle Speed

    Idle speed 1. Start the engine, and warm it up for a few minutes. 2. Set the engine idle speed to the specified level by adjusting the throttle stop screw on the rear cylinder carburetor. Turning the throttle stop screw in (clockwise) increases the engine speed;...

  • Page 25: Coolant

    5. Add 2.4 L (2.1 Imp qt, 2.5 US qt) of engine 4. Install the new oil filter element, new O-ring, oil through the oil filler hole. Reinstall the oil and filter cover; tighten the oil filter bolt. filler cap. Oil filter bolt: 10 Nm 1.0 m-kg, 7.2ft-lb) NOTE:...

  • Page 26: Clutch Adjustment

    WARNING: Mechanism adjustment 1. Fully loosen the cable inner wire length- Do not remove the radiator cap when the engine adjuster locknut and screw in the adjuster is hot. until tight. 2. Turn the handle lever adjuster in. CAUTION: 3. Remove the clutch adjuster plug from the Hard water or salt water is harmful to the engine right side crankcase cover.

  • Page 27: Checking Ignition Timing

    4. The stationary pointer (in the timing window) should be within the firing range shown on the flywheel. If the pointer is not within the range or if it is not steady, check the flywheel and/or pickup assembly for tightness and/or damage.

  • Page 28: Chassis

    1. Final gear oil 2. Correct oil level 6. If the pressure is too low, squirt a few drops Gear oil replacement of oil into the cylinder being measured. 1. Place an oil pan under the final gear case. Measure compression again. If there is a 2.

  • Page 29: Front And Rear Brake

    7. Reassemble by reversing the removal pro- cedure. Check whether the element is seated completely against the case. 8. The air filter element should be cleaned at the specified intervals. CAUTION: The engine should never be run without the air cleaner element installed;...

  • Page 30: Brake Light Switch Adjustment

    Rear brake pedal height adjustment WARNING: 1. Loosen the adjuster locknut (for pedal Check the operation of the brake light after ad- height). justing the rear brake. 2. By turning the adjuster bolt clockwise or counterclockwise, adjust the brake pedal po- Brake light switch adjustment sition so that its top end is flush with the top The brake light switch is operated by the movement...

  • Page 31: Rear Brake Shoe

    10W30 motor oil. Brake and change pedals/brake and clutch levers Lubricate the pivoting parts of each lever and pedal. Recommended lubricant: Yamaha chain and cable lube or 10W30 motor oil 1. Lower level Centerstand and sidestand Lubricate the centerstand and sidestand at their •...

  • Page 32: Front Fork Oil Change

    Front fork oil (each fork): 257 cm (9.0 Imp oz, 8.7 US oz) Yamaha fork oil 15 wt or equivalent 8. After filling, slowly pump the forks up and 1. Cap 2. Fork cap bolt down to distribute the oil.

  • Page 33: Rear Shock Absorber Adjustment

    Rear shock absorber adjustment. 3. If the steering head is loose, adjust it. The spring preload of the rear shock absorber can Loosen the front fork pinch bolts and steer- be adjusted to suit rider's preference, weight, and ing stem bolt. road conditions.

  • Page 34: Front Wheel

    Front wheel Fuel cock If either fuel cock is leaking or is excessively con- taminated, it should be removed from the fuel tank and inspected. 1. Raise the front end of the motorcycle, and spin the wheel by hand. Touch the axle or 1.

  • Page 35: Tubeless Tires And Aluminum Wheels

    Tubeless tires and aluminum wheels 4. Tires and wheels should be balanced when- This motorcycle is equipped with aluminum wheels ever either one is changed or replaced. Fail- designed to be compatible with either tube or tube- ure to have a wheel assembly balanced can less tires.

  • Page 36: Headlight

    Headlight Headlight bulb replacement 1. Remove the two screws holding the light unit assembly to the headlight body. 1. Holding screw 2. Disconnect the lead wires and remove the light unit assembly. CAUTION: The battery must be charged before using to ensure maximum performance.

  • Page 37: Fuse

    CAUTION: Fuse 1. The fuse block is located under the seat. Avoid touching the glass part of the bulb. Also keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and illuminous flux will be adversely affected. If oil gets on the lamp, clean it with a cloth moistened thoroughly with alcohol or lacquer thinner.
  • Page 38 CHAPTER 3. ENGINE OVERHAUL ENGINE REMOVAL……………………………………………………………………………………………….. Preparation for removal…………………………………………………………………………………….. Fuel tank………………………………………………………………………………………………………. Air filter and air baffle plate………………………………………………………………………………... Battery…………………………………………………………………………………………………………. Radiator……………………………………………………………………………………………………….. Exhaust pipes and mufflers……………………………………………………………………………….. Leads and couplers…………………………………………………………………………………………. Cables and pipes…………………………………………………………………………………………….. Footrests and sidestand……………………………………………………………………………………. Engine removal………………………………………………………………………………………………. ENGINE DISASSEMBLY…………………………………………………………………………………………. Carburetors, rear exhaust pipes, and inlet pipe………………………………………………………. Water pump cover and pipe joints………………………………………………………………………..
  • Page 39 ENGINE ASSEMBLY AND ADJUSTMENT……………………………………………………………………… Important information………………………………………………………………………………………… Left-side crankcase…………………………………………………………………………………………… Right-side crankcase…………………………………………………………………………………………. Crankcase assembly………………………………………………………………………………………….. Shifter……………………………………………………………………………………………………………. Front-cylinder chain guide and drive gears………………………………………………………………. Clutch……………………………………………………………………………………………………………. Rear-cylinder chain guide and drive gears……………………………………………………………….. Balancer gear and flywheel………………………………………………………………………………….. Starter motor and starter idle gear #1……………………………………………………………………… Crankcase covers, oil pump, and oil filter………………………………………………………………… Pistons, cam chain guides, and cylinders…………………………………………………………………...

  • Page 40: Chapter 3. Engine Overhaul

    ENGINE OVERHAUL ENGINE REMOVAL NOTE: It is not necessary to remove the engine in order to remove the front cylinder, clutch and/or the AC magneto. Preparation for removal 1. All dirt, mud, dust, and foreign material must be cleaned from the engine before the en- 1.

