Yamaha XT550J Service Manual Download Page 1

Page: 1 / 169

Summary of Contents for XT550J

Page 1: ..._YAMAHA LIT 11616 03 00 5Y1 28197 10 ...

Page 2: ...w o 2 Q u o C oJ J o t 3 Q 0 C ttl U o oJ oJ U 0 J en Q ttl en c Q oJ ttl U Q Q en 0 c ttl en c 2 en Q o ...

Page 3: ...is intended to provide the customer with the most satisfac tion from his motorcycle and to conform with federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all models manufactured by Yamaha Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will where applicable appear in futu...

Page 4: ...GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL APPENDICES ...

Page 5: ...Dry Sump System and Monocross Suspension 1 2 B Four Valve Engine 1 3 C Yamaha Duo Intake System YDIS 1 4 D Kick Synchronous Automatic Decompression 1 5 E D C Lighting System 1 6 F Detachable Lighting System 1 7 G Fuel Tank Cap with Check Valve 1 8 SPECIAL TOOLS 1 9 A For Tune up 1 9 B For Engine Service 1 9 C For Chassis Service 1 12 D For Electrical Components 1 12 ...

Page 6: ... Engine Serial Number The engine serial number is stamped into the elevated part of the right section of the engine NOTE ________________________ The first three digits of these numbers are for model identification the remaining digits are the unit production number 1 1 c Vehicle Identification Number The vehicle identification number is on the left side of the steering head pipe 1 Vehicle Identif...

Page 7: ...ES A Dry Sump System and Monocross Suspension The XT550J which inherits the traditional XT500 dry sump system features monoshock suspen sion light weight and a new diamond shaped frame with integrated oil tank 1 2 ...

Page 8: ...B Four Valve Engine Newly designed compact engine equipped with S O H C 4 Valve head Dual intake and dual ex haust ports gear driven balancer Yamaha Duo In take System YDIS and 5 speed transmission 1 3 ...

Page 9: ... the 4 valve layout offsets the intake ports relative to the cylinder bore axis a strong YICS type swirl is produced in the low to medium rpm range Combustion efficiency is significantly enhanced resulting in improved fuel economy In addi tion the single small bore provides excellent low and medium speed throttle response due to the high air velocity in the venturi This eliminates the need for a m...

Page 10: ... exhaust valves thus automatically decompressing the combustion chamber for ease in kick starting Combined with electronic ad vance ignition kick starting is free from possible kickback Correct adjustment is required of this kick synchronous automatic decompression system for effective performance 1 5 ...

Page 11: ...s a steady power source enabling all lights to keep bright even at low RPM This system also offers a safety advantage in that it keeps lights shining even when the engine is stalled iii C I o I I I I I I I 2 HEAD LIGHT VOLTAGE AC LIGHTING DC LIGHTING 3 4 5 6 7 8 ENGINE R MIN x 10 1 6 ...

Page 12: ...ance Lighting System is a modular design integrating headlight and in strument panel into one easy to remove and service package A few securing bolts an elec trical connector and the Easy maintenance Lighting System can be removed for quick service 1 7 ...

Page 13: ... ball normally settles at the bottom but when the machine is inclined to less than 30 from the ground as in a turnover the ball is made to roll accordingly while at the same time pushing up on the valve seat see drawing When the machine is laid flat on the ground the O ring on the valve contacts the tapered wall of the cap thereby closing the breather passage completely 1 8 ...

Page 14: ...tool PIN YM 08035 2 Compression gauge set Adapter M12 PIN YU 33223 PIN YU 33223 3 II 3 Oil pressure gauge adapter PIN YU 08030 1 This adapter is attached at the top of the oil filter cover after removing the air bleed screw 1 9 4 Inductive timing light 0 VII nan l7 5 Inductive tachometer PIN YU 08036 B For Engine Service 1 Universal clutch holder PIN YM 91042 This tool is used to hold the clutch w...

Page 15: ...25 This must be used to remove the valve guides 1 10 5 Valve guide installer PIN YM 04017 This tool is needed for proper installation of the valve guides 6 Valve spring compressor PIN YM 04019 This tool must be used for removing and installing the valve assemblies 7 Slide hammer set PIN YU 01083 These tools are used when removing the rocker arm shaft 1 Bolt PIN YU 01083 1 2 Weight PIN YU 01083 3 ...

Page 16: ... crankshaft and removing the final gear drive pinion 10 Crank pot spacer PIN YM 90070A This tool is used when installing the crankshaft 1 11 11 Crank protector PIN YM 04063 This tool protects the threads on the crankshaft 12 Flywheel puller PIN YU 33270 This tool is used for removing the COl rotor 13 Fu lev gauge PIN YM 01312 This tool is needed for checking the carburetor fuel level ...

Page 17: ... Front fork cylinder holder PIN YM 01327 T handle PIN YM 01301 or YM 01326 This tool is used to loosen and tighten the front fork cylinder bolt D For Electrical Components The uses of these tools are described in Chapter 6 1 Pocket tester PIN YU 03112 1 12 2 Electro tester PIN YU 03021 3 Coil tester PIN YU 33261 ...

Page 18: ...ressure Check 2 6 L Clutch Adjustment 2 7 M Checking Ignition Timing 2 7 N Compression Pressure Measurement 2 8 CHASSIS 2 8 A Down Tube Strainer 2 8 B Air Filter 2 9 C Front and Rear Brake 2 9 D Cable Inspection and Lubrication 2 11 E Brake and Change Pedals Brake and Clutch Levers Sidestand 2 11 F Drive Chain 2 11 G Front Fork Oil Change 2 12 H Front Fork and Rear Shock Absorber Adjustment 2 13 I...

Page 19: ...aximum performance In the following maintenance tables the services related toemissions control are grouped separately PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM Initial Break In Thereafter Every No Item Remarks 1 000km 5 000 km 4 000km 8 OOOkm 1600 mil 13 000 mil 12 500 mil 15 OOOmi or 1 month or 7 months or 6 months or 12 months 1 Valve clearance Check and adjust valve clearance when engine is...

Page 20: ...r oil Control and Apply chain lube Yamaha chain and 7 meter cable thoroughly cable lube or SAE 0 0 0 10W30 motor oil 8 Rear arm Apply grease Lithium soap base 0 0 pivot shafts lightly grease Brake pedal Yamaha chain and 9 Apply chain lube cable lube or SAE 0 0 shaft lightly 1OW130 motor oil Side stand Yamaha chain and 10 pivots Apply chain lube cable lube or SAE 0 0 and kick lightly crank boss 10W...

Page 21: ...earance should be checked and adjusted at T O C on the compression stroke by observing when the valve adjusters have clearance 2 3 3 Use a feeler gauge to determine the clearance Intake valve cold 0 05 0 10 mm 0 002 0 004 in Exhaust valve cold 0 12 0 17 mm 0 005 0 007 in Feeler gauge 4 Loosen the valve adjuster locknut Turn the adjuster in or out to obtain the cor rect clearance Hold the adjuster ...

Page 22: ...ication 3 If the electrodes become too worn replace it 4 When installing the plug always clean Standard spark plug NGK D7EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Spark plug tightening torque 20 Nm 2 0 m kg 14 ft Ib D Crankcase Ventilation System Check ventilation pipe from cylinder head cover to oil tank and breather assembly from crankcase to air cleaner for cracks or damage replace if necessa...

Page 23: ...1 Oil filler cap 2 Maximum oil level 3 Minimum oil level 6 The oil should be between the maximum and minimum marks on the filler cap gauge If the level is lower add sufficient oil to raise it to the proper level WARNING Never attempt to remove the oil tank filler cap just after high speed operation and or when engine is running The heated oil could spout out causing in jury Wait until the oil cool...

Page 24: ...he cause 9 After warm up stop the engine and check the oil level Refer to page2 5 Engine Oil J J Engine Oil Replacement without replacing filter 1 Start the engine and stop after a few minutes of warm up 2 Place an oil receiver under the engine 3 Remove the oil tank filter cap drain plugs at two places and air bleeder screw attached to the oil filter cover NOTE ____________ The oil filter cover is...

