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1982-1983 Yamaha Vision Xz550 Service Repair Manual – PDF Download
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1982-1983 Yamaha Vision Xz550 Service Repair Manual
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Description
1982-1983 Yamaha Vision Xz550 Service Repair Manual
FILE DETAILS:
1982-1983 Yamaha Vision Xz550 Service Repair Manual
LANGUAGE:ENGLISH
PAGES:228
DOWNLOADABLE:YES
FILE TYPE:PDF
1982-1983 YAMAHA VISION XZ550 SERVICE REPAIR MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
- 1982-1983 Yamaha Vision Xz550 Service Repair Manual
- This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified 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 understanding 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 performance and emissions. Proper service with the correct tools is necessary to ensure that the motorcycle will operate 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 customer with the most satisfaction 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 future editions of this manual
TABLE OF CONTENTS:
1982-1983 Yamaha Vision Xz550 Service Repair Manual
Chapter 1. General Information.................................. 8 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 chasis service...................................... 12 For middle gear service................................. 12 For shaft drive service................................. 13 For electrical components............................... 13 Chapter 2. Periodic inspections and adjustments................. 15 Introduction................................................ 15 Maintenance intervals charts................................ 15 Periodic maintenance emission control system................ 15 General maintenance/lubrication............................. 16 Engine...................................................... 17 Valve clearance adjustment.............................. 17 Spark plug.............................................. 23 Crankcase ventilation system............................ 23 Fuel line............................................... 23 Exhaus system........................................... 23 Carburetor synchronization.............................. 23 Idle speed.............................................. 24 Engine oil.............................................. 24 Coolant................................................. 25 Clutch adjustment....................................... 26 Checking ignition timing................................ 27 Compression pressure measurment......................... 27 Chassis..................................................... 28 Final gear oil.......................................... 28 Air filter.............................................. 28 Front and rear brake.................................... 29 Brake light switch adjustment........................... 30 Front brake pad......................................... 30 Rear brake shoe......................................... 31 Brake fluid............................................. 31 Cable inspection and lubrication........................ 31 Brake and change pedals/brake and clutch levers......... 31 Centerstand and sidestand............................... 31 Front fork oil change................................... 32 Rear schock absorber adjustment......................... 33 Steering head adjustment................................ 33 Wheel bearings.......................................... 33 Front wheel............................................. 34 Rear wheel.............................................. 34 Fuel cock............................................... 34 Tubeless tires and aluminium wheels..................... 35 Electrical.................................................. 35 Battery................................................. 35 Headlight............................................... 36 Fuse.................................................... 37 Chapter 3. Engine overhaul...................................... 40 Engine removal.............................................. 40 Preparation for removal................................. 40 Fuel tank............................................... 40 Air filter and air baffle plate......................... 40 Battery................................................. 41 Radiator................................................ 41 Exhaust pipes and mufflers.............................. 41 Leads and couplers...................................... 42 Cables and pipes........................................ 42 Footrests and sidestand................................. 42 Engine removal.......................................... 43 Engine disassembly.......................................... 43 Carburetors, rear exhaust pipes, and inlet pipe......... 43 Water pump cover and pipe joints........................ 44 Cylinder head covers, cylinder heads, and cylinder...... 44 Piston pin and piston................................... 46 Crakcase covers, starter motor, and oil................. 46 Flywheel................................................ 47 Clutch and primary gears................................ 48 Shifter................................................. 49 Crankcase............................................... 50 Inspection and repair....................................... 52 Cylinder head cover..................................... 52 Cylinder head........................................... 52 Valves, valve guides, valve seats, and valve springs.... 53 Camshafts, cam chains, and cam sprockets................ 57 Cylinder................................................ 59 Piston and piston rings................................. 59 Crankcase............................................... 61 Bearing and oil seals................................... 61 Crankshaft and connecting rod........................... 62 Oil pump................................................ 65 Primary drive........................................... 65 Clutch.................................................. 65 Transmission............................................ 67 Starter drives.......................................... 68 Engine assembly and adjustement............................. 69 Important information................................... 69 Left-side crankcase..................................... 70 Right-side crankcase.................................... 73 Crankcase assembly...................................... 73 Shifter................................................. 74 Front-cylinder chain guide and drive gears ............. 75 Clutch.................................................. 77 Rear-cylinder chain guide and drive gears............... 79 Balancer gear and flywheel.............................. 80 Starter motor and starter idle gear #1.................. 81 Crankcase covers, oil pump, and oil filter.............. 82 Pistons, cam chain guides, and cylinders................ 83 Cylinder heads and cam sprockets........................ 86 Cylinder head covers.................................... 90 Water pump cover, and joint pipes, and oil filter....... 91 Mounting the engine..................................... 91 Middle gear service......................................... 95 Drive axle positioning.................................. 95 Middle drive shaft removal.............................. 96 Disassembly............................................. 97 Inspection.............................................. 97 Assembly................................................ 97 Gear lash measurment and adjustment..................... 