  • Page 41: Battery

    5. Drain the cooling system: First, remove the Battery 1. Disconnect the battery leads. air breather bolt in the hose junction. Then remove the two cylinder drain plugs, the main drain plug, and finally, remove the NOTE: thermostatic cover. This will ensure that the Disconnect the negative lead first.

  • Page 42: Leads And Couplers

    1. Thermostatic switch Leads and couplers Cables and pipes 1. Remove the T.C.I, unit bracket and reser- 1. Disconnect the following cables. voir tank securing screw. Then remove the • Clutch cable T.C.I, unit and reservoir tank from the • Choke cable frame.

  • Page 43: Engine Removal

    Engine removal NOTE: In addition to the engine mounting bracket cylinder, four mounting bolts hold the engine in place: a thru- bolt, a large threaded stud, and one bolt on each side of the engine. 1. First, remove the right side frame tube and the engine mounting bracket.

  • Page 44: Water Pump Cover And Pipe Joints

    3. Remove the carburetor joint from each cyl- Cylinder head covers, cylinder heads, and inder. cylinders. 4. Remove the exhaust pipe clamp and 1. Remove the spark plug from each cylinder. flange bolts from the rear cylinder. Remove 2. Remove the engine mounting bracket...
  • Page 45 6. Remove the cam chain tensioner from each cylinder head and remove the cam sprock- ets. 1. Cam chain tensioner 1. Allen wrench 7. Remove each cylinder head. Loosen all the 8. Remove the three dowels and 0-ring from cylinder head nuts and bolts first. Each nut each cylinder.

  • Page 46: Piston Pin And Piston

    2. Remove the oil filter element. Piston pin and piston 1. Mark each piston so it can be reinstalled in 3. Remove the right side crankcase cover the appropriate cylinder. bolts, and remove the crankcase cover. 2. Remove the piston pin clip from the pis- ton.

  • Page 47: Flywheel

    8. Disconnect the neutral switch and oil pres- Flywheel sure switch leads. 1. Place a piece of rolled rag or a piece of lead between the primary gears, and remove the flywheel securing nut. 1. Oil pressure switch 2. Neutral switch 9.

  • Page 48: Clutch And Primary Gears

    NOTE: The balancer drive gear has six springs and three pins. Use care so that they don't fall out when re- moving the balancer drive gear. 1. Idle gear #2 2. Electric starter switch 3. Remove the woodruff key from the crank- shaft key way.

  • Page 49: Shifter

    1. Remove the timing gear stopper bolt, then 6. Flatten the lock tab on the primary-drive remove the shaft. gear securing nut. 7. Place a small piece of rolled rag or a small piece of lead between the primary gears, and remove the primary drive gear securing nut, lock washer, washer and key.

  • Page 50: Crankcase

    2. Disengage the shift lever from the shift 2. Remove the rightside crankcase from the drum pins, and remove the shift shaft as- leftside, and remove the three dowels. sembly. CAUTION: When separating the crankcase, be sure the shiftdrum star aligns with its corresponding contours in the crankcase.
  • Page 51 3. Remove the crankshaft and the balancer shaft from the left side crankcase. 1. Circlip 2. 2nd wheel The following steps are necessary only if you must service the middle gear or replace the crankcase. 1. Crankshaft 2. Balancer shaft 4.

  • Page 52: Inspection And Repair

    10. emove the drive axle bearing stopper bolts; 2. Mount the valve spring compressor on the use the torx driver. head and depress each valve spring. Re- move the valve retainers with a magnet or tweezers, and remove the valve springs. 1.

  • Page 53: Valves, Valve Guides, Valve Seats, And Valve Springs

    Cylinder head warpage: less than 0.03mm (0.0012 in) Valves, valve guides, valve seats, and valve springs Valves 1. Check the valve face and the stem end for wear. If the valve face and/or the stem end are pitted or worn, regrind the valve with a valve refacer.
  • Page 54 1. Valve guide installer 2. Valve guide remover Valve guides 4. After installing the valve guide, use the If oil leaks into the cylinder through a valve 6mm (0.24 in) reamer (special tool) to ob- due to a worn valve guide or if a valve is tain the proper valve guide-to-valve stem replaced, the valve guide should also be clearance.
  • Page 55 3. If the valve seat is uniform around the pe- CAUTION: rimeter of the valve face but is too wide or If the valve seat is obviously pitted or worn, it not centered on the valve face, it must be should be cleaned with a valve seat cutter.
  • Page 56 • Valve springs If the seat is too narrow and down near the This engine uses two springs of different sizes to bottom edge of the valve face, then first use prevent valve float or surging. The valve spring the 60° cutter and then the 45° cutter. specifications show the basic value characteristics.

  • Page 57: Camshafts, Cam Chains, And Cam Sprockets

    Valve installation WARNING: Proceed slowly. If a retainer has not been prop- erly installed, it could be ejected from the cylin- der head. 9. Gently tap the end of the valve stem with a plastic mallet. This will ensure that the re- tainers are properly seated in the collar.
  • Page 58 NOTE: Do not turn camshaft when measuring clearance with Plastigage. Camshaft-to-cap clearance: Standard: 0.020 ~ 0.061 mm (0.0008-0.0024 in) Maximum: 0.160 mm (0.006 in) If the camshaft-to-cap clearance exceeds specification, measure the camshaft bearing Install the camshaft on the cylinder head. surface diameter.

  • Page 59: Cylinder

    6. Cam chain dampers Inspect the top cam chain damper (stopper guide) and two (2) vertical (slipper-type) dampers for excessive wear. Any that shows excessive wear should be replaced. Worn dampers may indicate an improperly adjusted or worn-out cam chain. Cylinder Piston and piston rings 1.
  • Page 60 Piston ring The oversize top and middle ring sizes are stamped on top of the ring. The expander spacer of the bottom ring (oil control ring) is color-coded to identify sizes. The color mark is painted on the expander spacer. 2.

  • Page 61: Crankcase

    Crankcase 1. Thoroughly wash the case halves in a mild solvent. 2. Clean all gasket mating surfaces and crankcase mating surfaces thoroughly. 3. Visually inspect the case halves for any cracks, road damage, etc. Replace the crankcase as required. 4. Check the oil-delivery passage for signs of blockage.

