1981 Yamaha XJ550 Repair Manual

Technical reference for the Yamaha XJ550, covering all maintenance and repair procedures. Includes detailed diagrams and specifications for this iconic motorcycle. PN 4U8-000101

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Document Details

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Document Number / Seller:
26532 / Walter Thomas
File Size:
37.71 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Estimated Download Time:
0.77 Minutes
Delivery Format:
Digital (PDF) - Instant Access
Category:
Bike
Brand:
Yamaha
Reviewed and Approved:
Jul 28, 2025
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Models Covered & Key Technical Specifications

1981 Yamaha XJ550 (4U8-000101)
1981 Yamaha XJ550 / Yamaha Motor Company Technical Resolution Data: 1200 dpi establishes the maximum print output Architecture. Specific Temperature Range: For optimal operation, 15-30C defines the environmental limit Framework. Essential Power Rating: 450 W -- signifies the active printing consumption Threshold. Advanced Memory Capacity: The formatter board requires 64 MB for standard operation Logic. Core Speed Performance: Maximum throughput reaches 25 ppm Parameters. Standard Component Test: The system requires 2.5 A for standard operation Norms.

Professional Workshop Service Manual & Technical Specifications

1981 Yamaha XJ550 Repair Manual: Overhaul-Reference

Technical-Domain: XJ550 // Series-Validation: 1981 Motorcycle / Bike Logic // Technical-Domain: Service and Repair Data.

The documentation is partitioned into various sections to guide users through the motorcycle's systems. Reassembly procedures are specified for the engine, chassis, electrical, and carburetion systems. Service intervals are documented for routine maintenance, ensuring optimal performance. Component locations are identified for easy reference during disassembly and reassembly. Service procedures are documented for common issues and comprehensive overhauls. Calibration requirements are specified for critical systems like the ignition and carburetor.

Procedures

This manual covers the procedures for engine removal and installation, including detailed steps for cylinder head and cam disassembly, piston and ring replacement, crankshaft inspection, and more. It also documents procedures for clutch, transmission, and starter motor assembly.

Technical Specifications

Identifier Operational-Logic Framework
Engine Oil Capacity 2.9 L (3.1 US qt) Standard
Spark Plug Gap 0.6-0.7 mm (0.024-0.028 in) Specification
Piston Clearance 0.025-0.045 mm (0.0010-0.0018 in) Logic

Systems

Detailed system overviews are provided for the air cleaner and crankcase ventilation, front and rear wheels, brakes, and steering head. The manual also thoroughly documents the swing arm and rear shock absorber systems.

Specifications

This manual includes complete specifications for the engine, chassis, electrical, and ignition systems. It documents torque specifications for critical engine components to ensure proper pivot-point integrity.

FAQ

What components are **documented** with safety precautions in this manual? keyboard_arrow_down

Safety precautions are documented for the engine, including potential hazards during cam shaft and cylinder head removal, and specific warnings for handling piston rings and connecting rods, particularly pages 85-90.

Confirm the **precise** lubrication requirements for the Yamaha XJ550. keyboard_arrow_down

10W/30 SE motor oil is recommended for the engine and fork oil (7.78 cc or 2.3 US qt) for the front forks, with specific intervals outlined in the lubrication chart.

What tools are **proper** for testing parameters in this manual? keyboard_arrow_down

A compression gauge, tappet adjusting tool (PN 90890-01245-00), and a dial gauge are specified for testing engine parameters, especially in the detailed procedures found on pages 95 and beyond.

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Reviews (2)

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New
I was impressed with the quick response time when I had a question. The manual is detailed and covers everything I needed. The download was smooth, too!
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New
The download process was seamless, and I received the manual link almost instantly after purchase. Highly recommend for anyone looking to maintain their Yamaha XJ550!