Yamaha XZ550 Vision Repair Service Manual 1982-1985

The 1982-1985 Yamaha XZ550 Vision repair manual by Haynes, covers:

• Yamaha XZ550RJ Vision, U.S.A. 1982-1983
• Yamaha XZ550RK Vision, U.S.A. 1982-1983
• Yamaha XZ550, U.K. 1982-1985

Book Excerpt: 1982-1985 Yamaha XZ550 Vision Repair Manual ENGINE AND TRANSMISSION

CRANKCASE | DISASSEMBLY AND REASSEMBLY

1. To examine and repair or replace the crankshaft, connecting rods, bearings, transmission components and balancer shaft, the crankcase must be split into two parts.
2. Before this can be done, the clutch (Section 13), the oil pump (Section 16), the gearshift mechanism (Section 19), the alternator (Section 20), the cam drive components (Section 21), and the balancer shaft gears must be removed.
NOTE: Do not separate the shaft drive output gearbox from the engine. If gearbox service or repair work is required, take the engine to a Yamaha dealer service department. DISASSEMBLY
3. Remove the bolts from the left side of the crankcase (photo), and then support the engine on blocks of wood or a homemade engine stand with the right side facing up. To prevent distortion of the cases, loosen the bolts in three steps, following a criss-cross pattern. It may be helpful to make a simple holder from a piece of cardboard to ensure that the bolts are returned to their original locations when the crankcase is reassembled.
4. Remove the bolts from the right side (photo), and then align the shift drum cam plate with the cutouts in the right crankcase half (photo).
5. Gently tap the upper (right) case with a soft-faced hammer to break the seal, and then carefully lift it away from the lower (left) case half. If necessary use a screwdriver or pry bar to help separate the crankcase halves. CAUTION! Do not pry between the case sealing surfaces to separate them. Pry only at the slots provided in front of the number one (1) cylinder and along the bottom of the cases (photo). If resistance is encountered, double check to make sure that all of the bolts have been removed. Once the crankcase has been separated, remove the dowel pins from the bolt holes.
6. The balancer shaft, crankshaft and connecting rods, shift drum and transmission shafts will remain in place in the left crankcase half. Lift out the balancer shaft and the crankshaft and store them where they will not be damaged by moisture or contact without components. Refer to the following Sections (24 through 26) for transmission removal and servicing procedures for crankcase mounted components (bearings, seals, clutch actuating mechanism, etc.).

FRAME AND SUSPENSION

SWINGARM BEARINGS | REPLACEMENT

1. The swingarm bearings are press fit into the frame tube and must be driven out with a hammer and large punch. Insert the punch into the tube and drive the bearings out from the back side. Work carefully and do not gouge the inside of the frame tube.
2. The new bearings can be driven into the tube if it is done with extreme care, but the possibility of damaging the new bearings in the process is great. At any rate, the inside of the frame tube must be clean and free of burrs before the new bearings are installed. Lubricate the outside of the bearings and carefully drive them into place with a block of hardwood and a hammer until they are flush with or below the edge of the frame tube.
3. A preferred method would be to draw the bearings into place with a length of threaded rod and two nuts (or a large bolt and nut) and a couple of thick washers with a diameter slightly larger than the outside diameter of the bearing and frame tube. Slide one of the washers over the bolt or threaded rod with one nut installed, and then slip a bearing over the bolt. The manufacturer's mark on the bearing should face out after it is installed. Insert the bolt through the frame tube, slip the remaining washer over the end and install the nut. Position the bolt head with a wrench and tighten the nut until the bearing is drawn squarely into the tube. Disassemble the nut and bolt, and then repeat the procedure to install the remaining bearing. Remember to lubricate the outside of the bearing and work carefully to avoid distorting it.

Subject: 1982, 1983, 1984, 1985 Yamaha XZ550 Vision service, maintenance, repair. ISBN-10: 1850107610 | ISBN-13: 9781850107613 | Haynes 821