Transmission - Yamaha XZ550RJ 1982 Service Manual

Bend limit: 0.5mm (0.02 in)
Clutch springs
1. Measure the clutch spring free length. Re-
place the springs as a set if any is less than
the minimum free length.
Clutch spring minimum length:
40.2mm (1.583 in)

Transmission

1. Inspect each shift fork for signs of galling on
the gear contact surfaces. Check for bend-
ing. Make sure each fork slides freely on its
guide bar.
2. Roll the guide bar across a surface place. If
the bar is bent, replace it.
3. Check the shift cam grooves for signs of
wear or damage.
excessive wear and/or damage, replace the
cam.
If any profile has
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
damaged, replace the shift fork.
5. Check the shift cam dowel and side plate
for looseness, damage, or wear. Replace as
required.
6. Check the shift-cam stopper plate, cir-clip,
and stopper for wear. Replace as required.
7. Carefully inspect each gear.
signs of obvious heat damage (blue dis-
coloration). Check the gear teeth for signs
of pitting, galling, or other extreme wear.
Replace as required.
8. Check to see that each gear moves freely
on its shaft.
9. Check to see that all washers and clips are
properly installed and undamaged. Replace
bent or loose clips and bent washers.
10. Check to see that each gear properly en-
gages its counterpart on the shaft. Check
the mating dogs for rounded edges, cracks,
or missing portions. Replace as required.
Look for
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