YAMAHA XZ550 XZ550 RJ Full Service & Repair Manual

1 YAMAHA XZ550RJ SERVICE MANUAL 11H-28197-10

2 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.

3 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 intake 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

4 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 carburetor 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 intake 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.

5 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 suspension 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

6 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 dealers 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 motorcycle. 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.

7 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

8 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

9 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct 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

10 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 water pump seal.

YAMAHA XZ550 XZ550 RJ Full Service & Repair Manual

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