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Restoring my XZ550... troubleshooting... need some help...

Started by lonerider, July 10, 2012, 03:35:32 PM

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lonerider

Hello all. I am George, from Romania. My english is poor, so do not shoot me...
I bought a cheap Yamaha XZ550 two mounth ago, from some one, as wreck and I start to work on it. It is a 11U model and stayed for long time, incomplete and dismantled.
The big problem was that the engine frozen two times (two winters) and had wather in the cooling circuit. Both cylinder heads was broken, thermostat cover the same. Well, I replaced both cylinders, cylinder heads and pistons, bought from ebay, all engine gaskets and o-rings, reassembled and put it inside the frame. Changed the wiring harness with other one bought from Internet (the original one was chopped), another TCI and headlight. I was repainted all parts (engine, tank, front fender, frame side covers, wheels). The carbs was dismantled piece by piece, cleaned all parts and remounted back. That are all ok, till here... Filing gas in tank and try to start the engine..., disappointment, the engine start in one cylinder. Checked carbs, petcock, starter before, but forget to verify the ignition. Unmount both spark plugs, check the sparkles and surprise, one missed. I bought the TCI like used good one, but didn't work. I had another aftermarket one, noname, which gave me with the bike, look like http://www.ignitech.cz/english/aindex.htm and I connect it. The engine start well, work well and I could made the appropiate adjustments. Still I have two problems: the tacho didn't work (I checked all wires, DC voltage, all okay) and the starter spinning very hard when the engine is warm and do not start the engine. I checked the brushes and are in parameters.
The most important things are how can I fix the tacho troubles and one of TCI (I have two faulty TID12-06). Thanks
Regards,
George
'62 JAWA 350 (1954 model)-sold 2001
'66 IMZ 750 (URAL)-sold 2004
'85 Honda VT500E-sold 2006
'90 Suzuki VX800-sold 2009
'93 Suzuki LS650 Savage-sold 2011
'83 Yamaha XZ550-present
'84 Honda VF750S-present

"Life is short,...but it goes away."

Walt_M.

Hi George, your english is certainly good enough that I can understand you have done a great job on your bike! As for the tach, you probably need a replacement. Check the Swap Shop. Humber who is in Poland has an instrument cluster, tach and speedometer for sale. Maybe you can get together on it. As for the TCI, there is good information on Leathers Ignition. It is good reading. Welcome and good luck.
Whale oil beef hooked!

QBS

The tach gets its' signal from one of the low voltage wires on one of the spark coils.  I think it is a gray wire, but not sure.  Sorry, also not sure which coil the signal is taken from.

From what you have reported regarding bringing your poor bike back to life, I can say that you're a better man than me.  Well done!

Rick G

Your starter may be "out of time"  If it is assembled out of time it will turn very hard , if at all. Do you have a manual (book) on the XZ550?  If not Lucky has them  in CD form, for sale and postage would not be much.
Rick G
Go soothingly on the grease mud, as there in lurks the skid demon
'82.5 Yamaha XZ550 RJ  Vision,
'90 Suzuki VX800, 1990 Suzuki DR350.
'74  XL350   Honda , 77 XL350 Honda, 78 XL350 Honda, '82 XT 200 Yamaha, '67 Yamaha YG1TK, 80cc trail bike

lonerider

Back.
Changing the battery with new one. Charging system indicating 13.8-14.1 volts (before 13.6-13.8). Starter spinning well now, engine cold or warm start okay. The mA meter from tacho is broken (winding burned). Also electronic circiut is broken, probably integrated circuit T2295A faulted, so, another tacho  :(
The idle speed is not constant, oscillating high or low. Still working on it. The YICS dismantled, and holes opturated. Photos before and after (now)
'62 JAWA 350 (1954 model)-sold 2001
'66 IMZ 750 (URAL)-sold 2004
'85 Honda VT500E-sold 2006
'90 Suzuki VX800-sold 2009
'93 Suzuki LS650 Savage-sold 2011
'83 Yamaha XZ550-present
'84 Honda VF750S-present

"Life is short,...but it goes away."

Jimustanguitar

Those are great before and after pictures, what a clean engine! Looks great, I hope you get your technical oddities fixed up and can enjoy all of the hard work you've put in to it.

Rikugun

The engine does look clean! Is that painted and if so what type/color did you use?
It is far better to grasp the universe as it really is then to persist in delusion, however satisfying or reassuring.  Carl Sagan

lonerider

Quote from: Rikugun on July 26, 2012, 09:03:26 AM
The engine does look clean! Is that painted and if so what type/color did you use?
Hello. The engine was fully degreased before and I used Silver Metallic / Smoke Grey (code 140 / 96L) dye, for Opel Tigra and varnish over. I do not know how to resist on it...
Need to change oil. Can I use Repsol 15W50 4T?
'62 JAWA 350 (1954 model)-sold 2001
'66 IMZ 750 (URAL)-sold 2004
'85 Honda VT500E-sold 2006
'90 Suzuki VX800-sold 2009
'93 Suzuki LS650 Savage-sold 2011
'83 Yamaha XZ550-present
'84 Honda VF750S-present

"Life is short,...but it goes away."

QBS

Casrtol 20w50 works well for me in Texas, but may be a bit heavy for starting in colder climes.

