FULL OPERATIONAL

SERVICE BRAKE

("Partial failure "information is not applicable and is not included)

LOAD LIGHT

MAXIMUM

STOPPING DISTANCE IN FEET FROM 60 MPH

Manufacturer

MIKUNI

Fuel level

2± 1 mm (0.079± 0.039 in)

Model I.D. No.

5K500

Pilot screw

Preset

Main jet

# 112.5

Air jet. Main

# 70

Needle jet

O-8

Air jet. Pilot

# 165

Pilot jet

#35

Throttle valve

# 130

Starter jet

# 35 (0.7)

Float valve seat

2.0

Jet needle

4GN

Engine idle speed

1,200 r/m in

Wheels and tires:

Rim run-out:
vertical
horizontal

2.0 mm (0.079 in)
2.0 mm (0.079 in)

Tire pressure (cold):

Front

Rear

Up to 90 kg (198 lb) load*

1.8 kg/cm² (26 psi)

2.0 kg/cm² (28 psi)

90 kg (198 lb) -192 kg (423 lb) (Maximum load)

2.0 kg/cm² (28 psi)

2.8 kg/cm² (40 psi)

High speed riding

2.0 kg/cm² (28 psi)

2.3 kg/cm² (32 psi)

Minimum tire tread depth

0.8 mm (0.03 in)

0.8 mm (0.03 in)

Brakes:

Recommended fluid
Pad thickness: standard
wear limit
Rear brake lining: standard
wear limit
Brake disc maximum deflection
Brake disc minimum thickness
Front brake free play (end of lever)
Rear brake free play (end of pedal

DOT #3
6.8 mm (0.27 in)
4.0 mm (0.16 in)
4 mm (0.16 in)
2 mm (0.08 in)
0.15 mm (0.006 in)
4.5 mm (0.18 in)
5.0- 8.0 mm (0.2-0.3 in)
20- 30 mm (0.8- 1.2 in)

Front forks:
Travel
Spring free length
Spring preload length
Spring rate: 0 -105 mm (0- 4.13 in)
105-150 mm (4.13-5.91 in)
Fork oil capacity (each side)
Oil type

150 mm (5.91 in)
587 mm (23.11 in)
567 mm (22.32 in)
0.468 kg/mm (26.2 lb/in)
0.6 kg/mm (33.6 lb/in)230 cc (7.78 oz)
Yamaha Fork Oil 10Wt or equivalent

Rear shock absorber:
Spring free length
Spring preload length
Spring rate: 0-36 mm (0-1.42 in)
36 - 80 mm (1.42-3.15 in)
Travel

238.5 mm (9.39 in)
216.5 mm (8.52 in)
1.6 kg/mm (89.6 lb/in)
2.2 kg/mm (123.2 lb/in)
100 mm (3.94 in)

Ignition timing retarded:

5° at 1,200 r/min

Ignition timing advance:

Spark plug:
Electrode gap

D8EA (NGK) or X24ES-U (ND)
0.6 -0.7 mm (0.024 -0.028 in)

Spark plug cap resistance:

10KΩ

Pick up coil:

Resistance

650Ωt ± 20%at20°C(68°F)

Ignition coil type:

Primary resistance
Secondary resistance

2.5Ω ± 10%at20°C(68°F)
11kΩ ± 20%at20°C(68F)

MITSUBA SM-8204
0.0Ωft ± 6% at 20°C (68°F)

12.0 mm (0.472 in)
5.0 mm (0.20 in)
400± 60g (14.08 ±2.11 oz)
0.8 mm (0.031 in)

Charging rate

1.2 Amps for 10 Hours

Generator type:
Output
Field (inner) coil resistance
Stator (outer) coil resistance

HITACHI LD117-03
14V-17A at 5,000 r/min
4.5Ω ± 10% at 20°C(68°F)
0.5Ω ± 10% at 20°C(68°F)

Regulator type:
Regulated voltage
Allowable amperage

I.C. (S8515)
14.5 ± 0.3V
4A

Starter relay switch:
Cut-in voltage

8V

Headlight:
Tail/brake light:
Flasher light:
Pilot lights:
TURN
HIGH BEAM
NEUTRAL
OIL LEVEL
Meter light

12V.50W/40W
12V, 8W (3CP)/27W (32CP) x 2
12V,27W(32CP) x4

12V,3.4Wx 2
12V,3.4Wx 1
12V,3.4Wx 1
12V,3.4Wx 1
12V,3.4Wx2

XJ550H

Basic color Dimensions:

Overall length

Overall width

Overall height

Seat height

Wheel base

Minimum ground clearance

Caster (steering head angle)

Trail

New Yamaha Black or New Ruby Red

2,145 mm (84.4 in)

865 mm (34.1 in)

1,165 mm (45.9 in)

760 mm (29.9 in)

1,420 mm (55.9 in)

160 mm (6.3 in)

28°

114 mm {4.49 in)

Weight: Net

185 kg (407 lb)

Engine: Type

Bore xstroke x cylinders

Displacement

Compression ratio

D.O.H.C. air-cooled, gasoline

57.0 x 51.8 mm x 4 (2.244 x 2.039 in x 4)

528 cc (32.22 cu.in)

9.5: 1

Lubrication:

Lubrication system
Delivery pump type

Pressure lubricated,
wet sump Trochoid

Carburetion:

Manufacture

Type

Rated venturi size

MIKUNI

BS28, constant velocity

28 mm (1.10 in)

Air filter:

Dry type element

Ignition: Type Spark plug

Battery ignition (Full transistor ignition) D8EA (NGK) or X24ES-U (ND)

Charging: Type

Manufacture, I.D. No.