Page 25: ...stment required is maintenance of free play at the clutch handle lever Free play adjustment Loosen either the handle lever adjuster lock nut or the cable in line length adjuster lock nut Next turn the length adjuster either in or out until proper lever free play is achieved 2 7 1 Adjuster lock nut 2 Adjuster Mechanism adjustment See Chapter 3 Clutch Mechanical Adjust ment M Checking Ignition Timin...

Page 26: ...levels Compression pressure at seal level Standard 1 079 kPa 11 kg cm 2 156 psi Minimum 883 kPa 9 kg cm2 1 8 psi Maximum 1 177kPa 12kg cm2 171 psi WARNING When cranking the engine ground the spark plug wires to prevent sparking 2 8 1 Compression gauge set special tool P N YU 33358 2 Compression gauge adapter special tool P N YU 33358 3 6 If the pressure is too low squirt a few drops of oil into th...

Page 27: ...rial NOTE ____________ In order to function properly the element must be damp with oil at all times but not dripping with oil 7 Reinsert the guide into the element 8 Coat the mating surface of the filter with all purpose grease for an airtight seal between the filter case and filter seat 9 Install the filter element into the case 10 Install the filter cover and sidecover c Front and Rear Brake Fro...

Page 28: ... brake pedal free play adjustment 1 Turn the adjuster on the brake rod clockwise or counterclockwise to pro vide the brake pedal end with a free play of 20 30 mm 0 8 1 2 in WARNING Check to see whether or not the brake light operates correctly after adjusting Front brake shoe lining check To check examine the wear indicator posi tion while pulling in the brake lever If the in dicator reaches to th...

Page 29: ... motor oil F Drive Chain Drive Chain Tension Check Inspect the drive chain with both tires touching the ground and with rider on the seat Check the tension at the position shown in the illustration The normal vertical deflec tion is approximately 60 70 mm 2 4 2 8 in If the deflection exceeds 60 70 mm 2 4 2 8 in adjust the chain tension 2 11 Drive Chain Tension Adjustment a 60 70mm 2 4 2 8in 1 Loos...

Page 30: ...y it Immediately lubricate the chain to prevent the formation of rust Recommended lubricant YAMAHA CHAIN AND CABLE LUBE or SAE 10W30type SE motor oil G Front Fork Oil Change WARNING Securely support the motorcycle so there is no danger of it falling over 1 Raise the motorcycle or remove the front wheel so that there is no weight on the front end of the motorcycle Remove the handlebar if necessary ...

Page 31: ...nt 2 13 H Front Fork and Rear Shock Absorber Adjustment Front fork 1 Place the motorcycle on the stand and elevate the front wheel NOTE ____________ When checking and adjusting the air pressure there should be no weight on the front end of the motorcycle 2 Remove the rubber cap from the top of each fork 3 Using the air gauge check and adjust the air pressure If the air pressure is in creased the s...

Page 32: ... the steering ring nut until steering head is tight without binding when the forks are turned NOTE ________________________ Excessive tightening of this nut will cause rapid wear of the bearings and races Recheck for looseness and freedom of movement 2 14 1 Ring nut wrench 5 Retighten the top steering fitting nut steering fitting bolt and steering stem and the front fork pinch bolts in that order ...

Page 33: ...sket surfaces are scratched or corrod ed the fuel cock assembly must be replaced If there is abrasive damage to any components the fuel tank must be drained and flushed 5 Reassemble the fuel cock and install it on the fuel tank l Tires and Wheels To insure maximum performance long ser vice and safe operation note the following precautions 1 Check tire pressure before riding adjust as necessary 2 B...

Page 34: ... level will cause premature failure of the bat tery Charging current 1 6 amps 10 hrs or until the specific gravity reaches 1 280 at 20 C 68 F WARNING Battery electrolyte is poisonous and dangerous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesi...

Page 35: ...in the circuit in ques tion reset the breaker Turn on the switches and see if the electrical device operates If the breaker immediately opens again check the circuit in question See Chapter 6 ELECTRICAL CAUTION Wait 30 seconds before resetting the cir cuit breaker 2 17 ...

Page 36: ...e Gear 3 8 J Clutch Push Lever Axle 3 8 K Oil Pump Assembly 3 9 L Kick Axle Assembly 3 9 M Change Shaft Assembly 3 9 N Balancer Gear 3 9 O Crankcase 3 10 P Transmission 3 10 Q Crankshaft 3 11 R Oil Strainer Assembly 3 11 INSPECTION AND REPAIRING 3 12 A Cylinder Head Cover 3 12 B Cylinder Head 3 12 C Valves Valve Guides Valve Seats and Valve Springs 3 13 D Rocker Arms and Rocker Arm Shafts 3 17 E C...

Page 37: ...h 3 33 J CIutch 3 34 K Clutch Mechanical Adjustment 3 35 L Crankcase Cover Right 3 36 M Kick Crank Assembly 3 36 N Piston and Piston Ring 3 36 O Cylinder 3 37 P CYlinder Head Rocker Arm and Camshaft 3 39 Q Cylinder Head 3 40 R Cam Shaft Cam Sprocket Cam Chain 3 40 S Cam Chain Tensioner 3 41 T Cylinder Head Cover 3 41 U Flywheel 3 41 V Cran kcase Cover 3 41 W Decompression Cable 3 42 X Drive Sprock...

Page 38: ...er This includes gears cylinders pistons and other parts that have been mated through normal wear Mated parts must be reused as an assembly or replaced 3 During engine disassembly clean all parts and place them in trays in the order of disassembly This will speed up assembly time and help assure that all parts are correctly reinstalled in the engine 4 Start the engine and let it warm up Stop the e...

Page 39: ...r cleaner and mud guard to the frame 3 Remove the muffler 4 Remove the nuts holding the exhaust pipe to the cylinder head 5 Remove the exhaust pipe assembly 6 Remove the right side footrest with the brake pedal 3 2 D Oil Hoses 1 Remove the spark plug cap 2 Remove the breather pipe 3 Remove change pedal 4 Remove the left cran kcase cover 5 Remove the oil hose Inlet 1 Oil hose inlet ...

Page 40: ...ing bolts 2 and loosen carburetor hose clamp air cleaner side as shown in the photo 3 Remove the mud guard securing bolt 4 Remove the air cleaner case securing bolts and move the case backward 5 Remove carburetor assembly pulling carburetor toward you NOTE ________________________ Noting the presence location and routing of all vent and overflow tubes remove car buretor F Drive Chain and Drive Spr...

Page 41: ...ng bolts 4 Remove the front bracket 5 Remove the down tube strainer 1 Down tube strainer 3 4 6 Remove the engine mounting bolts 7 Remove the engine from the right side of the frame NOTE ________________________ The engine and rear arm are installed using the same pivot shaft Therefore take care so that the pivot shaft is not pulled entirely out but far enough to set the engine free ...

Page 42: ...nder Head Cover 1 Remove the spark plug 2 Remove the inlet and exhaust valve covers 3 Loosen the cylinder head cover securing bolts 16 and remove the cylinder head cover B Cylinder Head 1 Loosen the cam chain tensioner end plug and tensioner securing bolts and remove the cam chain tensioner assembly 1 End plug 2 Remove the cam chain guide stopper Front ...

Page 43: ...der 3 6 D Piston Pin and Piston 1 Remove piston pin clip 1 from piston NOTE _______________________ Before removing the piston pin clip cover the crankcase with a clean rag so you will not ac cidentally drop the clip into the crankcase 2 Push piston pin from opposite side then pull out Recommended practice is to use the piston pin puller special tool P N YU 01304 NOTE ______________ Before removin...

Page 44: ... to touch the projections 2 Remove the rotor by using the rotor puller special tool P N YU 901 05 G Cam Chain and Guide Stopper Loosen the guide stopper securing bolts and remove the guide stopper baffle plate and cam chain 3 7 H Crankcase Cover Right 1 Remove the oil filter cover holding bolts 3 and the cover 2 Remove the oil filter element 3 Remove the crankcase cover holding bolts and the cover...

Page 45: ...emove the nut and washer 3 Remove the five clutch spring holding screws pressure plates clutch plates friction plates ball and push rod 2 3 8 4 Flatten the lock washer on the clutch boss securing nut 5 Install clutch holding tool special tool PIN YM 91042 on clutch boss Loosen the locknut Remove the locknut washer clutch boss and housing in that order J Clutch Push Lever Axle Remove the push lever...

