Pistons, Cam Chain Guides, And Cylinders - Yamaha XZ550RJ 1982 Service Manual

1. O-ring
7. Install the oil pump assembly and oil baffle
into the right side crankcase. Torque the
bolts to specification.
Tightening torque:
10 Nm (1.0m-kg, 7.2ft-lb)
8. Install the two dowels in the right side
crankcase as shown in the photograph.
9. Install a new 0-ring onto the oil-pressure re-
lief valve, and install the valve into the right
side crankcase cover.
NOTE:
Rotate the valve so no part of the cotter pin inter-
feres with any crankcase mating surface.
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. Starter motor lead clamp
Tightening torque:
10 Nm (1.0m-kg, 7.2ft-lb)

Pistons, cam chain guides, and cylinders

1. Install the pistons on the rods. The "EX" on
the front piston should face the front of the
engine, and the "EX" on the rear piston
should face the rear of the engine. Use new
piston-pin clips.
NOTE:
If the engine has been run prior to disassembly, be
sure to assemble the #1 piston with the front (#1)
cylinder. They have been mated through wear.
Before installing the piston pin clips, cover the
crankcase with a clean rag so you will not acciden-
tally drop the clip into the crankcase.
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