Need help on a myriad of topics

First off, here she is:


Okay, no comments about my messy garage!

I've searched this site for threads involving ailments similar to those I'm trying to rectify but still can't find the solution. They are as follows:

Turn signals:
Problem:
The rear turn signal lights up but not the front and neither blinks.

What I've done: I checked all bulbs, all are good. I've retraced the wiring (using a Clymer's manual for guidance) and verified that all connections go together. What I don't know is where the flasher unit is located on the bike.

It should be noted that the front bulbs worked BEFORE I removed the battery and other mechanical components to work on the bike. The signals didn't flash but all lit up when the switch was toggled.

Headlight:
Problem: It don't work.

What I've done: I removed the sealed beam unit and examined the filaments, they look good. What puzzles me is that the headlight worked before I removed the battery and mechanical components to do some non-electrical work on the bike.

What I have left to do:

I want to bleed the front brake.
I want to examine the fuel petcock and, possibly, install a rebuild kit.
I want to do a charging system check to make sure all is well.
Carb rebuild/synch, I've been warned this is not something for an amateur.

Other "issues" I've noticed:

Stains on the starter and left side cases. I'm thinking this is due to fuel leaking from the petcock.

The previous owner must have messed around with the carbs because many of the phillips screw heads are worn out - especially the outer carb screws.

I replaced the oil and filter and even with three quarts I'm not seeing any oil showing on the sight glass.

When I drained the oil I noticed gas was in the crank case. This is not a good thing for a variety of reasons and it seems attributable to the petcock either being worn out of left in the wrong position.

Disclaimer:I'm a newbie to this site but belong to many others associated with BMW and Ducati and know the importance of participation and helping others. It's my intent to learn as much as possible about this sweet little Yamaha so that I may apply that knowledge and be a contributor to this site's members. The learning curve's a bit steep at this point and with my SO just having passed her MSF there's a little bit of pressure on me to get this baby up and running so we can ride together.

In other words....HELP!!!!!!!

 

Hey Randy, she is well on her way to happiness, relax! I had a similar issue when I mistakenly plugged two connectors together incorrectly behind the headlight of my FZR. Could you have possibly been following in my fine example? I really can't help too much since I don't have any experience with the 550's and don't have the schematics to browse. But I am wishing you well on your efforts, you've done quite a bit already and I've a feeling it won't be too much longer before your out running around on her. Best of luck to you!

 

Are you sure you are not seeing oil? Maybe you just overfilled? You can tip the bike on the sidestand, while watching the window, and see if you see the level go down...

Do you know how much oil you drained out? If less than about 3 quarts, then you probably overfilled.

I can't help you with electrical problems. Sorry! I haven't had much experience with this yet.

 

Hope this pic helps, courtesy Yamaha web site.

Sounds like the lights not working is related to the battery being replaced, although you mention other mechanical parts, what parts are you referring to?

Have you checked the fuses?

I would connect headlight directly to a battery and see if it lights up (if you don't have a test meter).

You should only need 2.6 quarts of oil for this bike.

Silly question, you are checking it with the bike on the center stand, not the side stand?

 

i would check fuses for most of the lighting issues. Also it sounds like you have corrosion in the wires, check the Ohm readings on the flasher wires, also check the bulb seats and any other obvious spots for corrosion. In addition your flasher wires may be no good, try using a self powered test light to check them, just because there is continuity doesnt make them good, also try turning the flasher on, and then wiggling wires to see if it EVER lights up. i know my right front flasher only works when i use something to pull the wire down after it exits the bulb housing.

good luck! keep us posted.

 

Turn signals most likely have corrosion in the bulb socket. I took mine apart and cleaned the inside with sand paper. One did not work even after this so I replaced it. If you have the single wire front signals check that the bolts on the stem mount are clean. I believe this is where they get their ground.
Stains on the case left side are petcock alright. Easy to check. Place the petcock on the tank and fill with fuel. Turn the petcock to on and see if fuel comes out. If it does replace the petcock. Rebuild kits only work 50% of the time.
Charging system: Check brush length on rotor. The brush is inside the alternator cover. To verify crank bike and while running check battery with a multimeter. 13.8 to 14.6 is a good system. If voltage is low check all connections for security and corrosion. Regulator check can be done with a multimeter and is in the haynes manual. However the check for polarity is reversed in the manual for the 650's and 750's. Don't know about the 550 manual.
Carbs: A novice can do it but needs patience and to study the XJCD section on carbs "throughly". Once familiar with the parts, how they fit together, where they are and how to treat not treat them, then start.

 

Wow! Great suggestions and well written too! I hope I can pay back other members with such insightful responses like these.

I'll be reporting back as I progress....the smile on my SO's face makes it worth while plus I'm finding that I'm bonding with this sweet little machine and want to see her up and purring PDQ.

More to follow...

 

We're good at getting bikes purring that's for sure! As for SO I think the official XJ designation for her will help also. It is SWMBO or............
She Who Must Be Obeyed!