New here, How do you do.

[Twincam.GTi]

Hello everybody,

In my family we run a 1981 Yamaha XJ550 (black with the orange pin striping)which we have owned since 1989 and used since as everyday transport all year round (winter and summer). It has now reached roughly 90,000 miles without an engine rebuild as yet (but read more of later) and still on original clutch/drivetrain.

Naturally during our time of ownership it has had a few replacement exhausts (thanks to all that lovely corrosive salt they put on the roads in the winter in the UK ), we've had to do a partial re-wire (original fuse box etc. carroded to bits), many tyres, many fork seals and many chain and sprocket kits plus many, many regular oil and filter changes. The panels/frame are still the original ones except the front mudguard which we replaced in '98 due to the original rusting (lovely UK Climate again). Only mods/Extras on bike are a JMC back suspension and engine protector bars.

Not a minter but a well used and reliable mode of transport.

However this week we suspect we have a burnt valve .

So a top end strip down may be required, my mechanical apptitude is fine due to years of running old timers/Jalopies/bangers of various sorts but I will be asking little bits of info, so firstly here goes

Does anybody here have the torque settings and tightening sequence for the cylinder head (Yes I know I should get a workshop manual ...and will be ...how I've managed till now I do sometimes wounder ).

Many thanks and happy riding.

[YamaHead]

to the forum TwinCam

I too, used to ride an '81 XJ550......everyday...year-round....for about 13 years.

It had over 130k on the clock when I sold it......& it's still running strong today

I sure miss that bike sometimes! ......

I've still got a factory repair manual for it........I'll see if I can find the info you're after

[Twincam.GTi]

very nice.

With regards to my colour scheme, whats painted white on yours is black on mine and whats red on yours is orange on mine.

What exhaust is that, i'm running aftermarket 4to1 Motad (good quality chrome on 'em)

Thanks for your offer to 'dig out' info, will probabley pester you for more info in the future, hope you don't mind .

Take care

[YamaHead]

Yeah......the '83's over here match your color scheme........same damn bike just with different paint.

The exhaust is a Kerker 4into1 with alum. can.......only cost me $225 delivered to my door......pretty good when everything else is $300 min.

I had mine torn down to the ground & back together again....3 different times

Also had a few mates who used to race 'em.......So I've picked up a few pointers over the years.

After I get home from work, I'll see if I can scan a few pages outta that manual for ya.

[Twincam.GTi]

I don’t need to take the head off (thankfully) .

As stated earlier I thought internal damage had happened such as a burnt/chipped valve etc. because on number 3 cylinder petrol was going in but not igniting yet a sparkplug tester showed a superb spark on all four leads to the plugs, plus new plugs where fitted, the carburettors operated correctly (linkage etc.), so naturally you can understand my thought of some form of engine damage. So the rocker cover was removed and the engine just turned over to check that the cams operated the valves up and down etc. Then I thought even if valve was burnt it would still ‘fire up’ in the cylinder so rocker cover put back on and I decided to take the top off No3 Carburettor …and …believe it or not …but a good piece of fibre/cotton/cardboard was in the carburettor tube, stopping all movement of the carb piston, hence ‘neat petrol’ going into the cylinder and flooding everything. It would appear the air filter element has broken up and a few bits of its fibre went in the carb.

The bike appears to be running fine now (famous last words ) but for a short while did smoke a bit due to all the unburnt fuel that has gone down the exhaust.

So my question to you all this time is …can anyone scan me an exploded diagram/picture of the carburettors (sorry to pester again ).

Although every thing is running fine I’m just a little concerned about the carb (rubber diaphragm at the top cause I’ve disturbed it for first time in 24 years etc.) .

Plus can anyone think of any damage that might have been cause by this?

Thanks again for help.