User manual YAMAHA XZ550RJ SERVICE MANUAL

[. . . ] YAMAHA XZ550RJ SERVICE MANUAL 11H-28197-10 1 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 characteristics. 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 unnecessary and virtually eliminates coolant loss on even the hottest days. [. . . ] WARNING: The rear cam chain guide must be fit in the cam chain guide stopper in the head. If the chain guide does not fit the chain guide stopper, take the following steps: a) b) c) Remove the cam chain guide stopper nut cover from the front cylinder. Loosen the cam chain guide stopper securing nut on each cylinder head. Fit the top and of the chain guide into the chain guide stopper. 86 d) Tighten the stopper securing nut to specification Tightening torque: 7 Nm (0. 7m-kg, 5. 1 ft-lb) e) Reinstall the stopper bolt cover, torque the bolts to specification. Tighten the four nuts and two bolts evenly, then torque them in the sequence shown below. NOTE: Turn the intake and exhaust camshafts so that their cam lobes face outward, and align the holes in the cam caps and the camshafts, then insert an 8 mm (0. 31 in) Allen wrench into the holes. Tightening torque: Cylinder head bolts: 10 Nm (1. 0m-kg, 7. 2 ft-lb) Cylinder head nut: 50 Nm (5. 0 m-kg, 36 ft-lb) 5. Turn the front cylinder intake and exhaust camshafts by hand so that the cam lobes face each other and the punch marks on the end of each camshaft align with the marks on the camshaft caps. 6. Position the cam sprocket so that the mark F is exposed to view and faces upward at the same time, and place the cam chain around the sprocket. 4. Turn the crankshaft counterclockwise, and align the T mark on the flywheel with the stationary pointer. NOTE: Pull the cam chains, and keep them taut when turning the crankshaft. NOTE: The cam chain sprocket has three stamped marks F, I and E on its front face and R, I and E on its back. 87 9. If the marks are not aligned, remove the sprockets from the camshafts, and change the position at which the sprockets mesh with the cam chain, then mount the sprockets on the camshafts. Release the cam chain tensioner oneway, cam, and insert the tension rod into the tension body. I. Slide the sprocket so that the channel (marked with I) in the sprocket fits over the locating pin on the intake camshaft. Likewise, fit the channel (marked with E) in the sprocket over the locating pin on the exhaust camshaft. Insert your finger into the hole in the cam chain tensioner and push the cam chain guide inward. While pushing it, make sure the punch marks on the camshafts align with the marks on the caps. Hold the center of the camshaft with a 22mm (0. 87 in) open-end wrench, and torque the cam sprocket securing bolt to specification. Turn the crankshaft 290 degrees counter clockwise, and align the I mark on the flywheel with the stationary pointer. NOTE: Be sure to keep the cam chain taut while turning the crankshaft. 88 15. Rotate the rear cylinder intake and exhaust camshafts by hand so that the cam lobes face outward, the punch marks on the ends of the camshafts should be aligned with the marks on the cam caps. 18. Insert your finger into the hole in the cam chain tensioner and push the cam chain guide inward. [. . . ] Tightening torque: 15 Nm (1. 5m-kg, 11. 0ft-lb) CAUTION: After replacing the thermo-unit, check the coolant level in the radiator and also check for any leakage. 184 CHAPTER 8. APPENDICES SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONSUMER INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [. . . ]