The XT550 Thread: Info, Stories and Mods Inside!

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

  1. TXXT550

    TXXT550 Adventurer

    Joined:
    Nov 20, 2018
    Oddometer:
    63
    Location:
    AZ
    After flattening the lock washer I was able to loosen the nut with little effort. I got the clutch off and it looks like I am missing the o-ring 93210-09525-00 on the push rod. I did have some clutch related noise - maybe this was it. Too bad I already placed an order for the other stuff. I wonder if I can find a suitable O ring at an auto parts store?
    IMG_2166.JPG

    The primary gear came off next. The key has wear marks and the keyway looks to be a bit worn. A replacement key is on the way.
    IMG_2162.JPG
    IMG_2156.JPG
    IMG_2153.JPG
    IMG_2150.JPG

    Here is a video of some of the other possible causes of the engine noise.
    https://photos.app.goo.gl/PnLqahaBDP8HcdTX8

    Next up will be removing the balance gear to check the key. Although there does not seem to be any play there.
  2. jjxtrider

    jjxtrider questionable

    Joined:
    Aug 17, 2013
    Oddometer:
    4,347
    Location:
    Halfway to hell (WI.)
    I personally would buy an oversize key or next bigger standard size and mill or file the key to fit tight in the keyways so there isn't any extra slop ,this depends just how much extra slop there really is . For just a little bit some red loctite(mount it with the keyway down so it pools in the sloppiest half , just to help take up some slop and keep things from moving very easy .Possible JB weld would work for this as well , Ideally all new parts should be used and no loctite or JB but it isn't worth the costs or time in some cases.
  3. DJCW

    DJCW Adventurer

    Joined:
    Jun 17, 2012
    Oddometer:
    39
    Great video TXXT550,
    the wear on that primary drive key is a twin to what I had on mine. Also no play on the balance shaft key on mine.
    The Oil pump Gear and kickstart idle gears on mine also rattle the same as yours but not sur if that is just "how they are". I don't want to spend on new ones if not necessary. Any one know how these are meant to be?
  4. TXXT550

    TXXT550 Adventurer

    Joined:
    Nov 20, 2018
    Oddometer:
    63
    Location:
    AZ
    The replacement keys should arrive on Tuesday. I have also ordered some loctite 660 that I may use if there is minimal play with the new keys fitted. If the play is too much with the new keys, then I may try replacing the gears or try a larger keystock shaved down to fit.

    I measured my clutch springs and they are all ~41mm. The replacement o-ring for the push rod has been ordered. I plan to go through the manual for inspecting and adjusting the clutch before putting it back together. Everything will be torqued to spec.

    I will be inspecting the oil screen, changing the oil filter, draining fuel tank/float bowl and adding new gas. I will then take a video of it starting and running to compare the sounds to before. I am hopeful that this will reduce the engine noise.

    DJCW, Do you have video/audio from before/after your repair?

    Thank you all for the help
  5. TXXT550

    TXXT550 Adventurer

    Joined:
    Nov 20, 2018
    Oddometer:
    63
    Location:
    AZ
    There is quite a bit of wear and play on the pressure plate 5Y1-16351-00-00 The nut for the pushrod fits in here and is held in place. It is supposed to be a tight fit? The pushrod nut rotates slightly inside the hole. Tightening things down doesnt stop this movement.
    IMG_2178.JPG

    I removed the balance gear nut but was unable to remove the gear. It seems to be stuck. The key and keyway appear to be ok though. There is some play if I push or pull on the balance gear shaft. I may just leave this as is and torque the nut properly. This nut actually felt tight when removing.
    IMG_2181.JPG
  6. JensEskildsen

    JensEskildsen Long timer

    Joined:
    Mar 24, 2009
    Oddometer:
    2,418
    Location:
    Denmark
    Stock is 92mm. 1mm over is no problem.
  7. DudeLiam

    DudeLiam n00b

    Joined:
    Jul 26, 2019
    Oddometer:
    8
    Location:
    Alberta, Canada
    Anyone know where to find a (front) brake cable for the XT 550? I am located in Canada, so shipping from the EU would be difficult. Everywhere sells clutch cables, but no brake.

    Thanks!
  8. TXXT550

    TXXT550 Adventurer

    Joined:
    Nov 20, 2018
    Oddometer:
    63
    Location:
    AZ
    The key arrived today so I tested fitment.
    IMG_2202.JPG
    IMG_2206.JPG
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    IMG_2194.JPG

    Here are videos of the new key in the gears:
    https://photos.app.goo.gl/uCigvMxbsLFUctcP7
    https://photos.app.goo.gl/1gHYhS1poChwMZeX7

    Before removing anything (keep in mind the nut was little more than hand tight):
    https://photos.app.goo.gl/aAwLhUwJrGoJJzpY9

    Old key on shaft:
    https://photos.app.goo.gl/SrCGYJAEzuMJdPD48

    New key on shaft:
    https://photos.app.goo.gl/4hYYhJKedUFE1uhP6

    New key in keyway:
    https://photos.app.goo.gl/ELHchWZS6naUo7VW6

    New key and both gears on shaft:
    https://photos.app.goo.gl/4U9kXJ2bL6ExYExk9

    What do yall think of the play with the new key? Will a properly torqued nut be enough to eliminate this or should I look at reducing play even more?

