🏷️ Basic Information

Make:

Yamaha

Model:

XZ550RJ

Model Variant:

XZ550RJ

Year:

1982, 1983

Chassis Code:

XZ550RJ

👋 Introduction

Segment:

Sport Touring Motorcycle

Era:

Early 1980s Japanese performance motorcycles

Competitors:

Models from Honda, Kawasaki, and Suzuki in the 500cc to 650cc sport-touring or sportbike segment of the early 1980s.

Engine Configuration:

V-twin engine, a distinctive feature for its time.

Drive System:

Shaft drive, offering lower maintenance compared to chain drive.

Design Philosophy:

Blend of sportbike performance with touring comfort and reliability.

📋 Manual Details

Engine:

Included

Transmission:

Included

Electrical System:

Included

Suspension:

Included

Brakes:

Included

Frame:

Included

Fuel System:

Included

Cooling System:

Included

Exhaust System:

Included

Body Panels:

Included

Maintenance:

Included

Troubleshooting:

Included

Wiring Diagrams:

Included

Estimated Pages:

Hundreds

Type:

Workshop Service Repair Manual

Source:

Official Factory

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Detailed procedures for disassembly, inspection, assembly, and adjustment of all engine components including cylinders, pistons, crankshaft, camshafts, valve train, lubrication system, and cooling system.

Engine Management:

Includes information on ignition system, carburetion (including jetting and float bowl adjustments), and related sensors for optimal performance and emissions.

Transmission Drivetrain:

Covers clutch operation, gearbox disassembly and assembly, gear selection mechanisms, and final drive (shaft drive system) maintenance and repair.

Braking System:

Detailed instructions for front and rear brake systems, including hydraulic components, caliper servicing, pad replacement, and fluid bleeding procedures.

Suspension Steering:

Covers front fork service (oil changes, seal replacement), rear shock absorber servicing, and steering head bearing maintenance and adjustment.

Electrical System:

Comprehensive coverage of the entire electrical system, including battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, ignition, and all wiring circuits with detailed diagrams.

Fuel System:

Detailed procedures for fuel tank removal and cleaning, fuel pump operation, fuel filter replacement, and carburetor synchronization and cleaning.

Chassis Frame:

Information on frame inspections, wheel bearing maintenance, and component mounting procedures.

Bodywork Trim:

Guidance on the removal and installation of body panels, fairings, seat, and other trim components.

Routine Maintenance:

Oil changes, filter replacements, spark plug checks/replacement, chain/drive shaft lubrication, brake adjustments, tire pressure checks.

Engine Overhaul:

Complete engine rebuild procedures, including torque specifications for critical fasteners, piston ring gap, valve clearance adjustments, and timing procedures.

Carburetor Rebuild:

Detailed instructions for carburetor disassembly, cleaning, reassembly, jetting specifications, and synchronization.

Electrical Diagnostics:

Troubleshooting guides for electrical issues, testing of components (e.g., stator output, regulator/rectifier function), and interpretation of wiring diagrams.

Suspension Servicing:

Fork seal replacement, fork oil level and type specifications, steering bearing adjustment, and rear shock absorber servicing.

Brake System Repair:

Brake pad replacement, caliper piston service, brake fluid flushing and bleeding, master cylinder inspection.

Troubleshooting Guides:

Systematic diagnostic procedures for common operational problems, including symptoms and potential causes.

Depth:

Comprehensive, covering all aspects from basic maintenance to complete engine and component rebuilds, suitable for both amateur and professional mechanics.