Page 46: ...out from the right hand side 2 Remove the shift lever 2 with the shift lever 3 as an assembly and then remove the stopper lever assembly with the tor sion spring Shift shaft 2 Shift lever 2 N Balancer Gear 3 Shift lever 3 4 Stopper lever assembly 1 Flatten the lock washer on the balancer gear shaft 2 First place a folded rag between the teeth of the drive gear and balancer gear to lock them Then l...

Page 47: ...the shift drum Use soft hammer to tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs up take pressure off the push screw realign and start over Ifthe cases do not separate check for a re maining case screw or fitting Do not force For this removal slits in the crankcase...

Page 48: ...ver the fitted area 1 O ring Q Crankshaft Remove crankshaft assembly with the crankcase separation tool Special tool PIN YU 01135 1 Crankcase separation tool 3 11 R Oil Strainer Assembly Remove the oil strainer and oil passage cover 1 Oil strainer 2 Oil passage cover NOTE ____________ It is recommended that the oil strainer be replaced whenever the engine is disassembl ed ...

Page 49: ...ker shaft hole 2 at the cam lobe contacting surface b Measure the rocker shaft hole in the rocker arm Standard size 12 000 12 018 mm 0 472 0 473 in 3 12 c The shaft has been hardened and it should not wear excessively If a groove has developed in this surface that can be felt or if it shows a blue discoloration then the shaft should be replaced and the lubrication system pump and passages checked ...

Page 50: ...d be replaced with a new one Cylinder head warpage less than 0 03 mm 0 0012 in Allowable limit 0 25 mm 0 010 in 3 13 C Valves Valve Guides Valve Seats and Valve Springs 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 Replace the valve if any dimension exceeds the specifications in the illustration INTA...

Page 51: ...guide inside diameter with a small bore gauge If it exceeds the limit replace it with an oversize valve guide Guide diameter 1 0 Limit 7 10 mm 0 280 in 2 To ease guide removal and reinstallation and to maintain the correct interference fit heat the head to 100D e 212D F Use an oven to avoid any possibility of head warpage due to uneven heating 3 Use the valve guide remover and valve guide installe...

Page 52: ...e valve into position and spin the valve quickly back and forth Lift the valve clean off all grinding com pound and check valve seat width The valve seat and valve face will have removed the bluing wherever they con tacted each other Measure the seat width with vernier calipers It should measure approximately 1 3 mm 0 051 in The valve seat contact area should be one uniform width If valve seat wid...

Page 53: ...ce and seat and rotate the valve Check for full seat contact which is indicated by a grey surface all around the valve face where the bluing has been rubbed away 3 16 2 After all work has been performed on the valve and valve seat and all head parts have been assembled check for proper valve valve seat sealing by pour ing solvent into each of the intake ports then the exhaust ports There should be...

Page 54: ... the valve stem and push it into position on top ofthe valve guide 3 Install the spring seat and install both valve springs 3 17 NOTE ____________ All valve springs must be installed with the larger pitch upward as shown LARGER PITCH o 0 o o oO SMALLER PITCH 4 Install the collar Be sure it is properly seated on the valve springs 5 Install the valve spring compressor and compress the springs 6 Inst...

Page 55: ...checked E Camshafts Cam Chains and Cam Sprockets Camshaft The cam lobe metal surface may have a blue discoloration due to excessive friction The metal surface could also start to flake off or become pitted 1 If any of the above wear conditions are readily visible the camshaft should be replaced 2 Even though the cam lobe surface ap pears to be in satisfactory condition the lobes should be measured...

Page 56: ...asuring instrument parallel to and at right angles to the crankshaft See the illustration If the cylinder wall is worn beyond the wear limit it should be rebored 3 19 0 and 0 0 3and O O and O Standard Cylinder bore 92mm 3 622 in Cylinder taper G Piston and Piston Rings Piston Wear limit 92 1 mm 3 626 in 0 OO5mm 0 0002 in 1 Using the micrometer measure the out side diameter of the piston at the pis...

Page 57: ... Oversize 4 1 00 mm 0 0394 in 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 3 20 Size Color Oversize 1 Brown Oversize 2 Blue Oversize 3 Black Oversize 4 Yellow 1 Measure the end gap of each piston ring Insert a ring into the cylinder and push it approximately 20 mm 0 8 in in to the cylinder Push the ring wi...

Page 58: ... free play There should be no noticeable fee play when the pin is in place in the piston If the piston pin is loose replace the pin and or the piston as required H Crankshaft and Connecting Rod Crankshaft bearing 1 Bearings should be cleaned dried and the races visually checked for pits rust spots or chatter marks where the balls have dragged If any of these conditions exist the bearings should be...

Page 59: ...sassemble the crankshaft and 0 65 mm 0 014 0 026 in replace any worn parts Check crankshaft assembly runout Dial gauge readings should be Correct any misalignment by tapp Misalignment of crankshaft parts within 0 03 mm 0 00118 in ing the flywheel with a brass ham mer and by using a wedge Crankshaft Specifications Unit mm in Rod clearance Runout limit Assembly width C A Min 0 03 74 95 75 00 0 8 0 0...

Page 60: ...is excessively noisy during operation replace both the drive and the driven gears K Clutch Clutch housing 1 Check the dogs on the clutch housing Look for cracks and signs of galling on the edges If damage is moderate deburr if severe replace the clutch NOTE ____________ Galling on the clutch plate splines will cause erratic operation 2 Check the clutch housing bearing for damage If damaged replace...

Page 61: ... OBmm 2 6mm 0 11 0 003 in 0 10 in Clutch plate 0 2mm warp limit 0 008 in 3 24 Clutch actuating mechanism 1 Push rod 1 4 Plain washer 2 O ring 5 Locknut 3 Push plate 1 Check the push rod 1 for wear and damage replace if damaged 2 Check the short push rod thrust bearing for damage replace if damaged 3 By rolling the push rod 2 on the V blocks check for bends If any bend is found replace the push rod...

Page 62: ...eplace as required 6 Check the shift cam stopper plate circlip and stopper for wear Replace as required 7 Check the transmission shafts using a centering device and dial gauge If any shaft is bent beyond the specified limit replace the shaft Maximum runout 0 08 mm 0 0031 in 8 Carefully inspect each gear Look for signs of obvious heat damage blue discoloration Check the gear teeth for signs of pitt...

Page 63: ...e the wheel 5 Check the ratchet wheel spring for fatigue If the free length shows the spr ing has collapsed beyond specification replace the spring Ratchet wheel spring free length Standard Minimum 17 2 mm 0 677 in 15 0mm 0 591 i 3 26 6 When reassembling the kick starter align the mark on the ratchet heel with the one on the kick axle as shown N Bearings and Oil Seals Inspection 1 After cleaning a...

Page 64: ...rclips should be inspected carefully before reassembly Always replace piston pin clips after one use Replace distorted circlips When installing a circlip make sure that the sharp edged corner is positioned op posite to the thrust it receives See the sectional view below SHARP EDGED CORNER Bearings and oil seals 1 Install the bearing s and oil seal s with their manufacturer s marks or numbers facin...

Page 65: ...Left Side Crankcase BEARING B6004 2ND WHEEL GEAR CIRCLIP 4TH WHEEl GEAR BEARING 3RD WHEEL GEAR 4TH PINION GEAR DRIVE SPROCKET SPROCKET HOLDER DRIVE AXLE 3RD PINION GEAR I 1 5TH PINION GEAR i BEARING 3 28 ...

Page 66: ...inst bearing 3 Install the drive axle and main axle NOTE ________________________ While installing the drive axle into the crankcase pay careful attention to the oil seal lip It is recommended to set a suitable O ring in to the drive axle groove O ring 3 29 4 Install the shiff cam Shift cam assembly 5 Install the shift forks 1 2 and 3 NOTE ________________________ The figure on the shift forks is ...

Page 67: ... is disassembl ed 10 Set the right half crankcase onto the shafts and tap lightly on the case with a soft hammer to assemble NOTE ________________________ 1 Do not tap on machined surface or end of crankshaft 2 Work slowly and carefully while making sure of the parallelism of the mating sur face of the left half with that of the right half 3 30 11 Install all crankcase bolts and tighten in stages ...