  • Page 62: Crankshaft And Connecting Rod

    Removal NOTE: 1. Pry oil seal(s) out of place with a screwdriver. If either of the right- or left-side main bearings is Replace all oil .seals when overhauling the worn or scratched, both bearings should be re- engine. placed as a set. NOTE: Crankshaft bearing clearance Place a piece of wood under the screwdriver to pre-...
  • Page 63 1. As shown in the photo, set the special tool CAUTION: set, and using a hydraulic press, pull the The diameter of counterbore should be meas- main bearing out to the outside of the ured at two places, and the average of the two crankcase.
  • Page 64 5. Apply molybdenum disulfide grease to the bolt threads, and torque both ends of the rod cap evenly. Do not move the connecting rod until the clearance check is completed. CAUTION: When tightening the rod cap, apply continuous torque between 3.4 and 3.8m- kg. Once you reach 3.4m-kg of torque, DO NOT STOP tighten- ing until final torque is reached.

  • Page 65: Oil Pump

    The connecting rod numbers are stamped in ink on the rod. Rotor-to-housing clearance: 0.03 ~ 0.09mm (0.0012 ~ 0.0035 in) Proper bearing selection is made by subtracting the crankpin number from the rod size number. Use the Primary drive color code to choose the proper bearing. The drive gear is mounted on the crankshaft;...
  • Page 66 Standard Wear limit Friction plate 2.8 mm 2.6 mm (0.10 in) thickness (0.11 in) Clutch plate 0.2 mm (0.008 — warp limit 2. Check the clutch housing bearing for dam- age. If damaged, replace the bearing. Clutch boss The clutch boss contains a built-in damper beneath the first clutch plate (clutch plate 2).

  • Page 67: Transmission

    Bend limit: 0.5mm (0.02 in) 4. Check the cam followers on each shift fork for wear. Check the ends that ride in the grooves in the shift cam. If they are worn or Clutch springs damaged, replace the shift fork. 1.

  • Page 68: Starter Drives

    After installing the pinions onto the main 11. Check the transmission shafts using a cen- axle, make sure the 4th and 5th pinions tering device and dial gauge. If any shaft is turn freely around the main axle. bent beyond specified limit, replace the shaft.

  • Page 69: Engine Assembly And Adjustment

    ENGINE ASSEMBLY AND ADJUSTMENT letters must be on the side exposed to view.) When installing oil seal(s), apply a Important information light coating of lightweight lithium base Gaskets and seals grease to the seal lips(s). When installing 1. All gaskets and seals should be replaced bearings liberally oil the bearings.

  • Page 70: Left-Side Crankcase

    Left-side crankcase 2. Install the drive axle assembly with the 1. Press the crankshaft bearing, balancer shaft proper shims (refer to page 3-56). Be sure bearing, and transmission bearing into the that the bearing is properly seated against left side crankcase. Liberally oil the bear- the crankcase.
  • Page 71 3. Install the bearing stopper plates and 7. Install the shift cam into the left side crankcase. 8. Install the shift fork #2 onto the third pinion. tighten the bearing stopper bolts. Use the Then insert the guide bar (short one) into the Torx driver and torque the bolts to specifica- crankcase through the shift fork.
  • Page 72 CAUTION: When tightening the rod cap, apply continuous torque between 3.4 and 3.8 m-kg. Once you reach 3.8 rtrkgof torque, DO NOT STOP tighten- ing until final torque is reached. If tightening is interrupted between 3.4 and 3.8 m-kg,loosen the nut to less than 3.4nvkg and start again. Tighten to full-torque specification without pausing.

  • Page 73: Right-Side Crankcase

    Apply pressure to the outer race of the bearing. NOTE: Use Yamaha bond #4 to seal the cases. CAUTION: First align the shift cam segment key with the keyway in the crankcase, and install the right side crankcase.

  • Page 74: Shifter

    Tightening torque: 10 Nm (1.0m-kg, 7.2 ft-Ib) NOTE: Apply Yamaha bond #4 to bracket securing bolts 1. Shift shaft oil seal 2. Install the shifter into the right side crank- case. Hook the shift-cam-stopper spring beneath the projection in the crankcase.

  • Page 75: Front-Cylinder Chain Guide And Drive Gears

    3. Install the washer and circlip onto the shift 3. Study the zero-lash timing gear. Note that it shaft. has two sets of gear teeth. One set is spring loaded and moves relative to the other set. 1. Washer 2. Circlip Front-cylinder chain guide and drive gears.
  • Page 76 6. Lower the timing gear into the cam chain journal. 1. Timing gear shaft 9. Install the primary drive gear (33T), oil pump drive gear (23T), plate washer, lock washer, and nut. Finger-tighten the securing 7. The punch mark on the timing gear should nut, do not torque it at this point.

  • Page 77: Clutch

    Clutch...
  • Page 78 1. Install the clutch housing onto the trans- mission main axle. 2. Install the thrust washer and the clutch boss onto the transmission main axle. 6. Install the friction and clutch plates. Begin with a friction plate and alternate clutch and friction plates until all of the plates are in the clutch boss.

  • Page 79: Rear-Cylinder Chain Guide And Drive Gears

    3. By turning the crankshaft by hand, bring the key position with the center of the rear cyl- inder bore. Rear-cylinder chain guide and drive gears 4. Attach a proper length of wire to the cam chain, and place the cam chain around the timing-gear sprocket (#2).

  • Page 80: Balancer Gear And Flywheel

    The balancer driven gear damper assem- Tightening torque: bly is composed of 6 springs and 3 pins. Stopper bolt: 12 Nm (1.2 m-kg, 8.7 ft-lb) Insert the balancer gear boss into the Union bolt: 18 Nm (1.8 m-kg,13 ft-lb) balancer gear, aligning the punch marks. Then install the damper springs;...

  • Page 81: Starter Motor And Starter Idle Gear #1

    5. Place a small piece of rolled rag or a piece 9. Install the washer and the flywheel securing of lead between the primary gears. This will bolt onto the crankshaft. Place a small piece hold the balancer drive gear so you can of rolled rag or a piece of lead between the tighten the securing nuts.

  • Page 82: Crankcase Covers, Oil Pump, And Oil Filter

    2. Install the left side crankcase cover. Use a new gasket and torque the securing bolts to specification. NOTE: Install the bolt with the clutch cable clamp as shown in the illustration. Tightening torque: 10 Nm (1m - kg, 7.2ft-lb) 1.

