Yamaha XT550J User manual

_YAMAHA
LIT-11616-03-00 5Y1-28197-10

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NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to put an entire mechanic's education into one
manual, so it is assumed that persons using this book to perform maintenance and repairs on
Yamaha motorcycles have a basic understanding
of the mechanical concepts and procedures in-
herent
to motorcycle repair technology. Without such knowledge, attempted repairs or service
to this model may render it unfit to use and/ or unsafe.
This model
has been designed and manufactured to perform within certain specifications in
regard to performance and emissions. Proper service with the correct tools is necessary to en-
sure that the motorcycle will operate
as designed. If there is any question about a service pro-
cedure, it
is imperative that you contact a Yamaha dealer for any service information changes
that apply to this model. This policy is intended to provide the customer with the most satisfac-
tion from his motorcycle and
to conform with federal environmental qualityobjectives.
Yamaha Motor Company, Ltd.
is continually striving to improve all models manufactured by
Yamaha. Modifications and significant changes
in specifications or procedures will be forwarded
to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this
manual.
NOTE:
______________________________________________________ __
This Service Manual contains information regarding periodic maintenance to the emission con-
trol system for the XT550J. Please read this material carefully.
Particularly important information is distinguished in this manual bythe following notations:
NOTE: A NOTE provides key information to make procedures easier or clearer.
CAU11ON: A CAUTION indicates special procedures that must be followed to avoid damage
to the motorcycle.
WARNING:
A WARNING indicates special procedures that must be followed to avoid injury
to a motorcycle operatoror person inspecting or repairing the motorcycle.
"
SERVICE DEPT.
INTERNATIONAL DIVISION
YAMAHA MOTOR CO., LTD.

GENERAL INFORMATION
PERIODIC INSPECTIONS
AND
ADJUSTMENTS
ENGINE OVERHAUL
CARBURETION
CHASSIS
ELECTRICAL
APPENDICES

CHAPTER·'. GENERAL INFORMATION
MOTORCYCLE IDENTIFiCATION ........ ........................ 1-1
A. Frame Serial Number .. . .... .. ............. . .................. 1-1
B. Engine Serial Number .......................... ... ....... ..... 1-1
C. Vehicle Identification Number . ..... . .................... . ...... 1-1
MAIN FEATURES. ............................................. 1-2
A. Dry Sump System and Monocross Suspension
............... . ..... 1-2
B. Four-Valve Engine ........................................... 1-3
C. Yamaha Duo Intake System (YDIS) ............... . .............. 1-4
D. Kick Synchronous Automatic Decompression ...................... 1-5
E. D. C. Lighting System ......................................... 1-6
F. Detachable Lighting System
.... . ... . ................ . ......... 1-7
G.
Fuel Tank Cap with Check Valve ................................ 1-8
SPECIAL TOOLS. .............................................. 1-9
A. For Tune-up .......... . ... ... ............ . .................. 1-9
B. For Engine Service ............ . .............................. 1-9
C. For Chassis Service ......... .. .............................. 1-12
D. For Electrical Components ..... . .............................. 1-12