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. [. . . ] 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. and Tighten torque: 6Nm(0. 6m - kg, 4. 3 ft-lb) 3. 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. This places the front (#1) piston at top dead center. 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. Also make sure that the cam lobes face each other. 11. Install the tension body into the front cylinder head. Use a new gasket and, torque the bolts to specification. Tightening torque: 12Nm(1. 2m - kg, 8. 7ft-lb) 12. Install the tension spring into the tension body. Tightening torque: 20Nm(2. 0mkg, 14ft-lb) 13. [. . . ] 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [. . . ]