  • Page 83: Pistons, Cam Chain Guides, And Cylinders

    10. Install the right side crankcase cover. Use a new gasket and torque the securing bolts to specification. NOTE: Place the bolt with the starter motor lead clamp as shown in the illustration. 1. O-ring 7. Install the oil pump assembly and oil baffle into the right side crankcase.
  • Page 84 2. Align the piston rings as shown. Tightening torque: 10 Nm (1.0m-kg, 7.2ft-lb) CAUTION: Be sure the ends of the oil ring expanders do not overlap. NOTE: The manufacturer's marks or numbers stamped on the rings should be on the top of the rings. 1.
  • Page 85 1. Rear cam chain guide 8. Install the cylinder head gasket, 0-ring and three dowels onto each cylinder. 1. Dowel 2. O-ring...

  • Page 86: Cylinder Heads And Cam Sprockets

    Cylinder heads and cam sprockets 1. The rear cam chain guide securing bolts in 2. Install the cylinder head on the front (#1) cyl- inder. Route the cam chain through the cam the cylinder head have embossed numbers chain journal in the head. 1 and 2.
  • Page 87 Tighten the stopper securing nut to speci- fication Tightening torque: 7 Nm (0.7m-kg, 5.1 ft-lb) Reinstall stopper bolt cover, and torque the bolts to specification. Tighten torque: 6Nm(0.6m - kg, 4.3 ft-lb) 5. Turn the front cylinder intake and exhaust camshafts by hand so that the cam lobes face each other and the punch marks on the 3.
  • Page 88 9. If the marks are not aligned, remove the sprockets from the camshafts, and change the position at which the sprockets mesh with the cam chain, then mount the sprock- ets on the camshafts. 10. Release the cam chain tensioner oneway, cam, and insert the tension rod into the ten- sion body.
  • Page 89 Insert your finger into the hole in the cam 15. Rotate the rear cylinder intake and exhaust chain tensioner and push the cam chain camshafts by hand so that the cam lobes guide inward. While pushing it, make sure face outward, the punch marks on the ends the punch marks on the camshafts align of the camshafts should be aligned with the with the marks on the caps.

  • Page 90: Cylinder Head Covers

    21. Apply engine oil to the camshafts, valves, Tightening torque: cam sprockets, and timing chain. Also turn 12Nm(1.2m-kg,8.7ft-lb) the crankshaft counterclockwise a few turns to check that it turns smoothly. Cylinder head covers 1. Adjust all the valves as described in the "VALVE CLEARANCE"...

  • Page 91: Water Pump Cover, And Joint Pipes, And Oil Filter

    Water pump cover, joint pipes, and oil filter Tightening torque: 1. Install the water pump cover O-ring and in- 10 Nm (1.0m-kg, 7.2ft-lb) stall the 0-rings on the joint pipes. 2. Sparingly apply rubber grease to the joint 5. Install the new oil filter element and O-ring. pipe 0-rings.
  • Page 92 3. Install the upper engine mounting bracket Tightening torque: bolts. Down tube frame & frame 26 Nm (2.6m-kg, 19ft-lb) Engine mounting bracket & frame 20Nm(2.0m-kg, 14ft-lb) Engine & down tube frame (center) 58Nm(5.8m-kg, 42ft-lb) Engine & down tube frame (rear) 48 Nm (4.8m-kg, 35ft-lb) NOTE: The rear lower mount will be secured when the...
  • Page 93 Radiator holding bolt 15. Route the wires listed below through the Tightening torque: wire clip, and secure the clip to the crank- 10 Nm (1.0 m-kg, 7.2ft-lb) case as shown in the photograph. Connect the wires. 11. Connect the rear exhaust pipe to the muf- Pickup coil leads, AC magneto leads, fler, and install the muffler to the muffler...
  • Page 94 22. Install the side covers. 23. Add. the engine oil into the engine. Oil capacity: 2.7 L (2.4 lmp qt, 2.9 US qt) 24. Pour the coolant into the radiator and reser- voir tank. Coolant capacity: 2.3L(2.0 lmp qt, 2.4 US qt) 25.

  • Page 95: Middle Gear Service

    MIDDLE GEAR SERVICE Drive axle positioning When the left side crankcase and/or the drive axle are replaced, you must position the drive axle in place...

  • Page 96: Middle Drive Shaft Removal

    1. Calculate the shim thickness using the for- 2. Shims are supplied in the following thick- mula shown below. nesses: Shim thickness (A) = a - b - c 0.15mm (0.00059 in), 0.30mm (0.0118 in), 59 plus the number printed on the 0.40mm (0.0157 in) and 0.50mm (0.0197 in) crankcase.

  • Page 97: Disassembly

    5. Remove the U-joint, bearing-housing plate, Disassembly 1. Remove the clips from the bearings in the the bearing housing, and the washers and middle gear yoke. spacers from the middle drive shaft. 2. Place the U-joint in a press. With a suitable diameter pipe beneath the yoke, CAUTION: press the bearing into the pipe as shown in...

  • Page 98: Gear Lash Measurement And Adjustment

    5. Tighten the holder bolts as tight as neces- Gear lash measurement and adjustment sary to keep the middle gear from turning. 1. Insert the semi circular clip into the crank- 6. Set the dial gauge on the outside edge of case.
  • Page 99 Check each bearing. The needles can easily fall the gear lash measurement is within speci- out of their races. Slide the yoke back and forth fication. You must proceed slowly, how- in the bearings. The yoke will not go all the way ever, so the collapsible collar will not be into a bearing if a needle is out of place.
  • Page 100 CHAPTER 4. CARBURATION CARBURETOR………………………………………………………………………………………………………. 101 Section view…………………………………………………………………………………………………….. 102 Specifications…………………………………………………………………………………………………... 102 Disassembly…………………………………………………………………………………………………….. 102 Inspection……………………………………………………………………………………………………….. 104 Assembly………………………………………………………………………………………………………… 105 Adjustment……………………………………………………………………………………………………… 106 FUEL PUMP AND FUEL REGULATOR………………………………………………………………………….. 107 Operation………………………………………………………………………………………………………… 107 Disassembly…………………………………………………………………………………………………….. 108 Inspection……………………………………………………………………………………………………….. 108 Assembly………………………………………………………………………………………………………... 108 AIR CLEANER AND CRANKCASE VENTILATION SYSTEM…………………………………………………. 110...