98 Chapter 4. Carburetion..........................................101 Carburetor..................................................101 Section view............................................102 Specifications..........................................102 Disassembly.............................................102 Inspection..............................................104 Assembly................................................105 Adjustment..............................................106 Fuel pump and fuel regulator................................107 Operation...............................................107 Disassembly.............................................108 Inspection..............................................108 Assembly................................................108 Air cleaner and crankcase ventilation system................110 Chapter 5. Chassis..............................................113 Front wheel.................................................113 Removal.................................................113 Front axle inspection...................................113 Front wheel inspection..................................113 Replacing the wheel bearings............................114 Installing the front wheel..............................114 Rear wheel..................................................115 Removal.................................................115 Checking brake shoe wear................................115 Brake drum..............................................116 Brake shoe plate........................................116 Rear axle inspection....................................116 Replacing the wheel bearings............................116 Rear wheel inspection...................................116 Installing the rear wheel...............................116 Front brake.................................................117 Brake pad replacement...................................117 Caliper disassembly.....................................117 Master cylinder disassembly.............................118 Brake inspection and repair.............................118 Brake assembly..........................................119 Front fork..................................................121 Removal and disassembly.................................121 Inspection..............................................122 Assembly................................................123 Steering head...............................................125 Adjustment..............................................125 Removal.................................................126 Inspection..............................................126 Assembly................................................127 Swingarm....................................................128 Free play inspection....................................128 Removal.................................................129 Inspection and lubrication..............................129 Assembly................................................130 Rear shock absorber.........................................131 Removal.................................................131 Inspection..............................................132 Note on disposal........................................132 Installation and adjustment.............................132 Cables and fittings.........................................133 Cable maintenance.......................................133 Throttle maintenance....................................133 Shaft drive.................................................134 Troubleshooting.........................................136 Final gear removal......................................138 Gear lash check and adjustment..........................138 Final gear disassembly..................................139 Final gear assembly.....................................140 Drive shaft.................................................143 Removal ................................................143 Inspection..............................................143 Installation............................................144 Chapter 6. Cooling system.......................................146 Cooling system..............................................146 Coolant replacement.........................................147 Handling notes..............................................147 Radiator....................................................149 Removal.................................................149 Inspection..............................................149 Installation............................................150 Water pump..................................................150 Disassembly.............................................150 Inspection..............................................151 Assembly................................................151 Thermostatic valve..........................................153 Operation...............................................153 Inspection..............................................153 Assembly................................................154 Chapter 7. Electrical...........................................156 XZ550RJ Circuit diagram.....................................156 Electric staring system.....................................157 Starting circuit cut-off system.............................158 Starter motor...............................................159 Removal.................................................159 Inspection and repair...................................159 Starter relay...............................................160 Inspection..............................................160 Starting circuit cut-off relay..............................161 Inspection..............................................161 Charging system.............................................163 AC generator and voltage regulator..........................164 Inspection..............................................164 Battery inspection......................................164 Stator coil inspection..................................164 Checking the silicon rectifier..........................165 Ignition system.............................................166 Description.............................................167 Operation...............................................167 Sidestand relay operation...............................167 Troubleshooting.........................................168 Lighting system.............................................172 Lighting tests and checks...............................173 Signal system...............................................175 Signal system tests and checks..........................176 Flasher self-cancelling unit............................176 Switches................................................177 Battery.................................................177 Cooling system..............................................179 Electric fan and thermostatic switch....................180 Engine temperature gauge................................181 Thermo-unit.............................................182 Troubleshooting.........................................182 Chapter 8. Appendices...........................................186 Consumer information........................................202 General Torque specifications...............................202 Definition of units.........................................203 Conversion Tables...........................................203 Exploded diagrams...........................................204 Cylinder head/valve.....................................204 Cylinder................................................205 Cam chain...............................................206 Crankshaft/connecting rod/piston........................207 Transmission............................................208 Water pump/thermostatic valve...........................209 Middle gear.............................................210 Frame...................................................211 Front wheel.............................................212 Front fork..............................................213 Front brake caliper.....................................214 Rear wheel/rear brake...................................215 Swingarm................................................216 Final gear/drive shaft..................................217 Electrical components...................................218 Lubrication diagrams............................................220 Cable routing...................................................224
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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