Maximum output

Battery type

Battery dimensions

Regulator/Rectifier

Regulating voltage (No. load)

Three-phase, regulated alternator

HITACHI, LD117-03

14V 17A

12N12A-4A

80 x 160 x 134 mm (3.15 x 6.30 x 5.28 in)

S8515,1.C. type, full wave

14.2-14.8V

Starting:

Electric starter

Primary drive:

Type

Teeth, ratio

Spur gear

22/21 x 65/28 (2.432)

Clutch:

Wet, multiple disc

Transmission: Type

Constant mesh, 6-speed drum shifter

Teeth, ratio 
1st 
2nd
3rd
4th
5th
6th

41/15 2.733
37/19 1.947
34/22 1.545
31/25 1.240
29/28 1.036
27/30 0.900

Secondary drive:
Type
Teeth, ratio

Chain
45/16 2.813

Chassis:
Frame

Suspension:
Front (type, travel)
Rear (type, travel)

Tires:
Front
Rear

Brakes:
Front
Rear

Fuel tank:
Total
Reserve

Wheels:
Front
Rear

Tubular steel double cradle

Telescopic fork 150 mm (5.91 in)
Swing arm, 100 mm (3.94 in)

3.25H19-4PR,Tubeless
130/90-16 67 H,Tubeless

Single hydraulic disc
Drum brake

13 lit. (3.4 US. gal)
3.6 lit. (1.0 US. gal)

MT1.85 x 19, Cast Aluminum
MT2.15 x 18, Cast Aluminum

Engine oil capacity:
Total amount
Oil and filter change
Oil change

Recommended lubricant:
If temperature does not go below  4°C (40°F)
If temperature does not go above 15C (60°F)

2,900 cc (3.1 US. qt)
2,500 cc (2.6 US. qt)
2,200 cc (2.3 US. qt)

SAE 20W/40SE motor oil

SAE 10W/30SE motor oil

Cranking pressure (at sea level):
Maximum difference between cylinders:

8.5 kg/cm² (121 psi)
1 kg/cm² (14 psi)

Dimensions

Standard size

Wear limit

A

34.80 mm (1.370 in)

34.65 mm (1.364 in)

Intake

B

28.0 mm (1.102 in)

27.85 mm (1.096 in)

C

6.80 mm (0 268 in)

-

A

34.80 mm (1.370 in)

34.65 mm (1.364 in)

Exhaust

B

28.0 mm (1.102 in)

27.85 mm (1.096 in)

C

6.80 mm (0.268 in)

-

Inner Intake/Exhaust

Outer Intake/Exhaust

Free length

35.5 mm (1.398 in)

37.2 mm (1.465 in)

Spring rate

2.429 kg/mm (136.0 lb/in)

4.726 kg/mm (264.7 lb/in)

Installed length (valve closed)

30.5 mm (1.201 in)

32.0 mm (1.260 in)

Installed pressure (valve closed)

9.3 kg (20.5 lb)

18.5 kg (40.8 lb)

Compressed length

(valve open)

IN: 24.0 mm (0.945 in)
EX: 25.5 mm (1.004 in)

IN: 24.0 mm (0.945 in)
EX: 25.5 mm (1.004 in)

Wire diameter

2.7 mm (0.106 in)

3.8 mm (0.150 in)

Number of windings

7.6

6.0

Winding O.D.

19.9^+0.3 _-0 mm (0.783^+0.012 _-0 in)

28.3 ⁺⁰ _-0.3 ^mm (1.114 ⁺⁰ _-0.012 in)

Clearance (Cold engine)

0.11~0.15mm

(0.004~0.006 in)

"A" head diameter

30 ± 0.1 mm (1.1811 ±0.0039 in)

"B" face width

2.3 mm (0.0906 in)

"C" seat width

1.0± 0.1 mm (0.0394 ± 0.0039 in)

"D" margin thickness (minimum)

1.2 ±0.2 mm

(0.0472±0.0079 in)

Stem diameter (O.D.)

₆ ^-0.010 _-0.025 ^mm (0.2362 ^-0.0004 _-0.0010 in)

Guide diameter (I.D.)