  • Page 101: Carburetor

    CARBURETION CARBURETOR...

  • Page 102: Section View

    SECTION VIEW Disassembly Specifications Main jet (Front) #122.5 (Rear) #127.5 Pilot jet Pilot air jet #130 Pilot screw Preset Float valve seat 01.8 Engine idle speed 1,300 ±50 r/min. WARNING: 1. Remove the two starter link securing The pilot screw settings are adjusted for maximum screws, and remove the starter link and performance at the factory with special equipment.
  • Page 103 2. Remove the synchronizing rod circlips and remove the synchronizing rod. 6. Gently tap the float pivot pin and remove the float pivot pin and float assembly. Be careful not to close the float valve which is under the float arm. 1.

  • Page 104: Inspection

    1. Diaphragm 2. Spring 1. Accelerator relay rod 2. Diaphragm NOTE: The accelerator relay rod is properly adjusted and locked with LOCTITE® at the Yamaha factory. Never attempt to disassemble or adjust it.

  • Page 105: Assembly

    As shown below, the fuel spray should be 5. Inspect the starter plunger. If it is worn or shaped conically. If not, pull out the ac- damaged, replace it. celerator pump nozzle and clean the nozzle with compressed air. 6. Inspect the secondary venturi gasket for damage.

  • Page 106: Adjustment

    5. Install the pilot air jet, float valve seat, float valve, and float into the carburetor upper body. 6. Install the upper body assembly onto the carburetor main body, and tighten the screws. Adjustment Fuel level NOTE: Before checking the fuel level, place the mo- 6.

  • Page 107: Fuel Pump And Fuel Regulator

    FUEL PUMP AND FUEL REGULATOR Operation The fuel pump diaphragm is operated by variations in the pressure in the carburetor joint and thus produces a pumping action that pumps fuel from the fuel tank to the carburetor. Fuel is drawn through the inlet and, as indicated by -», it flows through the inlet and outlet valves and is discharged from outlet.

  • Page 108: Disassembly

    Disassembly NOTE: As shown below, a gap of 0.125 mm (0.005 in) is provided between the valve seat and the fuel pump body on both inlet and outlet valves. 3. Inspect the regulator rubber diaphragm and spring. If the diaphragm is torn or the spring 1.
  • Page 109 CAUTION: Avoid tightening the screws too hard, or the gasket could be deformed or broken. NOTE: For the 40 mm (1.57 in) long bolt position, refer to the photo. 3. Install the fuel pressure regulator onto the fuel pump body. The valve seat positioned at the center of the diaphragm should be fitted to the fuel pump body.
  • Page 111 CHAPTER 5. CHASSIS FRONT WHEEL………………………………………………………………………………………………….. Removal……………………………………………………………………………………………………... Front axle inspection……………………………………………………………………………………… Front wheel inspection……………………………………………………………………………………. Replacing the wheel bearings…………………………………………………………………………… Installing the front wheel…………………………………………………………………………………. REAR WHEEL……………………………………………………………………………………………………. Removal……………………………………………………………………………………………………… Checking brake shoe wear……………………………………………………………………………….. Brake drum………………………………………………………………………………………………….. Brake shoe plate…………………………………………………………………………………………… Rear axle inspection………………………………………………………………………………………. Replacing the wheel bearings…………………………………………………………………………… Rear wheel inspection…………………………………………………………………………………….. Installing the rear wheel…………………………………………………………………………………..
  • Page 112 REAR SHOCK ABSORBER……………………………………………………………………………………. Removal……………………………………………………………………………………………………… Inspection…………………………………………………………………………………………………… Note on disposal…………………………………………………………………………………………... Installation and adjustment……………………………………………………………………………… CABLES AND FITTINGS……………………………………………………………………………………….. Cable maintenance………………………………………………………………………………………… Throttle maintenance……………………………………………………………………………………… SHAFT DRIVE……………………………………………………………………………………………………. Troubleshooting……………………………………………………………………………………………. Final gear removal…………………………………………………………………………………………. Gear lash check and adjustment………………………………………………………………………... Final gear disassembly…………………………………………………………………………………… Final gear assembly……………………………………………………………………………………….. DRIVE SHAFT…………………………………………………………………………………………………….. Removal……………………………………………………………………………………………………… Inspection……………………………………………………………………………………………………. Installation……………………………………………………………………………………………………...

  • Page 113: Chapter 5. Chassis

    CHASSIS FRONT WHEEL Removal 1. Place the motorcycle on its center stand. 2. Remove the cotter pin and wheel axle nut. Front axle inspection Remove any corrosion from the axle with fine emery cloth. Place the axle on a surface plate, and check for bends.

  • Page 114: Replacing The Wheel Bearings

    Refer to the Tubeless Tire and Aluminum Wheel 2. Drive the bearing out by pushing the spacer Manual for proper tubeless and aluminum wheel aside and tapping around the perimeter of service. the bearing inner race with a soft metal drift 1.

  • Page 115: Rear Wheel

    4. Tighten the axle nut and install a new cotter pin. Tightening torque: 110 Nm (11 m-kg, 80ft-lb) 5. Install the front fender. 6. Before tightening the pinch bolt, compress the front forks several times to check for proper fork operation. 7.

  • Page 116: Brake Drum

    2. Lightly grease the lips of the rear wheel oil Wear limit: 2mm (0.08 in) seals. 2. Remove any glazing from the brake shoes with coarse sandpaper. Brake drum Oil or scratches on the inner surface of the brake drum will impair braking performance or result in abnormal noises.

  • Page 117: Front Brake

    FRONT BRAKE CALIPER DISASSEMBLY CAUTION: Disc brake components rarely require dis- assembly. Do not disassemble components un- less absolutely necessary. If any hydraulic con- nection in the system is opened, the entire sys- tem should be disassembled, drained, cleaned, and then properly filled and bled upon reassem- bly.

  • Page 118: Master Cylinder Disassembly

    Master cylinder disassembly 1. Remove the brake light switch. Brake inspection and repair Recommended brake component Replacement schedule: Brake pads: As required Piston seal, dust seal: Every two years Brake hoses: Every four years Brake fluid: Replace only when brakes are disassembled 1.

