INTAKE AND CARBURETOR MODIFICATION KIT

[Summary]

This modification kit has been prepared to improve the 1982 XZ550 idling stability as well as
its driveability in the low and mid speed band.
You are requested to read the following description for the use of the kit parts.

1. Parts List of Modification Kit (Kit No. 90891-10093).

(13)
(2) (4) (3) --, ,---(1)
1 .,--- . ,

() 10 wfte
/ (ii)
(5) %
\ ,i, (10)

16) 1 '1*
(14) (9)

< photo 1>

Ref. PART NAME PART NUMBER r PCS.

1. i FLOAT CHAMBER COVER ASSEMBLY (FRONT) 90891-10087 1
2. AIR FILTER 28V-14460-00 1
3. AIR FILTER CASE STAY 90891-10088 1
4. 0-RING 93210-26033 1
5. HOSE (LONG) 90445-07723 1
6. CLIP 90467-07029 4
7. HOSE (SHORT) 90445-07747 1
8. SCREW PANHEAD 90891-10089 1
9. MAIN JET (FRONT) ( 7122#122.56.14944-75 1
10. GASKET 11H-14984-00
11. JOINT 28V-13595-00 1
12. CAP CASE ASS'Y 90891-10090 1
13. ELEMENT ASS'Y 28V-14450-00 1
14. PILOT AIR JET (REAR) ( 135)#1356256-14944-27 1

- 1 -
[Removal]
(1) Open the seat and remove the side cover, fuel tank and air cleaner.

(2) Remove the float chamber cover assembly.

i) Remove the bolt (C) and then the air

baffle plate (D).

ii) Remove two screws (B) and then the

starter link (A).

iii) Remove the bolt (E).

< photo 2>

iv) Remove two hoses (G).

v) Remove six screws (F). Then remove

the float chamber cover assembly (front).

< photo 3 >

[Installation]
(1) Sub-assemble the cap case assembly.
i) Break the pin (H) used for determining
the element position in the air cleaner
(HI under-cover.

ii) Place the element assembly (13) as in the

EI-EUEN
ASSEMUL left fig. and install the cap case assembly
(12).

< photo 4 >

(2) Sub-ELEMENTeASSEMBLYlter
Install onto the float chamber cover assembly
the longer hose (5), shorter hose (7), air filter
(2), air filter case stay (3), four clips (6), joint
3)
(11), and 0-ring (4). See the left fig.

0-O-ringThis comes between the aO-riter and

air filter case stay.)
(11)

II)

< photo 5 >

2
(3) Install float cover assembly .

i) Change the gasket to the one (10), and

fit the float chamber cover assembly
(front), as in the state shown in the
photo (5), using six screws (F).

ii) Install the starter link (A).

iii) Fit the hoses(G).

iv) Replace with the pilot air jet (14) on the

< photo 6 >
rear side.

[Note) For the front, pilot air jet is provided

on the float chamber cover assembly.

(4) Install the main jet.

Replace with main jet (9) (front) and fix it

with bolt (E).

(5) Install air filter case stay.

i) Install the air cleaner case stay with

screw panhead (8).

[Note] Pass the throttle cable between the

longer hose (5) and the carb.

ii) Bend inward three tabs of the air cleaner

case stay to eliminate air filter looseness.

iii) Connect the hose from the cap case

assembly and the shorter hose (7) at the
joint.

3
(6) Accelerator -- pump rod adjustment

[NOTE) This adjustment is applicable only to machines stocked in the USA and Canada.

i) Remove the drain-hose bracket to gain clear access to the accelerator pump rod.
ii) Measure the rod from the bend to the pump lever; see the illustration.
iii) With a pair of pliers, turn the portion of the rod indicated in the illustration to increase
the length of the rod by 5 mm.
iv) After measuring to ensure that the rod has been lengthened by 5 mm, apply a drop of
blue Loctite (R) to the threads of the pump rod.
v) Reinstall the drain-hose bracket.

(7) Install the air cleaner, side cover, and fuel tank. Then, close the seat.

(8) Please check the following as per the service manual.

i) Idle Speed 1,300 50 r/min.

ii) Co % 3%
iii) Vacuum Pressure at Idling Speed Above 180 mmHg
iv) Vacuum Synchronous Difference between Front and Rear Below 10 mmHg