Yamaha XZ550RJ 1982 Bedienungsanleitung

YAMAHA

XZ550RJ

SERVICE MANUAL

11H-28197-10

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. A thermostatic valve mounted in the engine

block provides quick warmups and stable coolant temperature.

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. When the intake valve reopens, the mixture

in the chamber shoots back out through the angled tube and into the cylinder, mixing with and swirling the

main intake charge. The swirling charge is then compressed and ignited, burning more completely and produc-

ing more power than that of a conventional engine.

INTAKE SYSTEM AND YICS

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; intake efficiency is remarkably high. An accelerator pump is installed in the carbu-

retor assembly to eliminate hesitation when the throttle is opened at low engine speeds. A fuel pump delivers

gas from the tank to the float bowls, and a regulator sends excess fuel through a circuit back to the fuel pump

inlet.

DOHC 4-valve heads

Each cylinder head has dual overhead camshafts, and each camshaft acts directly on top of the valves; there

are no pushrods or rocker arms. Both heads have four valves, two intake and two exhaust, instead of one in-

take and one exhaust valve. By using two slightly smaller valves in place of each large valve, port area is sig-

nificantly increased. This provides a much greater volume of mixture and exhaust flow. In addition, the smaller,

lighter valves are easier to control at high engine speeds; the valves can follow the cam profiles more closely

to resist "floating" and allow a 9,500 r/min red line.

Chassis bits

The "hang-support" frame on this motorcycle allows a lower engine placement and center of gravity while pro-

viding excellent rigidity for precise handling. Cornering clearance is also enhanced. The trailing-axle front sus-

pension performs superbly. 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.

FRAME AND MONOCROSS SUSPENSION SYSTEM

NOTICE

This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their quali-

fied mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that

persons using this book to perform maintenance and repairs on Yamaha motorcycles have a hasic under-

standing of the mechanical concepts and procedures inherent to motorcycle repair technology. Without such

knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe.

This model has been designed and manufactured to perform within certain specifications in regard to perform-

ance and emissions. 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.

Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifica-

tions and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha deal-

ers and will, where applicable, appear in future editions of this manual.

NOTE:

This Service Manual contains information regarding periodic maintenance to the emission control system for

the XZ550RJ. Please read this material carefully.

Particularly important information is distinguished in this manual by the following notations:

NOTE: A NOTE provides key information to make procedures easier or clearer.

CAUTION: A CAUTION indicates special procedures that must be followed to avoid damage to the motorcy-

cle.

WARNING: A WARNING indicates special procedures that must be followed to avoid injury to a motorcycle

operator or person inspecting or repairing the motorcycle.

SERVICE DEPT.

INTERNATIONAL DIVISION

YAMAHA MOTOR CO., LTD.

CHAPTER 1. GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION………………………………………………………………………………..... 8

Frame serial number……………………………………………………………………………………….. 8

Engine serial number………………………………………………………………………………………. 8

Vehicle identification number…………………………………………………………………………….. 8

SPECIAL TOOLS……………………………………………………………………………………………………... 9

For tune-up…………………………………………………………………………………………………… 9

For engine service………………………………………………………………………………………….. 9

For chassis service…………………………………………………………………………………………. 12

For middle gear service……………………………………………………………………………………. 12

For shaft drive service……………………………………………………………………………………... 13

For electrical components………………………………………………………………………………… 13

MOTORCYCLE IDENTIFICATION

Frame serial number

The frame serial number is stamped into the right

side of the steering head pipe.

1. Frame serial number

Engine serial number

The engine serial number is stamped into the ele-

vated part of the right rear section of the engine.

Starting serial number:

XZ550RJ

11H-000101

NOTE

The first three digits of these numbers are for model

identification; the remaining digits are the unit pro-

duction number.

1. Engine serial number

Vehicle identification number

The vehicle identification number is on the left side

of the steering head pipe.

1. Vehicle identification number

GENERAL INFORMATION

SPECIAL TOOLS

The proper special tools are necessary for complete

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)

Fuel level gauge (P/N YM-01312)

Cooling system tester (P/N YU-24460)

Compression gauge (P/N YU-33223)

Compression gauge

12 mm (0.47 in) adapter (P/N YU-33223-3)

Vacuum gauge (P/N YU-08030)

This gauge is needed for carburetor synchronization

For engine service

Universal clutch holder

(P/N YM-91042)

This tool is used to hold the clutch when removing

or installing the clutch boss locknut

Tappet adjusting tool (P/N YM-28899)

This tool is necessary to replace valve adjusting

pads.

Valve spring compressor

(P/N YM-04019)

This tool must be used for removing and installing

the valve assemblies

Vavle guide remover

(P/N YM-04064)

This must be used to remove the valve guides

Valve guide reamer

(P/N YM-04066)

This must be used when replacing the valve guide.

Valve guide installer

(P/N YM-04065)

This tool is needed for proper installation of the

valve guides.

Valve seat cutter set

(P/N YM-91043)

This tool is needed to resurface the valve seat.

Flywheel puller

(P/N YU-33270)

This tool is used for removing the flywheel

8mm (0,3 in) wrench adapter

(P/N YM-28897)

This tool is used to loosen or tighten the cylinder

head securing nut.

Water pump seal installer

(P/N YM-33221)

This tool is needed for proper installation of the wa-

ter pump seal.

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