  • Page 119: Brake Assembly

    5. Inspect the brake hoses. Repalce the hoses every four years or immediately if cracked, frayed, or damaged. 6. Check for wear and deflection of the disc. If the disc is worn beyond minimum thickness or if deflection exceeds the specified amount, replace the disc.
  • Page 120 6. If the brake disc has been removed from the 2. Connect a clear plastic tube, 4.5mm (3/16 in) hub or is loose, tighten the bolts. Use new inside diameter, tightly to the caliper bleed lock plates, and bend the lock tabs against a screw.

  • Page 121: Front Fork

    2. Remove the wire holder and loosen the front fork pinch bolts. Removal and disassembly WARNING: Securely support the motorcycle so there is no dan- ger of it falling over. 1. Disconnect the speedometer cable. Remove the brake caliper and the front wheel. Re- move the front fender.

  • Page 122: Inspection

    8. Remove the dust seal from the outer fork 3. Remove the caps and fork cap bolts from tube with a screwdriver. Be careful not to the inner fork tubes. scratch the inner fork tube surface. 1. Cap 2. Fork cap bolt 1.

  • Page 123: Assembly

    Fork spring free length: Recommended oil: 461 mm (22.1 in) Yamaha fork oil 15 wt or equivalent 5. Check the 0-ring on the cap bolt. If it's dam- 9. Install the fork spring and cap bolt with a aged, replace it.
  • Page 124 11. Tighten the pinch bolt at the under bracket. Torque the bolt to specification. Tightening torque 38 Nm (3.8 m-kg,27 ft-lb) 12. Tighten the cap bolt to specification, use the special tool. Tightening torque: 20 Nm (2.0 m-kg, 14 ft-lb) 13.

  • Page 126: Removal

    Removal 7. Remove the top ring nut. 1. Remove sidecovers and the fuel the tank. 2. Remove the headlight lens unit, and disconnect all wiring connectors in the head- light shell. 3. Remove the handlebars from the steering crown. 4. Remove the front wheel and front forks. 5.

  • Page 127: Assembly

    Assembly 1. Grease the bearings and races with wheel bearing grease. 2. Install the steering stem, balls, and races. 3. Install the lower ring nut. Tighten it to ap- proximately 20 Nm (2.0 rrrkg, 14 fflb) and loosen it approximately 1/4 turn. 4.

  • Page 128: Swingarm

    Free play inspection 2. The swingarm is mounted on needle bear- 1. Remove the rear wheel and the shock ab- ings. Move the swingarm up and down as sorber. Grasp the swingarm and try to move shown. swingarm should move it from side to side as shown.

  • Page 129: Removal

    Inspection and lubrication 1. Remove the bearing caps. Inspect the bear- Removal 1. Remove the rear wheel, sidecovers, starter ings for pitting or other damage. Make sure relay and rubber plugs. that the bearings roll freely. If a bearing is 2.

  • Page 130: Assembly

    5. Measure the length of the bushing (A), the thickness of each thrust washer (Bi and B and the length of the swingarm mounting bracket (C) in the lower frame member. 6. Calculate the swingarm side clearance by using the formula given below: Side clearance = A - (Bj + B + C) 7.

  • Page 131: Rear Shock Absorber

    Removal 1. Remove the fuel tank. 2. Remove the rear wheel. Refer to "REAR WHEEL REMOVAL". 3. Remove the cotter pin from the swing-arm, drive out the shock absorber pivot shaft, and disconnect the shock absorber from the swingarm.

  • Page 132: Inspection

    4. Remove the shock absorber mounting bolt, CAUTION: and remove the shock absorber from the Always wear a proper eye protection to prevent frame by carefully pulling it towards the front eye damage from escaping gas and/or metal of the motorcycle. chips.

  • Page 133: Cables And Fittings

    3. Wash parts a mild solvent, and CABLES AND FITTINGS check all contact surfaces for burrs or other Cable maintenance damage. (Also clean and inspect the right- hand end of the handlebar.) NOTE: 4. Lubricate all contact surfaces with a light See "MAINTENANCE AND LUBRICATION"...

  • Page 136: Shaft Drive

    Troubleshooting The following conditions may indicate damaged shaft drive components: NOTE: Damage areas A, B, C, and D above may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal motorcycle operating noise. If there is reason to believe these com- ponents are damaged, remove the components for specific inspection.
  • Page 137 4. Troubleshooting chart Where basic conditions "1" and "2" above exist, consider the following chart: leak. There is the possibility that a component hous- 5. Oil leak inspection ing may have been damaged by road debris or an If a shaft drive component is suspected of accident, or a gasket or a seal may be cracked or leaking oil, first thoroughly clean the entire mo- broken.

  • Page 138: Final Gear Removal

    6. Checking drained oil 6. Install the final gear lash measurement tool Whenever a problem is suspected in either on the gear coupling. the middle or final gear assemblies, drain and inspect the oil. Metal particles on the drain plug or in the oil could indicate a bear- ing seizure or other problem.

  • Page 139: Final Gear Disassembly

    6. If the gear lash exceeds the specified limits, CAUTION: adjust as follows: The final-drive-shaft-bearing-retainer nut has • To reduce gear lash, increase the ring gear left-hand threads. Turn the retainer nut clock- shim. wise to loosen it. • To increase gear lash, reduce the ring gear shim.

  • Page 140: Final Gear Assembly

    10. Remove the guide collar, oil seal, and roller bearing from the main housing by using the press tool No. 1 and a press. Use the appro- priate supports for the main housing during this operation. The roller bearing may be re- used if undamaged.
  • Page 141 NOTE: The removed roller bearing can be used if undam- aged; however, we recommend replacement with a new one. The shim thickness, A, necessary for the final-drive-shaft gear positioning, can be calculated from the information found on the final gear case and on the drive gear end.
  • Page 142 To find shim thickness, B, use the following formula: Example: final-drive-shaft gear marked B = c + d-(e + f) "+01".."a" is 84.01. If the gear case is marked "83.50" "b" is 83.50. Where: c = the numeral on the gear case (i.e. 45.52) A =84.01 -83.50 d = a numeral (usually a decimal number) on A = 0.51 (0.020 in)

  • Page 143: Drive Shaft

    Tightening torque: 110 Nm (11 m-kg, 80 ft -lb) Ring gear thrust clearance: 0.1 ~ 0.2mm (0.004 ~ 0.008 in) 5. Install the ring gear assembly without the 9. If the clearance exceeds the specified value, thrust washer. Adjust the gear lash (refer to replace the thrust washer to obtain the "GEAR LASH...