Page 68: ...Oil passage 3 Install the oil pump assembly 3 31 4 Install the oil pump gear CD E Shifter 1 Set the stopper lever and then install the change shaft assembly 2 During installation note the index mark on change lever 2 and center of change lever 1 Align I stopper lever 2 Shift cam 3 Shift lever 1 4 Shift lever 2 a Align the mark 3 Install the pump gear and circlip F Kick Starter 1 While pushing the ...

Page 69: ...ancer gear and install 3 Install the keys for the balancer drive and driven gears with the marks in align ment 3 32 4 Tighten the balancer gear locknut by first placing a folded rag between the teeth of the balancer gears to lock them as shown in the photo TIGHTENING TORQUE 60 Nm 6 0 m kg 43 ft lb 5 Bend the lock washer H Push Lever Assem bly 1 Install the clutch push lever assembly 2 Tighten the ...

Page 70: ...I Primary Gears and Clutch THRUST PLATE 110 Nm 11 m kg 80 ft lb PRIMARY DRIVEN GEAR COMPLETE LOCK WASHER PRIMARY DRIVE GEAR PUSH ROD 1 3 33 ...

Page 71: ...clutch holding tool special tool PIN YM 91042 on clutch boss and tighten locknut 3 34 TIGHTENING TORQUE 70 Nm 7 0 m kg 50 ft lb 5 Bend the lock tab 6 Install clutch plate and friction plate 7 Install clutch pressure plate 8 Continue installation of clutch and fric tion plates CAUTION When installing the friction plates pay careful attention to the inside diameter The friction plate with the larges...

Page 72: ...f rolled rug or a piece of lead between the primary drive gears as shown in the photograph It will hold the gears so you can tighten the primary drive securing nut Torque the nut to specification and bend the lock tab against a nut flat TIGHTENING TORQUE 110 Nm 11 0m kg 80ft lb 3 35 K Clutch Mechanical Adjustment With the crankcase index mark and the pointed end of the push lever in line with each...

Page 73: ...7 Nm 0 7 m kg 5 1 ft Ib N Piston and Piston Ring 1 Mount the piston rings installed onto the connecting rod Be sure the arrow stamped on the piston crown points forward 2 Install new piston pin clips in their grooves 3 36 NOTE ____________ Before installing the piston pin clips cover the crankcase with a clean rag so you will not accidentally drop the clip into the crankcase 3 During reassembly co...

Page 74: ...ring and cylinder base gasket 1 a ring 3 Offset the three ring end gaps as shown 3 37 1 Top 3 2nd 2 Oil ring Lower rail 4 Oil ring Upper rail 4 Install the cylinder with one hand while compressing piston rings with other hand t 5 Install the cam chain with a wire in stalled 6 Install the guide stopper and tighten the securing bolts TIGHTENING TORQUE 8 Nm 0 8 m kg 5 8 ft Ib L ...

Page 75: ...7 Tighten the cylinder securing nuts and bolts 3 38 20Nm 2 0 m kg 14 ft Ib 10Nm 1 0m kg 7 2ft lb ...

Page 76: ... Rocker Arm and Camshaft CAMSHAFT 10Nm r J 1 0 m kg 7 2ft lb EXHAUST VALVE 3 39 DECaMP LEVER INTAKE TAPPET COVER 10Nm 1 11 0 m kg 7 2ft lb LOCKNUT 14Nm 1 4m kg 10ft lb WAVE WASHER a RING VALVE SPRING SEAT INTAKE VALVE ...

Page 77: ...marks on the crankshaft sprocket and crankcase as shown in the following photo 3 40 3 Install the cam sprocket onto the cam shaft The timing mark on the sprocket must be aligned as shown in the illustra tion while pulling all the slack from the front side of the cam chain The front side of the cam chain must be taut when the cam chain sprocket is installed CAMSHAFT INSTALLATION FRONT CAM CHAIN GUI...

Page 78: ...dowels in the cylinder 2 Use a new gasket and tighten the secur ing bolts TIGHTENING TORQUE 10 Nm 1 0 m kg 7 2 ft Ib L _ _ _ _ _ _ _ _ _ _ _ _ _ _ 3 41 3 Adjust the valve clearance Refer to Chapter 2 Valve clearance 4 Install the intake and exhaust tappet covers U Flywheel 1 Install the woodruff key into the crankshaft keyway 2 Install the flywheel assembly onto the crankshaft The key in the crank...

Page 79: ... Decompression lever 3 Adjust the decompression cable free play 1 Adjuster 2 Lock nut 3 42 Decompression cable free play 0 5 mm 0 02 in Clamp the lead to the crankcase X Drive Sprocket Install the collar drive sprocket and sprocket holder Tighten the securing bolts TIGHTENING TORQUE 10 Nm loOm kg 7 2ft lb Y Oil Delivery Pipe Install the oil delivery pipe onto the crankcase Install and finger tight...

Page 80: ...nder the engine 2 Take care the left side swingarm collar is in the support plate 2 Install the engine mounting bolts and nuts 3 Install the engine protector and tighten the securing bolts 3 43 4 Install the inlet and outlet hose and tighten the securing bolts and nuts NOTE _______________________ Oil the inlet oil passage before installing the inlet oil hose and install the O ring to the inlet ho...

Page 81: ...bly Refer to removal procedure in Chapter 4 Car buretor 9 Install the drive chain and caulk the joint using the drive chain cutter 10 Install the exhaust pipes and muffler Tighten the securing bolts Tightening torque Size Nm m kg ft lb M8 Hex bolt 20 2 0 14 M6 Nut 10 1 0 7 2 11 Clamp the decompression cable to the frame 12 Install the fuel tank and seat Tighten the securing bolt 13 Add 1 2 L 1 1 I...

Page 82: ...CHAPTER 4 CARBURETION CARBURETOR 4 1 A Section View 4 3 B Specifications 4 4 C otsassembly 4 4 O Inspection 4 5 E Assembly 4 6 F Adjustment 4 6 AIR CLEANER AND CRANKCASE VENTILATION SYSTEM 4 9 ...

Page 83: ...DARY __ NEEDLE JET WIRE DRUM ASSEMBLY CARBURETION CABLE CONNECTOR Y f PRIMARY CARB CAP GASKET i L i SECONDARY THROTTLE VALVE 6 JET NEEDLE PRIMARY THROTTLE VALVE STARTER PLUNGER GASKET THROTTLE STOP SCREW FLOAT CHAMBER FRONT PLATE STAY 4 1 O RING d DRAIN SCREW ...

Page 84: ...Primary Carbo VMtype Cable operated slide type 4 SECONDARY THROTTLE PUSH LEVER SECONDARY THROTTLE SHAFT 4 2 Secondary Carbo BStype Vacuum controlled slide type ...

Page 85: ...E JET I I I PRIMARY MAIN JET I L ____________________ J I I 1 _____________ J PILOT AIR PASSAGE PRIMARY SYSTEM STARTER SEAT STARTER JET PRIMARY AIR JET J AIR I MIXTURE FUEL 4 3 SECONDARY AIR JET SECONDARY JET SECONDARY SYSTEM o o g o o g o o o o o o o o o o cf ...

Page 86: ...ions c Disassembly 1 Remove the seat 2 Turn the fuel cock to OFF and remove the fuel hose and the fuel tank 3 Remove the throttle cables and the starter cable 4 Loosen the four bolts securing the air cleaner case 5 Loosen the four bolts securing the rub ber joint band 4 4 6 Remove the carburetor 7 Remove the rear and front plate stays from the carburetors 8 Separate the primary carburetor and the ...

Page 87: ...condary piston 4 5 3 Remove the needle jet out of the suction piston NOTE ______________________ 1 Loosen the jet needle tightening screw and pull out the jet needle then they can be pulled out with the needle holder 2 Pay close attention to the small spring supporting the jet needle it may jump out when the jet needle is removed from the secondary piston 4 Assemble the secondary carbo cap and the...

Page 88: ...ing the secondary cap securing panhead screws make sure that the suction piston moves smoothly Gradually tighten the two screws alter nating between them Move the piston while the screws are tightened ensuring that the piston does not bind 3 Be sure that the suction piston moves smoothly after tightening the screws F Adjustment Fuel level NOTE ____________ Before checking the fuel level note the f...

