Chapter 3. Engine Overhaul; Engine Removal; Preparation For Removal; Fuel Tank - Yamaha XZ550RJ 1982 Service Manual

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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-
gine is removed and disassembled. This will
help keep foreign material out of the engine
oil.
2. Before engine removal and disassembly, be
sure that you have the proper tools and
cleaning equipment. With them you can per-
form a clean and efficient job.
NOTE:
When disassembling the engine, keep "mated"
parts together. This includes gears, cylinders, pis-
tons, and other parts that have been "mated"
through normal wear. "Mated" parts must be re-
used as an assembly or replaced.
3. During engine disassembly, clean all parts
and place them in trays in their order of dis-
assembly. This will speed up assembly and
help assure that all parts are correctly rein-
stalled in the engine.
4. Place the motorcycle on its centerstand.
Start the engine and let it warm-up. Stop the
engine and drain the engine oil.
5. Remove the three (3) drain bolts and ther-
mostatic valve cover to drain the coolant
completely.
6. Remove the left and right sidecovers.

Fuel tank

1. Turn the fuel cock to "ON".
2. Disconnect the fuel and vacuum lines from
the fuel cock.
3. Open the seat and remove the fuel tank
holding bolt.
ENGINE OVERHAUL
1. Fuel tank holding bolt

Air filter and air baffle plate

1. Remove the air filter assembly holding
band.
2. Loosen the two air filter assembly holding
screws.
3. Disconnect
pipe from each cylinder head cover.
NOTE:
After removing the air filter assembly, cover the
carburetor with a clean cloth to keep dust and dirt
out of it.
the
crankcase
ventilation
1. Crankcase ventilation pipe
40

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