  • Page 144: Installation

    Installation When installing the drive shaft, reverse the removal procedure. Note the following points: • Lubricate the shaft splines with moly- bdenum disulfide grease. • Torque the final gear case nuts and bolts to specification. Tightening torque: Bolts/Nuts: 42 Mm (4.2 m-kg, 18 ft-lb)
  • Page 145 CHAPTER 6. COOLING SYSTEM COOLING SYSTEM……………………………………………………………………………………………… HANDLING NOTES……………………………………………………………………………………………… COOLANT REPLACEMENT……………………………………………………………………………………. RADIATOR………………………………………………………………………………………………………… Removal……………………………………………………………………………………………………… Inspection……………………………………………………………………………………………………. Installation…………………………………………………………………………………………………… WATER PUMP……………………………………………………………………………………………………. Disassembly………………………………………………………………………………………………… Inspection……………………………………………………………………………………………………. Assembly…………………………………………………………………………………………………….. THERMOSTATIC VALVE……………………………………………………………………………………….. Operation…………………………………………………………………………………………………….. Inspection……………………………………………………………………………………………………. Assembly……………………………………………………………………………………………………..
  • Page 146 COOLING SYSTEM The coolant is circulated by an impeller-type pump through coolantways, and after circulating around mounted on the right-hand crankcase and driven by combustion chamber jacketing, enters the radiator a gear. The coolant is drawn by the pump from the upper tank via the inlet pipe.

  • Page 147: Cooling System

    HANDLING NOTES WARNING: Do not remove the radiator cap, especially when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pres- sure, which could cause a serious injury. To open the radiator cap, remove the radiator cover by removing the four screws.
  • Page 148 2. Filling with the coolant. 4) Remove the sidecovers and fuel 1) Check the drain bolt gaskets and 0- tank. ring in the thermostatic valve cover 5) Remove the air breather bolt from the for damage. If damaged, replace as T-joint as shown.

  • Page 149: Removal

    Remove the coolant pipes Remove the radiator. Inspection 1. Using the cap radiator tester, check that the radiator cap vacuum valve and pressure valve operate correctly. Measuring with a tester, apply the specified pressure for 10 seconds, and make sure there is no pres- sure drop.

  • Page 150: Radiator

    Installation 1. Install the radiator and coolant pipes. Torque the radiator mounting bolts to specification. Tightening torque: 7 Nm (0.7 m-kg, 5.1 ft-lb) 2. Fill with the coolant. 3. Inspect the cooling system for leaks. At- tach the cap tester to the radiator and pump it to the specified pressure.

  • Page 151: Inspection

    7. Remove the impeller shaft from the crank- case cover. Remove the bearing and oil seal from the case by taping them away from the water Inspection pump seal side. 1. Remove the deposits from the impeller and water pump housing. 2.
  • Page 152 2. Install bearing into the crankcase cover. 3. Apply Yamaha Bond #4 to the pump seal #2 body. Install the pump seal #2 into the crankcase cover. Use the water pump seal installer with a hydraulic press. Tilt Limit: 0.15mm (0.006 in)

  • Page 153: Operation

    CATION: Take special care so that water pump seals #1 and #2 are not scratched when installing them. Replace any scratched seal. THERMOSTATIC VALVE 1. Thermostatic valve Operation The thermostatic valve is installed in the water pump cover and automatically opens and closes the cooling circuit to regulate the coolant flow depend- ing on the engine temperature.

  • Page 154: Thermostatic Valve

    Assembly For installing the thermostatic valve, reverse the removal procedure. Refer "COOLANT REPLACEMENT" on page 6-2.
  • Page 155 CHAPTER 7. ELECTRICAL XZ550RJ CIRCUIT DIAGRAM………………………………………………………………………………….. ELECTRIC STARTING SYSTEM………………………………………………………………………………. STARTING CIRCUIT CUT-OFF SYSTEM……………………………………………………………………. . STARTER MOTOR……………………………………………………………………………………………….. Removal…………………………………………………………………………………………………….… Inspection and repair……………………………………………………………………………………..STARTER RELAY……………………………………………………………………………………………….. Inspection…………………………………………………………………………………………………… . STARTING-CIRCUIT CUT-OFF RELAY……………………………………………………………………… . Inspection…………………………………………………………………………………………………… . CHARGING SYSTEM…………………………………………………………………………………………… . AC GENERATOR AND VOLTAGE REGULATOR………………………………………………………….. Inspection…………………………………………………………………………………………………… Battery inspection………………………………………………………………………………………….

  • Page 158: Electric Starting System

    STARTING CIRCUIT CUT-OFF SYSTEM The starting circuit cut-off system is employed. The starting circuit cut-off relay prevents the starter from operating when neither of these conditions has Hence, the following description. been met. In this instance, the starting circuit cut-off relay is off so current cannot reach the starter motor.

  • Page 159: Removal

    Removal level. If not, scrape the mica to proper lim- 1. See Chapter 3. "ENGINE DISASSEMBLY." its with an appropriately shaped tool. (A Inspection and repair hacksaw blade can be ground to fit.) 1. Check the outer surface of the com- mutator.

  • Page 160: Starter Relay

    6. Check the brush spring pressure. Compare 3. The armature coil should be checked for in- it with a new spring. Replace the old spring sulation breakdown (shorting to each other if it is weak. or to ground) and for continuity. Use a pocket tester.

  • Page 161: Inspection

    5. Check the resistance of the relay coil wind- ings with the pocket tester. If the resistance is not within specification, replace the relay. STARTING CIRCUIT CUT-OFF RELAY Inspection 1. Lift the seat, and remove the right side- cover. 6. Check the relay function with a 12 volt bat- 2.
  • Page 162 NOTE: Only the Yamaha Pocket Tester will give a 9.5Ω read- ing when testing continuity. The particular characteris- tics of other testers will vary the continuity test read- ings.

