The XT550 Thread: Info, Stories and Mods Inside!

Discussion in 'Thumpers' started by XTwarrior, Feb 16, 2010.

  1. orforester

    orforester Adventurer

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    Just fixed mine last week with Helicoil. Actually on the long bolt I used two. Seems to hold just fine. You have to take the cover off, as there are lots of metal shaving invovled in the fix and you would not want them in your oil.
  2. Futura

    Futura Been here awhile

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    Cool

    Can you provide details on the helicoil size you used?
  3. orforester

    orforester Adventurer

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    Yeah I got it at Shucks or Autozone. Spendy devil around $36 US. Emhart Technologies #5546-6 M6x1 that is 6 mm by 1.00 thread. [​IMG]
  4. Futura

    Futura Been here awhile

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    Thanks orforester,
    I don't see how the insert tool can place the insert deep enough in the hole though. How do you get the insert down to where you need the threads?
    Did you break off the tang or leave it on?
    cheers
  5. orforester

    orforester Adventurer

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    First you drill the hole out to the size stated in the directions, not sure, something like 11/32, but directions tell you. Then you use the tap to tap out the new threads. Then use the insert tool and basically screw in the Heilcoil. It can go as deep as the tool, about 3/4 the way down the threads for the oil filter cover. Then use a small punch or I used a Chainsaw carb screwdriver and gently tap out the cross piece that is used to screw in the Heilcoil. I then inserted another coil to add strength, casue it is a long ways down in there. Two is better than one. Worked like champ.

    Just take your time, read all the directions and think about what you are doing. Especially on the drilling and taping, critical parts of the install. Actually this is my first and it is EASY!
  6. Irishman

    Irishman Adventurer

    Joined:
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    Oddometer:
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    Birmingham. Alabama
    Hey Guys,

    I'ma new guy just checking in. I just picked up a pretty decent 1983 XT550 and I found this thread searching on the internet, so I joined up to hopefully benefit from all of you guy's experience.

    My XT550 seems to run pretty decent, but I haven't had the opportunity to really run it through its paces, because the PO just welded on a straight pipe with a turnout and I don't want to be "that guy" running around the streets with no muffler. Also the battery doesn't appear to be taking a charge, and the bike will only start with the kick starter. On top of that the speedo and tach are missing, but the cables appear to be there and capped off. I assume that it has a mechanical tach.

    I already have a very nice Triumph Bonneville Cafe Racer/Sport Touring bike, I am not depending on this as my only bike. I don't have much money in it, and I would like to get it in good mechanical order and then slowly outfit it as an adventure bike with some decent brakes up front, some paniers and just in overall good nick. Having said that I want to do it all on the cheap, because I know I will never gat my money out of this bike other than enjoying riding it.

    My questions are these:

    Good ideas for a muffler?
    Good ideas for a speedo and tack?

    I have read most of this thread, but I am still curious as to where I should start other than a oil change, carb clean-up, new battery, some kind of cheap muffler, and some kind of gauges. Is there a link to a repair manual that I missed in my reading?

    Thanks for any help....

    Oh... Here's a picture from the day I brought it home:

    [​IMG]
  7. dsefcik

    dsefcik n00b

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    That looks pretty clean, way nicer than mine with 24K+ miles and rust. I have seen speedo/tach assy's on ebay have you looked there? My old beater has a SuperTrapp and they have "Universal" systems

    http://www.supertrapp.com/product_sections/universal/index.asp

    Maybe one will work for you..?
  8. Zecatfish

    Zecatfish XTique Rider

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    Irishman:
    I have an old Cobra muffler from an XR350R on mine.
    ITs not to quiet but it is Forest legal and I kind of like the sound of it.
    There is no direct fit aftermarket ones for it that I know of.
    I would suggest just getting a Trailtech speedo setup unless your a purist
    and then again your going to be looking at Ebay. I have the Stock gauges
    here someplace if I can find it. I'll never put it back on.
    Brakes: they just plain suck in stock trim, the best you can do with the
    drum is an old dual leading shoe setup from a TT600 without changing
    the front end to get a disc up there. I used the same XR350R front end
    on mine for the disc brake and better suspension.
    One more thing, even with a good battery your still going to be kicking it.
    these things have no electric leg. :lol3 But you get the carb right and they
    are some of the easiest starting machines there is.
  9. dsefcik

    dsefcik n00b

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    Irishman:

    As Zecatfish says, they start easy if tuned right, mine will start first kick no throttle..even with no battery installed. If you want to see a photo of my SuperTrapp let me know, I can try to post it.
  10. dsefcik

    dsefcik n00b

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    Most of my shaft seals are leaking (kickstart, gear shift, counter shaft, etc) and I wondered if anyone has had success replacing them without motor disassembly. I have done this with other motors but wanted to know if there were any gotchas with the Xt motor.

    TIA...
  11. G600

    G600 Been here awhile

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    Congrats on the new bike. It looks to be in good shape.

    There is a workshop manual floating around on the internet. Do a search and you should find it.

    When you check the charging / regulator-rectifier do so with a new (or tested) battery. The R/R unit will not work properly without one. You will get some weird voltages.

    I have read about somebody adapting a DRZ400 muffler to the XT550. Also a muffler from a YZ450F. It did not require much work it seemed.

    Check this out:
    http://www.advrider.com/forums/showthread.php?t=250322&page=2

    [​IMG]
  12. Bart

    Bart Constant Lurker

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    It is on 4 cylinder bikes combined with the carb balance where I have had the idle hang. I can't quite explain why but it has fixed quite a few idle hangs for me. I am not saying that it is necessarily the cause here but for the time it takes to check it is worth the piece of mind.
  13. Irishman

    Irishman Adventurer

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    Thanks everyone for replying to my post. I am starting on the leads you guys gave me on the mufflers [Spark arrestors :D]. I am watching some on Ebay as we speak.

    My carbs must be in decent shape, because It starts with one easy kick every time. I'm still going to run some Seafoam through the tank for several tankfulls.

    Zecatfish, I will PM you about the gauge cluster [If I can PM at this early stage of noobdom]. I am interested in those if you are willing to sell for a reasonable price. I had considered a Trailtech.
  14. G600

    G600 Been here awhile

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    Thanks. Interesting. I have read about hanging idle and valve adjustments somewhere else, but don't recall where.
  15. Futura

    Futura Been here awhile

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    [​IMG]

    I used a used DRZ400 muffler. Cut off two inches and it bolted right on.
  16. Zecatfish

    Zecatfish XTique Rider

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    Irishman: I'll have to look around and find the gauges I took off.
    Just been busy with other projects right now, my CJ-5 and fuel tank mod.

    I think I'm going to primer the tank tomorrow.
    Heres a picture of it sitting on the bike for an idea to scale of my 5 gallon mod.

    [​IMG]

    Its not perfect but sure a long ways from where I started.
  17. G600

    G600 Been here awhile

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    Looks really good. Do you have more pics preferably from the side and where it meets the headers?
  18. Irishman

    Irishman Adventurer

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    I just thought I would give back to the community... Here are two links to XT550 repair manuals. The first one is a compressed version:

    [Edited the link out.]

    and the second one is the full version:

    [Edited the link out.]

    I downloaded the second one and it seems to be pretty nice. Not the best quality, but it was free.

    You never know how long these types of sites will be up and online. Get it while you can. Good luck.

    Credit goes to a guy by the name of caduncle over on www.thumpertalk.com the links were posted back on January 30th, 2009.

    http://www.thumpertalk.com/topic/647466-yamaha-xt550-manual/

    It took me a bit of looking to find them though. Enjoy.

    I edited both of those direct links out because I didn't want to get anyone in trouble.
  19. dsefcik

    dsefcik n00b

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    @Irishman / Repair Manual :

    Nice, thanks!

    I actually have the original paper one but all the pages are falling apart. It is exactly the same one you posted links to.

    Thanks!
  20. Irishman

    Irishman Adventurer

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    Edit: Never mind... It looks pretty easy.

    PS: I'm hoping to get to a motorcycle junkyard in a couple of days to search for a muffler. Wish me luck.