Page 89: ...etor from the motorcycle and check the fuel valve and float assembly for damage Replace if damaged 6 If no damage is found correct the fuel level by slightly bending the float arm tang 4 7 1 Roat arm tang 7 Check the float height for reference Using a vernier caliper measure the distance from the top of the float chamber gasket seat with the gasket removed to the top of the float see the photograp...

Page 90: ...ecure the locknut on it FULL OPENING ADJUSTING SCREW Secondary carb synchronization Raise the primary carb valve to a height of 10 mm 0 394 in as indicated Then adjust the synchronizing screw so the secondary throt tle shaft just contacts the secondary throttle push lever PRIMARY CARS 4 8 As the primary carb valve is further opened the secondary butterfly valve will finally be opened to its full h...

Page 91: ...AIR CLEANER AND CRANKCASE VENTILATION SYSTEM AIR CLEANER c FRESH AIR _ BLOW BY GAS CARBURETOR 4 9 ...

Page 92: ...5 4 E Rear Axle Inspection 5 4 F Replacing Wheel Bearings 5 4 G Rear Wheel Inspection 5 4 H Installing Rear Wheel 5 4 RIMS AND SPOKES 5 4 A Checking for Loose Spokes 5 4 B Checking Rim Run Out 5 4 TIRES AND TUBES 5 5 A Removal 5 5 B Installation 5 5 DRIVE CHAIN AND SPROCKETS 5 5 A Drive Sprocket 5 5 B Driven Sprocket 5 6 C Chain Inspection 5 6 D Chain Maintenance 5 7 FRONT FORK 5 8 A Removal and D...

Page 93: ... Inspection and Lubrication 5 15 D Assembly 5 17 REAR SHOCK ABSORBER 5 18 A Removal 5 19 B Inspection 5 19 C Installation and Adjustment 5 20 CABLES AND FITTINGS 5 21 A Cable Maintenance 5 21 B Throttle Maintenance 5 21 C Lubrication of Levers Pedals etc 5 21 ...

Page 94: ... YAMAHA LlT 11616 0J OO 5Y1 28197 10 ...

Page 95: ... mm 5 91 in Replacement limit 146 mm 5 75 in 2 Remove any glazing from the brake shoes with coarse sandpaper C Brake Drum Oil or scratches on the inner surface of the brake drum will impair braking performance or result in abnormal noises Remove oil by wiping with a rag soaked in lacquer thinner or solvent Remove scratches by lightly and evenly polishing with emery cloth D Brake Shoe Plate 1 Remov...

Page 96: ...nsion rim deformation and wheel bearings Replace the wheel as re quired Rim run out limits Vertical 2 mm 0 079 in Lateral 2 mm 0 079 in 5 2 1 Dial gauge 3 Check the wheel balance Rotate the wheel lightly several times and note where the wheel comes to rest If the wheel is not statically balanced it will come to rest at the same point each time Install an appropriate balance weight at the lightest ...

Page 97: ...uts CAUTION First tighten the nuts on the upper end of the axle holder then tighten the nuts on the bottom 5 3 REAR WHEEL A Removal 1 Remove the axle nut cotter pin and the axle nut 2 Place the motorcycle on a suitable stand 3 Remove the brake rod from the brake shoe plate The brake rod can be removed by removing the adjuster 1 Adjuster 2 Brake rod 4 Remove the drive chain from the driven sprocket...

Page 98: ...rear wheel 0 1 seals 2 Install the wheel and the axle and the ax le nut 3 Connect the drive chain the brake rod and the adjuster 5 4 4 Adjust the drive chain See Chapter 2 Drive Chain 5 Adjust the rear brake See Chapter 2 Front and Rear Brake 6 Tighten the axle nut TIGHTENING TORQUE OONm 10 0m kg 72ft lb 7 Install the new cotter pin on the axle nut RIMS AND SPOKES A Checking for Loose Spokes Loose...

Page 99: ... creases that might exist Release the air and continue with reassembly Also right after the tire has been completely slipped onto the rim check to make sure that the stem comes out of the hole in the rim at a right angle to the rim Finally inflate the tire 5 5 Front Tire Pressure Off Road Riding 98 1 kPa 1 0kg cm 2 14 psi Normal Riding 147 1 kPa 1 5kg cm 2 21 psi High Speed Riding 147 1 kPa 1 5kg ...

Page 100: ... 21 7 ft lb 5 6 1 Lock washer 2 Nut C Chain Inspection 1 With the chain installed on the machine excessive wear may be roughly deter mined by attempting to pull the chain away from the rear sprocket If the chain will lift away more than one half the length of the sprocket teeth remove and inspect If any portion of the chain shows signs of damage or if either sprocket shows signs of excessive wear ...

Page 101: ...use wire brush then rag 2 Apply lubricant between roller and side plates on both inside and outside of chain Don t skip a portion as this will cause uneven wear Apply thoroughly Wipe off excess Recommended lubricant YAMAHA CHAIN AND CABLE LUBE or SAE 10W30 type SE motor oil 3 Periodically remove the chain Wipe and or brush excess dirt off Blow off with high pressure air 4 Soak chain in solvent bru...

Page 102: ...FRONT FORK 8 AXLE HOLDER DAMPER ROD 5 8 CAP BOLT 23 Nm 2 3 m kg 17 ft lbl RUBBER CAP G AIR VALVE C RIJ Q NG I FORK SPRr DRAIN JOLT 1 CYLINDER SECURING BOLT 137 Nm 3 7 m kg 27 ft o lbll ...

Page 103: ... ring by carefully prying out one end with a small screwdriver 5 Place an open container under each drain hole Remove the drain screw from each outer tube 6 Loosen the pinch bolts on the upper and lower brackets and remove the forks 7 Remove the cylinder securing bolt from the bottom of the fork assembly Hold the inner tube with the front fork cylinder holder special tool P N YM 01327 Pull the inn...

Page 104: ...k seal and install the fork seal by pressing it in with a large socket Install the retaining clip 3 Install the inner fork tube into the outer fork tube 4 Apply Loctite Stud N 8earing Mount red to the cylinder securing bolt and install the bolt and a copper washer into the outer fork tube Torque the bolt to specification TIGHTENING TORQUE 37 Nm 3 7 m kg 27 ft lb 5 10 5 Reinstall the spring seat an...

Page 105: ...STEERING HEAD UPPER BRACKET COVER HEADLIGHT BRACKET 5 11 20 Nm 2 m kg 14 tt Ib HANDLE HOLDER o a _ HANDLE CROWN ...

Page 106: ... fork assembly 5 Remove the steering fitting bolt and remove the handle crown 5 12 6 Remove the ring nut supporting the under bracket so that it may not fall down 7 Remove the bearing cover and the upper and lower bearings c Inspection 1 Wash the bearings in solvent 2 Inspect the bearings for pitting or other damage Replace the bearings if pitted or damaged 3 Clean and inspect the bearings Spin th...

Page 107: ...Nm 3 8 m kg 27 ft lb 4 Continue assembly reverse the dIsas sembly procedure 5 When assembly is complete check the under bracket by turning it from lock to lock If there is any binding or looseness readjust the tightness of the under bracket TIGHTENING TORQUE Front fork pinch bolt 23 Nm 2 3 m kg 17 ft Ib Steering fitting bolt 95 Nm 9 5 m kg 68 ft Ib 5 13 ...

Page 108: ...SWINGARM CHAIN COVER PIVOT SHAFT SWING ARM CHAIN GUARD CHAIN TENSIONER 5 14 ...

Page 109: ...ar wheel 2 Remove the cotter pin from the sw ingarm drive out the shock absorber pivot shaft and disconnect the shock absorber from the swingarm 5 15 1 Pivot shaft 3 Remove the swingarm pivot bolt and remove the swingarm J C Inspection and Lubrication 1 Examine the thrust covers and oil seals Replace if they are damaged 2 Inspect the bearings and bushings in the swingarm member for scratches on ot...

Page 110: ...SPACER PIVOT SHAFT FRAME BRACKET SWINGARM MEMBER 4 Check the collar spacer length B Collar spacer length B 77ffl 3 mm 3 03ffl 012 in ffl 2 ffl OO8 If B is not within specification replace the collar spacer 5 Calculate the side clearance C by using the formula given below C B A Swingarm side clearance C 0 1 0 3mm 0 004 0 012 in ...