  • Page 164: Charging System

    AC GENERATOR AND VOLTAGE REGULATOR Stator coil inspection 1. Remove the right sidecover, TCI unit, and reservoir tank from the frame. Inspection 1. Connect the pocket tester to the battery terminals. 2. Start the engine. 3. Accelerate the engine to approximately 2,000 r/min or more, and check the generator voltage.

  • Page 165: Checking The Silicon Rectifier

    Checking the silicon rectifier 1. Check the silicon rectifier as specified using the pocket tester. 2. If any element is broken, replace the entire unit. CAUTION: The silicon rectifier can be damaged if sub- jected to overcharging. Special care should be taken to avoid a short circuit and/or incorrect connection of the positive and negative leads at the battery.

  • Page 167: Ignition System

    Description This unit controls wave form, duty con- This model is equipped with a battery operated, trol, switching, electronic ignition ad- fully transistorized, breakerless ignition system. By vance, etc. The duty control circuit re- using magnetic pickup coils, the need for contact duces electrical consumption by con- breaker points is eliminated.

  • Page 168: Troubleshooting

    Troubleshooting The entire ignition system can be checked for misfire and weak spark by using the Electro Tester. If the ignition system will fire across a specified gap, the entire ignition system is good. If it will not fire across the gap, proceed with the individual component tests until the source of the problem is located.
  • Page 169 Ignition spark gap test 1. Remove the sidecovers and fuel tank, and disconnect the ignition coil leads from the wiring harness and from the spark plugs. 2. Connect the Electro Tester as shown. 3. Connect a fully charged battery to the tester.
  • Page 170 3. Check the resistance of the pickup coil windings with the pocket tester. If the resis- tance is not within specification, replace the pickup coil assembly. 2. Check the resistance of the relay coil wind- ings with the pocket tester. If the resistance is not within specification, replace the relay.
  • Page 171 Sidestand switch 1. Remove the right sidecover, TCI unit, and reservoir tank from the frame. 2. Disconnect the connector from the wiring harness. 3. Connect the pocket tester leads as shown, and set the tester selector to ohm x 1. When sidestand is up, the tester...

  • Page 173: Lighting System

    Lighting tests and checks The battery provides power for operation of the 1. Headlight check. headlight, taillight, license light, and meter lights. If none of the above operates, always check battery NOTE: voltage before proceeding further. Low battery volt- When the main switch is turned "ON" the headlight, age indicates either a faulty battery, low battery meter light, taillight, and license light come on.
  • Page 174 2. Taillight and license light does not work: • Check the bulb. • Check for 12V on the blue wire. • Check for ground on black wire to tail/ brake light and/or license light assembly.

  • Page 176: Signal System

    The neutral light does not work: Signal system tests and check The battery provides power for operation of the 1. Check the bulb. horn, brake light, indicator lights, and flasher light. If 2. Check for 12V on the sky blue wire to the none of the above operates, always check the bat- neutral switch.

  • Page 177: Signal System Tests And Checks

    meter shaft. If the tester needle swings back 3. Start switch. and forth between 0 and oo, the speedome- ter sensor circuit is in good condition. If not, the sensor-to-wiring harness may be inop- erative. 3. Pull the 6-pin connector from the flasher self-cancelling unit.

  • Page 178: Battery

    3. Specific gravity readings after a long, slow Battery YB16AL charge indicate a cell to be lower than any Electrolyte Specific gravity: 1.280 others. 4. Warpage or buckling of plates or insulators Initial charging current 1.6 amp for 10 hours (new battery) is evident.

  • Page 180: Cooling System

    Electric fan and thermostatic switch operates, check the following points. Replace or/and repair as necessary: a) Smooth operation of the fan motor; b) Excessive vibration of the fan motor; c) Cracks in the fan motor bracket; d) Cracks in fan blades; e) Loose bolts securing the...
  • Page 181 An electronic temperature gauge is equipped to indicate the engine operating temperature. This engine temperature gauge consists of a tempera- ture indicator, a thermo-unit, and an indicator unit mounted on the T-joint. Inspection 1. The meter reading and the temperature show the following relationship: *When the water begins boiling in tests 3 and 4, stop heating the water and allow it to cool down,...

  • Page 182: Engine Temperature Gauge

    Thermo-unit 1. Thermo-unit Thermo-unit changes its resistance in a way that at higher temperatures, it has less resistance and thus passes more current. When more current flows to the coil in the engine temperature gauge, the armature to which the needle is attached is attracted by the increased magnetic field.
  • Page 183 2. Disconnect the blue/green lead of the thermostatic switch and ground it to the mo- tor body. If the electric fan turns, it is in good con- dition and instead, the thermostatic switch is considered to be faulty. Replace it and check that the fan rotates.
  • Page 184 WARNING: When the engine temperature gauge needle swings into the red zone, stop grounding of the lead (green/red) immediately.) 3. When the engine temperature gauge needle swings to the red zone, the engine tempera- ture gauge is in good condition but the thermo-unit is considered to be faulty.
  • Page 185 CHAPTER 8. APPENDICES SPECIFICATIONS………………………………………………………………………………………………... CONSUMER INFORMATION…………………………………………………………………………………... GENERAL TORQUE SPECIFICATIONS……………………………………………………………………… DEFINITION OF UNITS………………………………………………………………………………………….. CONVERSION TABLES…………………………………………………………………………………………. EXPLODED DIAGRAMS………………………………………………………………………………………… CYLINDER HEAD/VALVE………………………………………………………………………………….. CYLINDER……………………………………………………………………………………………………. CAM CHAIN………………………………………………………………………………………………….. CRANKSHAFT/CONNECTING ROD/PISTON………………………………………………………….. TRANSMISSION…………………………………………………………………………………………….. WATER PUMP/THERMOSTATIC VALVE……………………………………………………………….. MIDDLE GEAR………………………………………………………………………………………………. FRAME………………………………………………………………………………………………………... FRONT WHEEL……………………………………………………………………………………………… FRONT FORK………………………………………………………………………………………………... FRONT BRAKE CALIPER…………………………………………………………………………………. REAR WHEEL/REAR BRAKE…………………………………………………………………………….. SWINGARM…………………………………………………………………………………………………..

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