📊 Manual Specifications

Format:

PDF

Searchable Text:

Likely searchable (depending on PDF source quality)

Quality:

High-resolution, suitable for printing individual pages or the entire manual.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

4-stroke, Liquid-cooled, 4-valve, DOHC V-twin

Displacement:

552cc

Bore X Stroke:

72.0 mm x 67.0 mm (approximate)

Compression Ratio:

9.2:1 (approximate)

Horsepower Est:

Approx. 50-55 HP @ 8,000 RPM

Torque Est:

Approx. 45-50 Nm @ 6,500 RPM

Carburetion:

Dual Mikuni CV carburetors (e.g., Mikuni BS34)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

Approx. 16 Liters (4.2 US gal)

Ignition System:

CDI (Capacitor Discharge Ignition)

Lubrication System:

Wet sump

Cooling Method:

Liquid-cooled

Coolant Type:

Ethylene glycol-based coolant, 50/50 mix with distilled water

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch:

Wet, multi-disc

Drive Type:

Shaft Drive

Final Drive Fluid:

Yamaha Hypoid Gear Oil SAE 80W-90 (or equivalent)

📐 Dimensions

Length:

Approx. 2,175 mm (85.6 in)

Width:

Approx. 760 mm (29.9 in)

Height:

Approx. 1,190 mm (46.9 in)

Wheelbase:

Approx. 1,455 mm (57.3 in)

Dry Weight:

Approx. 180 kg (397 lbs)

Wet Weight:

Approx. 202 kg (445 lbs)

Maximum Load:

Not specified in product info, refer to manual.

🛡️ Safety Features

Crash Test Ratings:

N/A for motorcycles of this era.

Braking System:

Dual front disc brakes, single rear disc brake.

Lighting:

Halogen headlight, taillight, turn signals.

Frame Construction:

Steel frame providing structural integrity.

Tires:

Tubeless radial tires (typical fitment).

💡 Technology Features

Infotainment System:

N/A (Analog instrumentation only)

Instrumentation:

Analog speedometer, tachometer, odometer, trip meter, fuel gauge, and warning lights.

Electronic Aids:

None (ABS, traction control not available)

Connectivity Features:

N/A

🔧 Maintenance

Engine Oil Change:

Every 3,000 - 5,000 km (1,800 - 3,000 miles) or annually, refer to manual for exact interval.

Oil Filter Change:

With every oil change.

Spark Plug Check:

Every 5,000 - 10,000 km (3,000 - 6,000 miles).

Valve Clearance Check:

Every 10,000 - 15,000 km (6,000 - 9,000 miles), critical for DOHC engines.

Fork Oil Change:

Every 10,000 - 20,000 km (6,000 - 12,000 miles).

Brake Fluid Flush:

Every 2 years or 20,000 km (12,000 miles).

Engine Oil:

Yamalube 4 (or equivalent) SAE 10W-40 or 20W-40 API SE/SF, JASO MA (check manual for precise recommendation)

Engine Oil Capacity:

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

Coolant:

50% Ethylene Glycol and 50% Distilled Water

Brake Fluid:

DOT 3 or DOT 4 (refer to manual for specific type)

Electrical Gremlins:

Common in older bikes; aging wiring, corroded connectors, and failing rectifier/regulators.

Carburetor Issues:

Varnish buildup from stale fuel, requiring thorough cleaning and potentially new jets or diaphragms.

Liquid Cooling System:

Potential for radiator leaks, hose degradation, and water pump seal leaks over time.

Shaft Drive Maintenance:

Requires regular inspection and lubrication of the universal joint and final drive splines.

📚 Vehicle History

Heritage:

Yamaha Motor Company, established in 1955, has a rich history in motorcycle manufacturing, known for innovation, performance, and reliability across various segments.

Development:

The XZ550RJ was part of Yamaha's effort to compete in the increasingly popular sport-touring and performance motorcycle market of the early 1980s, featuring an advanced V-twin engine and shaft drive.

Production Years:

1982-1983

Manufacturing Location:

Japan

🏆 Awards & Recognition

Performance Reviews:

Praised for its V-twin engine character and shaft drive convenience upon release.

Industry Recognition:

Represented a significant engineering effort by Yamaha in the sport-touring segment of the early 80s.

Certifications:

N/A