    Thank you
  9. jjxtrider

    jjxtrider questionable

    Joined:
    Aug 17, 2013
    Oddometer:
    4,347
    Location:
    Halfway to hell (WI.)
    That's more than I'd care to leave but could be worse . Chances are very high that if you add some Loctite to fill all the gaps and then properly torque the nut it will work fine and not have any issues . But there's also a slight chance it'll loosen up over time and get noisy again , just how long it takes is any ones guess . Do you have any shim stock that you can cut into strips to take up the extra space before adding any Loctite . For my own bike and since I have access to a mill , I'd make an oversized key to make it tight . Stock they do have about .001" clearance but everything is nice and square , your groove are worn tapered so things will wear sloppy much quicker .

    This is the Loctite made for just such issues , https://www.amazon.com/Loctite-442-66010-Retaining-Compound-Silver/dp/B000O03DK0

    .
  10. TXXT550

    TXXT550 Adventurer

    Joined:
    Nov 20, 2018
    Oddometer:
    63
    Location:
    AZ
  11. Westcoasthumpin

    Westcoasthumpin Been here awhile

    Joined:
    Jul 20, 2016
    Oddometer:
    631
    Location:
    Palm Springs of Washington
    I haven't posted here in a while. Hope everyone had a great summer. We have some excellent fall riding to look forward to!

    EFFECTS.jpg
    pete63 likes this.
  12. Westcoasthumpin

    Westcoasthumpin Been here awhile

    Joined:
    Jul 20, 2016
    Oddometer:
    631
    Location:
    Palm Springs of Washington
    I have a list of things I would like to accomplish this winter including getting rid of the pod filter mod and returning to a stock airbox, valve check/adjustment, and swingarm lubrication to name a few.

    For now I am trying to get my blinkers functioning again. To many dirt naps and brush strikes. I will probably look for some low profile blinkers.

    Edit: So I glued my lenses back together and wrapped a small stick with duct tape to support one of the stems. All work except one of the rears. The small brass contact for the bulb fell off. I glued it in place. I will need to solder the connection back on.

    Any suggestions for aftermarket blinkers?
    20190909_140227.jpg
  13. TXXT550

    TXXT550 Adventurer

    Joined:
    Nov 20, 2018
    Oddometer:
    63
    Location:
    AZ
    I have decided to sell my XT550 and move on to something newer. It's located in Austin, TX. Feel free to make an offer. I would like it to go to a good home.
  14. Westcoasthumpin

    Westcoasthumpin Been here awhile

    Joined:
    Jul 20, 2016
    Oddometer:
    631
    Location:
    Palm Springs of Washington
    Vintage bikes are challenging. I have came close to selling mine more than once.

    Good luck with the sale and purchase of a new bike.
  15. jjxtrider

    jjxtrider questionable

    Joined:
    Aug 17, 2013
    Oddometer:
    4,347
    Location:
    Halfway to hell (WI.)
    http://www.extremedualsport.com/index.php/products , a bit high priced but are tuff , I had my xt fall on concrete right on the rear signal without a problem .

    .
    Westcoasthumpin likes this.
  16. MrrHouse

    MrrHouse Adventurer

    Joined:
    Jan 22, 2018
    Oddometer:
    39
    Location:
    Netherlands
    image-04-09-2019_22-07-21-81.jpg Well, i finally found the missing part in my life so i can finally start building.
    I really miss the old 550, been riding around on a Suzuki xf650 and although it's a nice bike i rather ride on the old Yamaha.

    I'll keep posting updates on the build. Gonna be a slow build tho, there are more things i wanna do now that i have a second bike.
  17. TXXT550

    TXXT550 Adventurer

    Joined:
    Nov 20, 2018
    Oddometer:
    63
    Location:
    AZ
    I found another bike so I may end up keeping the XT550 in hopes that I stumble upon a nice xt600 motor or get the time/space to rebuild this one.
    IMG_2398.JPG
  18. xlv

    xlv Been here awhile

    Joined:
    Nov 12, 2004
    Oddometer:
    252
    Location:
    Sweden
    Quick question, does a 16 tooth front sprocket fit a yamaha xt550 -83 ?
  19. TXXT550

    TXXT550 Adventurer

    Joined:
    Nov 20, 2018
    Oddometer:
    63
    Location:
    AZ
    I am running a 16 tooth sprocket up front
  20. xlv

    xlv Been here awhile

    Joined:
    Nov 12, 2004
    Oddometer:
    252
    Location:
    Sweden
    perfect, i´ll order one then, thank´s