Page 111: ... Swingarm side clearance 0 1 0 3 mm 0 004 0 012 in 7 Grease the swingarm periodically D Assembly 1 Assemble the swingarm by reversing the removal procedures Use a new lock plate and torque the swingarm pivot bolt to specification TIGHTENING TORQUE 100 Nm 10 m kg 72 ft Ib Use a new cotter pin when installing the shock absorber pivot shaft Bend the cotter pin as shown in the photo 2 Using a grease g...

Page 112: ...REAR SHOCK ABSORBER SPRING UPPER SEAT SPRING GUIDE SPRING LOWER SEAT WAVE WASHER BUMP STOPPER 48 Nm 14 8 m kg 35 ft Ibl DUMPER SUB ASS Y 5 18 BUSH SHOCK ABSORBER PIVOT SHAFT ...

Page 113: ...hock ab sorber To do so drill a 2 3 mm 0 08 0 12 in hole through the cylinder wall at a point 10 15 mm 0 39 0 59 in above the bottom of the cylinder 5 Wear eye protection to prevent eye damage from escaping gas and or metal chips 1 Drill 2 3 mm0 0 08 0 12 in0 a 10 15 mm 0 39 0 59 in 1 Remove the seat and the fuel tank 2 Remove the rear wheel Refer to page 5 3 5 19 3 Remove the cotter pin from the ...

Page 114: ...check to see if it has proper damping effect Slight resistance should be felt on the compression down stroke and considerable resist ance should be felt on the return up stroke 01 3 m 1 Install the spring and guide and turn to set the seat spring as shown in the il lustration Normal position 1 286 mm 11 3 in 2 Install the shock absorber on the motor cycle Rear shock absorber Tightening torque 48 N...

Page 115: ...upon condi tions and preferences However a Yamaha chain and cable lubricant or its equivalent will perform adequately under most conditions B Throttle Maintenance 1 Remove the Phillips head screws from the throttle housing assembly and separate the two halves of the housing 2 Disconnect the cable end from the throt tle grip assembly and remove the grip assembly 5 21 3 Wash all parts in a mild solv...

Page 116: ...ion 6 6 C Stator Coil Inspection 6 6 IGNITION SYSTEM 6 7 A Description 6 8 B Ignition Timing 6 8 C C D I Unit Test 6 8 D C D I Unit Test by Yamaha Pocket Tester 6 9 E Troubleshooting 6 9 LIGHTING SYSTEM 6 13 A Easy maintenance Lighting System 6 14 B Lighting Tests and Checks 6 15 SIGNAL SYSTEM 6 16 A Signal System Tests and Checks 6 17 B Switches 6 17 C Battery 6 18 ...

Page 117: ...ELECTRICAL ELECTRICAL COMPONENTS ELECTRICAL COMPONENT 1 MAIN SWITCH PLATE CONNECTOR COVER 6 1 COl UNIT ASSEMBLY CIRCUIT BREAKER BATTERY ...

Page 118: ...ElECTRICAL COMPONENT 2 HORN REFLECTOR STOP SWITCH SIDESTAND SWITCH FLASHER RELAY I Nm 12 0 m _ Ibll NEUTRAL SWITCH 6 2 ...

Page 119: ...TER LIGHT __ B r __ P__ O____ B IHORN SWITCH lI7b HORN B L __ __________ L __ Sb B B NEUTRAL INDICATOR B ON o OFF LOCK IMAIN SWITCH R W R R NON FUSE RECTIFIERI BREAKER REGULATOR R 12V15A W B BATTERY 12V5AH J HIGH BEAM INDICATOR COLOR CODE R Red B Black Sb Sky blue Br Brown Ch Chocolate Dg Dark green L Blue Y Yellow O Orange G Green P Pink W White B W Black White Y R Yellow Red B Y Black Yellow G Y...

Page 120: ...l heat up and deform When its deformation exceeds a certain amount the bimetal forces the knob out The bimetal is kept warped by the semielliptic spring In this manner the circuit is left open The circuit can be closed by simply pushing the knob down By repeating this operation the same circuit breaker can be used repeatedly J 4 Circuit is open In operation Wait 30 seconds before resetting the cir...

Page 121: ... 8 8 IIIIAKE IIWI I CHI GIYO 8 fREAR IlllAKE SWfTCHI llR l IWITCHf B Br R RECTIFIERI REGULATOR ON Fl A8HER RELAY o OFFI LOCK IMAIN SWITCH R R BATTERY 12VSAH B W Black White VIR YeHow Red B Y Black Yellow G Y Green Yellow L W Blue White Br W Brown White III CIt NON FUSE BREAKER 12V15A R W Red White L B Blue Black L Y Blue Yelow L R Blue Red W R WhitelRed W G White Gte This circuit diagram shows the...

Page 122: ... Never disconnect the cables from the battery while the generator is operating If the battery is disconnected the volt age across the generator terminals will increase and you may be shocked B Battery Inspection 1 Check the battery terminals and couplers They should be tight 2 Measure the specific gravity of the bat tery If it is less than 1 260 remove and charge the battery until the specific gra...

Page 123: ... Br CIt 0I0eaIIiI8 Og DIIk L Blue Y YeIow 0 Orenge G ar t p PInk W MIte B W at ck White YIR Yellow Red S Y BtecklYeliow G Y Green Yellow lIW a ue Br W Brown White R W RedlVYhite LIB BIue lIY Blue Yellow lIR 8luelRId W R WhiMlRed WIG M o t This circuit diagram shows the ignition circuit in the wiring diagram SPARK PLUG H 4_ J L ENGINE STOP SWITCH R H IGNITION COIL SIDESTAND SWITCH 6 7 COl UNIT UNDE...

Page 124: ...perative or if the engine misfires at the minimum spark gap or at a smaller gap there is a problem in the ignition system Follow the trouble shooting chart until the source of the problem is located 6 10 I Check entire ignition I p oo r I for connections connection I OK l Check battery for voltage and specific gravity I OK Check non fuse breaker and connections I OK Check resistance of ignition co...

Page 125: ...condary coil resistance 6KQ 15 at 20 C 68 F 6 11 PRIMARY COIL CHECK 2 7Q o x1Q IGNITION COIL SECONDARY COIL CHECK B SKQ o x100Q IGNITION COIL u Spark plug The life of a spark plug and its discoloring vary according to the habits of the rider At each periodic inspection replace burned or fouled plugs with new ones of the specified type It is actually economical to install new plugs often since it w...

Page 126: ...age Type D7EA NGK Electrode gap 0 6 0 7 mm 0 024 0 028 in Tightening torque 20Nm 2 0m kg 14ft lb Sidestand switch 1 Remove the seat and disconnect the connector 2 Connect the pocket tester leads as shown and set the tester selector to ohms x 1 When the sidestand is up the tester should read zero ohms When the sidestand is down the tester should read infinity Wire color Switch position B L Y FREE P...

Page 127: ...WITCHI B R R T BATTERY 12V5AH B W Black Nhite YIR YeIIowlRed B Y Bleck Yellow G V Green Yellow L W Blue VVhne Bt W Brown VVhne Hi V NON FUSE BREAKER 12V15A RIW Red White LIB 1IIck L Y Blue Vellow L R Red W R WhltelRed WIG White Green This circuit diagram shows only the lighting circuit in the wiring diagram MAIN SWITCH DIMMER SWITCH L H I METER LIGHT BATTERY R H I TAILLIGHT HEADLIGHT 6 13 ...

Page 128: ...e motorcycle correctly Removal 1 Remove the connector cover and disconnect the wiring connector Put the main harness connector back in its place 2 Remove the three headlight bracket securing bolts 6 14 NOTE _________________________ When loosening the bolts take care not to lose the underside clamp nuts 3 Remove the cables from the speedo and tachometer Install the rubber caps 4 Remove the headlig...

Page 129: ...TCH IS TURNED TO ON Check non fuse breaker No good 1Push knob I Check for battery voltage at No voltage IDimmer switch or wiring I dimmer switch terminal I l circuit defective I Voltage OK Check for battery voltage at headlight high beam or low beam terminal Voltage OK Poor ground or poor connection of headlight wiring No voltage An open or poor connection between headlight and dimmer switch termi...

