Yamaha XJ550 Motorcycle Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Yamaha Model: XJ550 Model Variant: Maxim, Seca Years Covered: 1981, 1982, 1983 👋 Introduction Market Position Segment: Mid-size Sportbike/Standard Motorcycle Era Competitors: Suzuki GS550, Kawasaki...

Type: Motorcycle

Sku: 206666

Tags:

商品バリエーション

Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XJ550

Model Variant:

Maxim, Seca

Years Covered:

1981, 1982, 1983

👋 Introduction

Market Position

Segment:

Mid-size Sportbike/Standard Motorcycle

Era Competitors:

Suzuki GS550, Kawasaki KZ550, Honda CB550

Competitive Analysis

Differentiation:

Yamaha's XJ550 offered a blend of performance, comfort, and advanced features for its time, often appreciated for its smooth inline-four engine and refined handling.

Key Features

Engine Layout:

Inline-Four Cylinder, DOHC, Air-Cooled

Drive Type:

Shaft Drive

Framing:

Steel frame

Design Variants:

Available in Maxim (cruiser-styled) and Seca (sportier, faired) variants, sharing the same core mechanicals.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Repair, Workshop

Diagnostic Coverage:

Troubleshooting Procedures

Page Count

Estimated Page Count:

Manual Type

Type:

Factory Service Manual

Language

Language:

English

Format

Digital Format:

Accessibility:

Instant Download, Multi-device Compatible

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, tuning, lubrication, cooling, fuel system (carburetion, fuel pump), ignition system, exhaust system

Transmission:

Gearbox internal inspection and repair, clutch operation, shift mechanism

Drivetrain:

Shaft drive system inspection, maintenance, and repair

Chassis And Suspension:

Front fork service, rear shock absorber maintenance, swingarm inspection, steering head bearing service

Brakes:

Front and rear brake system maintenance (hydraulic lines, calipers, master cylinders, discs), bleeding procedures

Electrical System:

Wiring diagrams, lighting system, charging system (stator, rectifier/regulator), starting system (starter motor, solenoid), battery maintenance, instrumentation

Fuel System:

Carburetor disassembly, cleaning, adjustment, synchronization (Mikuni VM series typical), fuel tank and petcock maintenance

Cooling System:

Air cooling system analysis and maintenance

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacement, chain adjustment (if applicable), spark plug service, valve clearance adjustment, air filter cleaning/replacement

Troubleshooting:

Diagnostic flowcharts, symptom-based problem resolution for engine, electrical, and mechanical issues

Repair Procedures:

Step-by-step instructions for all major component repairs and replacements

Component Overhaul:

Detailed rebuild procedures for engines, carburetors, and other key components

Technical Specifications:

Torque values, clearances, fluid types and capacities, electrical specifications

Technical Depth

Depth:

Comprehensive (from basic maintenance to full engine rebuilds and advanced diagnostics)

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Likely text-searchable (standard for professional PDFs)

Print Quality

Print Capability:

Printable (single pages or entire manual)

Binding Type

Binding Type Digital:

N/A (Digital Format)

Paper Type

Paper Type Digital:

N/A (Digital Format)

Licensing

Usage License:

Unlimited Use, No Expiry

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, inline-four cylinder, DOHC, 2 valves per cylinder

Displacement:

550 cc (529 cc for some sources)

Bore X Stroke:

58.0 mm x 50.5 mm

Compression Ratio:

9.5:1

Cooling System:

Air-cooled

Performance

Horsepower Rated:

Approx. 49-54 HP @ 9000 RPM (varies slightly by source and model variant)

Torque Rated:

Approx. 28-30 lb-ft @ 7500 RPM

Fuel System

Carburetion:

4 x Mikuni VM Series Carburetors (typically 34mm)

Fuel Capacity:

Approx. 16 Liters (4.2 US gal)

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Features

Clutch Type:

Wet, multi-plate

Final Drive:

Shaft drive

📐 Dimensions

Exterior

Length:

Varies by model (Maxim vs. Seca), approx. 2100-2200 mm

Weights

Dry Weight:

Approx. 175-185 kg (386-408 lbs)

Wet Weight:

Approx. 190-200 kg (419-441 lbs)

🛡️ Safety Features

Ratings

Safety Features Era:

Standard motorcycle safety features for the period: effective braking, stable chassis, reliable electricals.

Active Features

Braking System:

Front: Single Disc Brake (Hydraulic), Rear: Disc Brake (Hydraulic)

Passive Features

Lighting:

Halogen headlight, taillight, turn signals

💡 Technology Features

Infotainment

Infotainment System:

N/A (Classic Motorcycle Technology)

Driver Assistance

Assistance Systems:

N/A (Classic Motorcycle Technology)

Connectivity

Connectivity Features:

N/A (Classic Motorcycle Technology)

Instrumentation

Gauge Cluster:

Analog speedometer, tachometer, fuel gauge (on some models), warning lights.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 km (1,800-3,000 miles) or 6 months

Valve Clearance Check:

Every 10,000-15,000 km (6,000-9,000 miles)

Spark Plug Replacement:

Every 10,000-15,000 km (6,000-9,000 miles)

Fluid Specifications

Engine Oil Type:

API SE or SF, SAE 10W-40 or 20W-40 (check manual for specific recommendation)

Engine Oil Capacity:

Approx. 2.4 Liters (2.5 US qt) with filter change

Brake Fluid Type:

DOT 3 or DOT 4

Final Drive Oil Type:

Yamaha Chain & Gear Oil or equivalent hypoid gear oil API GL-4 SAE 80

Final Drive Oil Capacity:

Approx. 120 ml

Known Issues

Common Wear Items:

Carburetor synchronization issues, aging fuel lines and seals, fork seal leaks, exhaust pipe corrosion.

Electrical Gremlins:

Older wiring harnesses can degrade; issues with charging system components (rectifier/regulator) can occur.

Shaft Drive Maintenance:

Regular lubrication of the shaft drive spline is crucial to prevent wear.

📚 Vehicle History

Brand Heritage

Yamaha Motors:

Yamaha Motor Corporation, a Japanese manufacturer with a long history in musical instruments and later, motorcycles. Known for innovation and performance.

Model Evolution

Xj Series:

The XJ series was Yamaha's line of transverse inline-four motorcycles that replaced the outgoing XS models. The XJ550 was a key step in offering a more modern, shaft-driven, four-cylinder package.

Production

Production Years:

1981-1983

Manufacturing Location:

Japan