Rick G

I'm using Suzuki 4 stroke oil (10-40),s highly recommended and is $4.95 a quart!!
Rick G
Go soothingly on the grease mud, as there in lurks the skid demon
'82.5 Yamaha XZ550 RJ  Vision,
'90 Suzuki VX800, 1990 Suzuki DR350.
'74  XL350   Honda , 77 XL350 Honda, 78 XL350 Honda, '82 XT 200 Yamaha, '67 Yamaha YG1TK, 80cc trail bike

lonerider

Bought two pices of BDW93 (for TCI) and one LM2907 to redesign tachometer circuit (I will eliminate the rev. limiter wire). Next days will work for its. Keep in touch...
'62 JAWA 350 (1954 model)-sold 2001
'66 IMZ 750 (URAL)-sold 2004
'85 Honda VT500E-sold 2006
'90 Suzuki VX800-sold 2009
'93 Suzuki LS650 Savage-sold 2011
'83 Yamaha XZ550-present
'84 Honda VF750S-present

"Life is short,...but it goes away."

lonerider

Quote from: Jimustanguitar on July 26, 2012, 08:15:04 AM
Those are great before and after pictures, what a clean engine! Looks great, I hope you get your technical oddities fixed up and can enjoy all of the hard work you've put in to it.
That pics are when I bought the motobike and what is now...
Rick G you still have the VX?
'62 JAWA 350 (1954 model)-sold 2001
'66 IMZ 750 (URAL)-sold 2004
'85 Honda VT500E-sold 2006
'90 Suzuki VX800-sold 2009
'93 Suzuki LS650 Savage-sold 2011
'83 Yamaha XZ550-present
'84 Honda VF750S-present

"Life is short,...but it goes away."

Rick G

Yes i still have the VX , its my only ride for now,
Rick G
Go soothingly on the grease mud, as there in lurks the skid demon
'82.5 Yamaha XZ550 RJ  Vision,
'90 Suzuki VX800, 1990 Suzuki DR350.
'74  XL350   Honda , 77 XL350 Honda, 78 XL350 Honda, '82 XT 200 Yamaha, '67 Yamaha YG1TK, 80cc trail bike

lonerider

Quote from: lonerider on July 29, 2012, 05:36:29 PM
Bought two pices of BDW93 (for TCI) and one LM2907 to redesign tachometer circuit (I will eliminate the rev. limiter wire). Next days will work for its. Keep in touch...
I dismantled the ETD41 transistors from TCI unit. They are ok at junctions measurement, but I changed it because I tought that they lost the ยต factor (I met that situation other time) and I considered obsolete. Nothing changed, the TCI isn't work. I think that is something "deep" and I believe I need to draw the schematic..., maybe is something to one or both integrated circuits located under the SMD circuit board. Still work on it...
Bad things with carbs. After few more minutes after the engine starts, the gas leaking on drain nozzle and the engine "drown". I checked the fuel level and seems to be okay (like I see in repair manual). Any ideas...
'62 JAWA 350 (1954 model)-sold 2001
'66 IMZ 750 (URAL)-sold 2004
'85 Honda VT500E-sold 2006
'90 Suzuki VX800-sold 2009
'93 Suzuki LS650 Savage-sold 2011
'83 Yamaha XZ550-present
'84 Honda VF750S-present

"Life is short,...but it goes away."

Rick G

The O ring above the needle seat has probably failed, this will cause gas to bypass the needle seat assembly and flood the engine. Check it out.
Rick G
Go soothingly on the grease mud, as there in lurks the skid demon
'82.5 Yamaha XZ550 RJ  Vision,
'90 Suzuki VX800, 1990 Suzuki DR350.
'74  XL350   Honda , 77 XL350 Honda, 78 XL350 Honda, '82 XT 200 Yamaha, '67 Yamaha YG1TK, 80cc trail bike

lonerider

'62 JAWA 350 (1954 model)-sold 2001
'66 IMZ 750 (URAL)-sold 2004
'85 Honda VT500E-sold 2006
'90 Suzuki VX800-sold 2009
'93 Suzuki LS650 Savage-sold 2011
'83 Yamaha XZ550-present
'84 Honda VF750S-present

"Life is short,...but it goes away."

Rick G

You must remove the needle seat to find the o ring. There is a small forked retainer , held in by a small screw. remove the screw and pull the seat out with needle nose pliars. The o ring will be on the back,   opposite the seat .
Rick G
Go soothingly on the grease mud, as there in lurks the skid demon
'82.5 Yamaha XZ550 RJ  Vision,
'90 Suzuki VX800, 1990 Suzuki DR350.
'74  XL350   Honda , 77 XL350 Honda, 78 XL350 Honda, '82 XT 200 Yamaha, '67 Yamaha YG1TK, 80cc trail bike

lonerider

I have some o-ring on the needle seat, seems to be used... I'll change tomorow, if I find pieces...
My mistake, I was tought that the needle "rests" on a small o-ring inside the seat...
'62 JAWA 350 (1954 model)-sold 2001
'66 IMZ 750 (URAL)-sold 2004
'85 Honda VT500E-sold 2006
'90 Suzuki VX800-sold 2009
'93 Suzuki LS650 Savage-sold 2011
'83 Yamaha XZ550-present
'84 Honda VF750S-present

"Life is short,...but it goes away."

Rick G

The tip of the needle has "vitron "tip , it is not replaceable , only the needle is.
Rick G
Go soothingly on the grease mud, as there in lurks the skid demon
'82.5 Yamaha XZ550 RJ  Vision,
'90 Suzuki VX800, 1990 Suzuki DR350.
'74  XL350   Honda , 77 XL350 Honda, 78 XL350 Honda, '82 XT 200 Yamaha, '67 Yamaha YG1TK, 80cc trail bike

Rikugun

Mine are metal, not viton, including replacements I recently used. Either way they don't last forever. Having said that they will generally provide long service. Maybe there was just some debris fouling the fit? It doesn't take much. The o-ring fits around the brass seat and should be a snug fit in the carb body.  These are often the culprit.
It is far better to grasp the universe as it really is then to persist in delusion, however satisfying or reassuring.  Carl Sagan