Page 130: ...KE SWITCHI UR NEUTRAL INDICATOR B RECTIFIER REGULATOR ON o OFF LOCK BATTERY l2V5AH 1 B W Black White Y R Yellow Red B Y Black Yellow G Y Green Yellow l W Blue White Br W Brown White NON FUSE IBREAKER 12V15A R W Red White l B Blue Black l Y Blue Yellow l R Blue Red W R White Red WIG White Green This circuit diagram shows only the signal circuit in the wiring diagram MAIN SWITCH FRONT FLASHER LIGHT ...

Page 131: ...witches Flasher light s do not work 1 Check the bulb 2 Right circuit a Check for 12V on the dark green wire to the light b Check for ground on the black wire to the light assembly 3 Left circuit a Check for 12V on the dark brown wire to the light b Check for ground on the black wire to the light assembly 4 Right and left circuits do not work a Check for 12V on the brown white wire to the flasher s...

Page 132: ...Bat teries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield your eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 6 18 The service life of a battery is usually two to three years Lack of care as described below will shorten the life of the battery Negligence in keeping battery topped off with distilled w...

Page 133: ... 18 COLOR CODES 7 18 DEFINITION OF UNITS 7 19 CONVERSION TABLES 7 19 EXPLODED DIAGRAMS 7 20 A Cylinder 7 20 B Camshaft Chain 7 21 C Kick Starter 7 22 D Front Wheel 7 23 E Rear Wheel 7 24 F Frame 7 25 G Oil Pump Oil Cleaner 7 26 POWER FLOW CHART 7 27 LUBRICATION CHARTS 7 28 CABLE ROUTING DIAGRAMS 7 32 WIRING DIAGRAM 7 33 ...

Page 134: ...ment 558 cm 3 34 1 cu in Bore x Stroke 92 x 84 mm 3 622 x 3 307 in Compression Ratio 8 5 1 Compression Pressure 1 079kPa 11 kg cm2 156 psi Starting System Kick starter Lubrication System Dry sump Oil Type or Grade SAE 20W40 type SE motor oil Engine Oil Oil Capacity Engine Oil Periodic Oil Change 1 8 L 1 6 Imp qt 1 9 US qt With Oil Filter Replacement 1 9 L 1 7Imp qt 2 0 US qt Total Amount 2 2 L 1 9...

Page 135: ...47 1 5 21 Off Road Riding 98 1 1 0 14 98 1 1 0 14 High Speed Riding 147 1 5 21 147 1 5 21 Brake Front Brake Type Drum brake Operation Right hand operation Rear Brake Type Drum brake Operation Right foot operation Suspension Front Suspension Telescopic fork Pneumo mechanical Rear Suspension Unit swing Monocross suspension Shock Absorber Front Shock Absorber Air Coil spring Oil damper Rear Shock Abs...

Page 136: ...Model XT550J Bulb Wattage Quantity Headlight 45W 40W Tail Brake Light 8W 27W Flasher Light 27Wx4 Indicator light Wattage Quantity 12V3 4Wx3 METER LIGHT 3 4Wx2 NEUTRAL 3 4W HIGH BEAM 3 4W TURN 3 4W 7 3 ...

Page 137: ...Clearance Cold IN EX XT550J 0 03 mm 0 0012 in Lines indicate straightedge measurement 92 01 02 mm 3 61 007 in 0 005 mm 0 0002 in Chain Left 0231 021 mm 00 91 0 0008 in 023 8 mm 00 91 8 in 0 020 0 054 mm 0 0008 0 002 in A 36 55 0 05 mm 1 44 0 002 in Limit 36 40mm 1 4331 in B 30 12 0 05 mm 1 19 0 002 in Limit 28 97mm 1 1405in C 6 55 mm 0 26 in A 36 72 0 05 mm 1 45 0 002 in Limit 36 57mm 1 4398 in B ...

Page 138: ... Spring IN EX IN EX XT550J c I 1 0 Seat Width Margin Thickness 36 0 1 mm 1 42 0 004 in 30 0 1 mm 1 18 0 OO4in 2 26 mm 0 09 in 2 26mm O 09in 1 1 0 1 mm 0 04 0 004 in 1 1 0 1 mm O 04 O OO4in 1 2 0 2 mm 0 05 0 008 in 1 0 2 mm 0 04 0 008 in 7 8 g gmm 0 28 8 in 7 8 mm 0 28 8 in T 1l 012 mm 0 2761 0005 in 7 10 mm 0 280 in 71 012 mm 0 2761 0005 in 7 10mm 0 280 in 0 010 0 037 mm 0 0004 0 0015 in 0 030 0 0...

Page 139: ...Top Ring 2nd Ring Oil Ring 22 7mm 0 89 in 22 7mm 0 89 in 25 7 mm 1 01 in 25 7 mm 1 01 in XT550J 2 50 or 1 7 mm 0 067 in 2 50 or 1 9 mm 0 074 in Inner Spring Outer Spring Left c 92 S mm 3 62 S lru in I 6mm 0 24in From bottom line of oiston skirt Right 0 045 0 065 mm 0 0018 0 0026 in 0 25 mm 0 01 in 0 50 mm 0 02 in 0 75 mm 0 03 in 7 6 1 00 mm 0 04 in Plain B 1 2 S lmm 0 05 S in T 3 8 0 1 mm 0 15 0 O...

Page 140: ...r Oil Grade Oiled Filter Carburetor Type Manufacturer Quantity I D Mark Main Jet Main Air Jet Jet Needle clip Position Needle Jet M J M A J J N N J XT550J 0 2 0 4 mm 0 008 0 016 in 0 2 0 4 mm 0 008 0 016 in 0 3 0 9 mm 0 01 0 035 in 0 04 0 08 mm 0 0016 0 0031 in 0 03 0 07 mm 0 001 0 003 in 0 02 0 06 mm 0 0008 0 002 in 75 2 05 mm 2 95 2 002 in 74 95 75 00 mm 2 951 2 953 in 0 03 mm 0 001 in 0 8 mm 0 ...

Page 141: ...2 0 10in Roat valve seat 02 5 Engine Idling Speed 1 200 50 r min Vacuum Pressure at Idling Speed 26 6kPa 2oommHg 7 9inHg Lubrication System Oil Filter Type Paper Wire mesh Oil Pump Type Trochoid pump TIp Clearance Limit 0 12mm 0 005 in Side Clearance 0 03 0 08mm 0 001 0 oo3in Bypass Valve Setting Pressure 98 07 19 6 kPa 1 0 0 2 kg cm 2 14 22 2 84 psi Relief Valve Operating Pressure 98 07 19 6 kPa ...

Page 142: ...Model Lubrication Chart C ankc se Tightening Sequence eft Side Pressure Feed 7 Splashed Oil Tank XT550J Cylinder head I r __________ Ir Oil pan Right Side 7 9 n n T 3 3 n j ...

Page 143: ... Drum Brake Type Front Rear Drum Inside Dia Limit Front Rear XT550J Taper roller bearing 205 mm 8 1 in 1 88mm 1 3 5in 12 348 5 mm 12 13 7 in K 3 4 N mm 0 35 kg mm 19 6Ib in o 115mm 0 4 5in K2 5 5 N mm 0 56 kg mm 31 3Ib in 115 205mm 4 5 8 1 in 369 cm 3 12 5Imp oz 13 0 US oz 158 mm 6 2 in From top of inner tube fully compressed without spring KAYABA G 10 39 2 kPa 0 4 kg cm2 5 7 psi 100 mm 3 9 in 293...

Page 144: ...Lever Free Play position 10 20mm 0 39 0 79in at lever pivot Brake Pedal Position 20 30mm 0 79 1 18 in Brake Pedal Free Play 20 mm 0 79 in Vertical height below footrest top Clutch Lever Free Play position 2 3 mm 0 08 0 12 in at lever pivot 7 11 ...

