550RH (Seca/Euro)

Clutch

Submitted by xjcdadmin on Mon, 05/17/2010 - 13:11

Clutch assembly

a. Install the primary drive gear and collar.

Tightening torque: 5.0 m-kg (36.0 ft-lb)

b- Install the primary driven gear assembly.

c. Install the clutch boss and thrust plate.

Crankcase Assembly

Submitted by xjcdadmin on Mon, 05/17/2010 - 13:09

Crankcase assembly

a. Apply Yamaha bond # 4 sealant or equivalent to the crankcase mating surface. Be very careful not to allow any sealant to come in contact with the oil gallerly "O-ring" and crankshaft bearings. It is extremely important, however, that sealant be applied around the case stud holes. Apply sealant to within 2~3 mm (0.08 - 0.12 in) of the bearings.

Transmission Assembly

Submitted by xjcdadmin on Mon, 05/17/2010 - 13:08

1. Upper crankcase

a. Install the connecting rods onto the crankshaft with the proper connecting rod bearings and apply molybedenum disulfide grease to the bolt threads. Apply torque evenly to both ends of the cap.

Transmission, Starter clutch and Seals

Submitted by xjcdadmin on Mon, 05/17/2010 - 12:15

Inspect each shift fork signs of galling on gear contact surfaces. Check for bending. Make sure each fork slides freely on its guide bar.

2.    Roll the guide bar across a surface place. If the bar is bent, replace.

3.    Check the shift cam grooves for signs of wear or damage. If any profile has excessive wear and/or damage, replace cam.

Oil Pump and Clutch

Submitted by xjcdadmin on Mon, 05/17/2010 - 12:13

Oil pump

1. Check the clearance between housing and outer rotor.

Standard clearance:

0.09 ~ 0.15 mm (0.0035 ~ 0.0059 in)

2. Check the clearance between outer rotor and inner rotor.

Standard clearance: 0.03 ~ 0.09 mm (0.0012 ~ 0.0035 in)

3. Check the plunger for scrathces and wear.

Crankshaft

Submitted by xjcdadmin on Mon, 05/17/2010 - 12:11

1. Crankshaft run-out

Support the crankshaft at both ends on V-blocks. Measure the amount of crankshaft run-out on the main bearing journals with a dial gauge while rotating crankshaft.

Run-out limit: 0.03 mm (0.0012 in)

If run-out exceeds limit, replace crankshaft.

2.    Inspection of bearings

Piston, rings and pin

Submitted by xjcdadmin on Mon, 05/17/2010 - 12:09

Piston

a. Measure the outside diameter of the piston at the piston skirt. Measurement should be made at a point 7.5 mm (0.3 in) above the bottom edge of the piston. Place the micrometer at right angles to the piston pin.

Standard

57.00 mm (2.244 in)

Camshaft, chain and sprockets

Submitted by xjcdadmin on Mon, 05/17/2010 - 12:07

1. Camshaft

a.   The cam lobe metal surface may have a blue discoloration due to excessive friction. The metal surface could also start to flake off or become pitted.

b.   If any of the above wear conditions are readily visible, the camshaft should be replaced.