Page 145: ...sistance Color 160 240Q at 20 C 68 F Br R C 0 1 Unit Modell Manufacturer 5Y1 85540 51 I NIPPONDENSO Ignition Coil Modell Manufacturer 5Y1 82310 50 NIPPONOENSO Minimum Spark Gap 17 kVor more at 300 r min 25 kV or more at 1 000 2 500 r min 17 kVor more at 6 500 r min Primary Winding Resistance 0 5Q 20 at 20 C 68 F Secondary Winding Resistance 6KQ 20 at 20 C 68 F Charging System Type A C Magneto Gene...

Page 146: ...re SH222 12C SHINDENGEN No Load Regulated Voltage 14 5V Rectifier Model Manufacturer SH222 12C SHINDENGEN Battery Capacity 12V 5AH Specific Gravity 1 260 Horn Type Quantity Plain type x 1 Modell Manufacturer MF 12 NIKKO Maximum Amperage 1 5A Flasher Relay Type Condenser type Model Manufacturer FU257SD NIPPONDENSO Flasher Frequency 85 10 cycle min Wattage 27Wx2 3 4W Circuit Breaker Type Non fuse br...

Page 147: ... M16 1 60 6 0 43 A C G Rotar nut M14 1 90 9 0 65 Valve clearance nut M6 4 13 5 1 35 9 4 Stopper guide 2 hex bolt M6 2 8 O S 5 8 Cam sprocket M7 2 20 2 0 14 Tensioner assembly Internal hex bolt M6 2 10 1 0 7 2 Tensioner spring retainer plug M16 1 20 2 0 14 Decompression cam bolt M6 1 S O S 5 8 Rocker shaft stopper bolt M6 2 10 1 0 7 2 Oil pump assembly Internal hex bolt M6 3 10 1 0 7 2 Cover 2 panh...

Page 148: ...nal hex bolt M6 1 10 1 0 7 2 Internal hex bolt M6 1 10 1 0 7 2 Crank case cover 2 Internal hex bolt M6 2 10 1 0 7 2 bolt M6 1 10 1 0 7 2 Crank case cover 3 Internal hex bolt M6 7 10 1 0 7 2 Internal hex bolt M6 1 10 1 0 7 2 Internal hex bolt M6 2 10 1 0 7 2 Cover 1 Internal hex bolt M6 2 10 1 0 7 2 Plate bridge cover flat head screw M6 3 7 0 7 5 1 Ratchet wheel guide hex bolt M6 2 10 1 0 7 2 Cable...

Page 149: ... torque Thread Size O ty Nm m kg fHb Pulser panhead W W screw M6 2 7 0 7 5 1 Neutral switch neutral switch assembly M10 1 20 2 0 14 Cylinder head side cover 1 M32 2 12 1 2 8 7 Kick crank screw M6 1 7 0 7 5 1 7 16 ...

Page 150: ...ine and frame Ml0 58 5 S 42 Nipple hose and frame M22 90 9 0 65 Oil tank drain plug MS 18 1 S 13 Pivot shaft and nut M16 100 10 0 72 Rear wheel shaft and nut M16 100 10 0 72 Rear cushion and frame Ml0 48 4 S 35 Lever cam shaft and cam shaft Front Rear M6 10 1 0 7 2 Sprocket wheel holder Ml0 62 6 2 45 Steering shaft and ring nut M25 38 3 S 27 Under bracket and Inner tube MS 23 2 3 17 Inner tube cap...

Page 151: ...rt GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I S O pitch threads Torque specifications for special components or assemblies are included in the applicable sections of this book To avoid warpage tighten multi fastener assemblies in a crisscross fashion in progressive stages until full torque is reached Unless otherwise specified torque specificat...

Page 152: ...b in lb 0 01152 m kg em kg 0 0723 fHb ft Ib 13 831 em kg em kg 0 8680 in Ib in Ib 1 1521 em kg kg 2 205 Ib Ib 0 4535 kg 9 0 03527 oz oz 28 352 9 km lit 2 352 mpg mpg 0 4252 km lit km hr 0 6214 mph mph 1 609 km hr km 0 6214 mi mi 1 609 km m 3 281 ft ft 0 3048 m m 1 094 yd yd 0 9141 m em 0 3937 in in 2 54 em mm 0 03937 in in 25 4 mm ee em 3 0 03382 oz US Iiq oz US liq 29 57 ee em ee em 0 06102 euin ...

Page 153: ...EXPLODED DIAGRAMS CYLINDER 7 20 J22 Nm 2 2 m kg 16 h lbl CYLINDER HEAD NUT CYLINDER Vr o 10 Nm 1 0 m kg 7 2 h lbl CYLINDER GASKET ...

Page 154: ...CAMSHAFT CHAIN CAMSHAFT ASSEMBLY SPROCKET STOPPER GUIDE 1 o r 20 Nm 2 0 m kg 14 tt lb 10 Nm 1 0 m kg 7 2 tt Ib END PLUG 20 Nm G 14 tt lb CAM CHAIN TENSIONER GASKET ASSEMBLY STOPPER GUIDE 2 7 21 ...

Page 155: ...KICK STARTER 8 Nm 10 8 m kg 5 8 ft lbl 20 Nm _ 12 m kg 14 ft lbl ll r SPROCKET f1 IDLE GEAR KICK GEAR CABLE LEVER T OIL SEA JJ L DECOMP LEVER ASSEMBLY 7 22 RATCHET WHEEL ...

Page 156: ...HEEL____ WHEEL SHAFT B6202 DUST C O S RING 4J r BEARING SPACER 1 0 m kg 7 2 ft lb 10 Nm BEAD STOPPER APPLY LlTHIUM BASE GREASE BRAKE SHOE PLATE BRAKE SHOE CAMSHAFT CAMSHAFT L EVER k 72 ft lb 1 O m g 10 Nm 7 23 ...

Page 157: ...REAR WHEEL 100 Nm 10 TUBE TIRE 4 608 18 ftolbl m okg 72 CAMSHAFT CHAIN PULLER 7 24 LEVER WHEEL SHAFT ...

Page 158: ...FRAME _______ 58 m kg 42 ft lb 58 Nm _ _ ENGINE PROTECTOR 15 8 m k g 4242 tft Ib 58 Nm SUPPORT PLATE 7 25 158 m kg 42 ft lb 58 Nm 5 __ 1 0m kg 7 2 ft Ib 10 Nm __ ...

Page 159: ...OIL PUMP OIL CLEANER o O RING OIL HOSE 1 7 26 ...

Page 160: ...POWER FLOW CHART CAM SPROCKET _ CRANK SHAFT ASSEMBLY MAIN AXLE DRIVE AXLE 7 27 CAM SHAFT CYLINDER HEAD PISTON OIL FILTER CLUTCH ASSEMBLY KICK SHAFT ...

Page 161: ...LUBRICATION CHARTS LUBRICATION CHART 1 7 28 1 t 1 FEED OIL Itllt rtt l SCAVENGE OIL ...

Page 162: ...LUBRICATION CHART 2 7 29 1 1 FEED Oil mt ii fM SCAVENGE Oil ...

Page 163: ...LUBRICATION CHART 3 7 30 1 1 FEE0 01L fttttt SCAVENGE OIL ...

Page 164: ...LUBRICATION CHART 4 7 31 I I FEED OIL ttttttlli SCAVENGE OIL ...

Page 165: ...ndle crown and then install the meter s ront flasher light lead Right Route along the rear side of the tachometer cable Speedometer lead Clutch cable Front flasher light lead Left Route along the rear side of the speedometer cable Front flasher light lead Horn switch lead 7 32 Wire harness ...

Page 166: ...CABLE ROUTING DIAGRAM 2 Rear stop switch lead Sidestand switch lead Clutch cable ...

Page 167: ...CABLE ROUTING DIAGRAM 3 Throttle cable 2 Cable guide Circuit breaker lead Decomp cable ...

Page 168: ...CABLE ROUTING DIAGRAM 41 Rasher relay C D I unit Regulator Rear flasher light lead Right Rear stop switch Rear stop switch lead I Battery breather pipe 7 35 Outer air vent Overflow pipe ...

Page 169: ...I YAMAHA OR CO LTD PRINTED IN U S A ...

Search results

Summary of Contents for XT550J

Reviews:

Brands by name

Popular brands

Yamaha XT550J, Service Manual

Search results

Summary of Contents for XT550J

Reviews:

Brands by name

Popular brands