6 ^+0.012 ₀ mm (0.2362 ^+0.0005 _-0 in)

Stem-to-guide clearance

0.010 —0.037 mm (0.0004-0.0015 in)

Clearance

(cold engine)

0.16-0.20 mm (0.006-0.008 in)

"A" head diameter

26 ±0.1 mm (1.024± 0.0039 in)

"8" face width

2.3 mm (0.0906 in)

"C" seat width

1.0± 0.1 mm (0.0394 ±0.0039 in)

"D" margin thickness (minimum)

1.0 ±0.2 mm

(0.0394 ±0.0079 in)

Stem diameter (O.D.)

₆ ^-0.025 _-0.040 ^mm (0.2362 ^-0.0010 _-0.0016 in)

Guide diameter (I.D.)

6 ^+0.012 ₀ mm (0.2362 ^+0.0005 _-0 in)

Stem-to-guide clearance

0.025—0.052 mm (0.0010-0.0020 in)

Cylinder and piston:

Cylinder material

Aluminum alloy

Cylinder liner

Pressed in; special cast iron

Bore size:
standard
wear limit

57.00 mm (2.2441 in)
57.10 mm (2.2480 in)

Cylinder taper limit

0.05 mm (0.0020 in)

Cylinder out-of-round limit

0.01 mm (0.0004 in)

Piston clearance:
standard
maximum

0.025- 0.045 mm (0.0010- 0.0018 in)
0.1 mm (0.0039 in)

Piston rings:

Top

2nd

Oil

Design

Barrel

Taper

Expander

End gap (installed):

standard

0.15-0.35 mm (0.0059 -0.0138 in)

0.15-0.35 mm (0.0059-0.0138 in)

0.3-0.9 mm (0.0118-0.035 in)

limit

1.0 mm (0.0394 in)

1.0 mm (0.0394 in)

1.5 mm (0.0591 in)

Side clearance:

standard

0.03—0.07 mm (0.0012-0.0028 in)

0.02-0.06 mm (0.008-0.0024 in)

-

limit

0.15 mm (0.0059 in)

0.15 mm (0.0059 in)

-

Crankshaft:

Crank journal/bearing oi! clearance

0.040~ 0.064 mm (0.0016-0.0025 in)

Main journal run out (maximum)

0.03 mm (0.0012 in)

Connecting rods:

Rod bearing oil clearance

0.03 -0.09 mm (G.0012-0.0035 in)

Oil pump:

Housing-to-outer rotor clearance

0.09-0.15 mm (0.0035- 0.0059 in)

Outer rotor-to-inner rotor clearance

0.03-0.09 mm (0.0012- 0.0035 in)

Clutch:

Frictionpplate:

thickness/q'ty
minimum thickness

3.0 mm (0.12in)/8
2.8 mm (0.11 in)

Clutch plate:

thickness
warp limit

1.6 mm (0.063 in)/7
0.05 mm (0.0020 in)

Clutch spring:

length/q'tv
minimum length
spring rate

41.2 mm (1.622 in)/5
40.2 mm (1.583 in)
1.22 kg/mm (68.3 lb/in)

Clutch lever freeplay (at lever pivot point)

2 -3 mm (0.08-0.12 in)

A (Nut)

B (Bolt)

General torque specifications

m-kg

ft-lb

10 mm

6 mm

0.6

4.5

12 mm

8 mm

1.5

11

14 mm

10 mm

3.0

22

17 mm

12 mm

5.5

40

19 mm

14 mm

8.5

51

22 mm

16 mm 13.0

94

METRIC TO INCH SYSTEM

KNOWN

MULTIPLIER

RESULT

TORQUE

m-kg

7.233

ft-lb

m-kg

86.80

in-lb

cm-kg

0.0723

ft-lb

cm-kg

0.8680

in-lb

WT.

kg

2.205

lb

9

0.03527

oz

FLOW /

DISTAMCE

km/lit

2.352

mpg

km/hr

0.6214

mph

km

0.6214

mi

m

3.281

ft

m

1.094

yd

cm

0.3937

in

mm

0.03937

in

CAPACITY

cc (cm³)

0.03382

oz (US liq)

cc (cm )

0.06102

cu. m

lit (liter)

2.1134

pt (US liq)

lit (liter)

1.057

qt (US liq)

lit (liter)

0.2642

gal (US liq)

kg/mm

56.0C7

lb/in

kg/cm

14.2234

psi (lb/in²)

INCH TO METRIC SYSTEM

KNOWN

MULTIPLIER

RESULT

ft-lb

0.13826

m-kg

in-lb

0.01152

m-kg

ft-lb

13.831

cm-kg

in-lb

1.1521

cm-kg

WT.

lb

0.4535

kg

oz

28.352

g

DISTANCE

mpg

0.4252

km/lit

mph

1.609

km/hr

mi

1.609

km

ft

0.3048

m

yd

0.9141

m

in

2.54

cm

in

25.4

mm

VOLUME /

CAPACITY

oz (US liq)

29.57

cc (cm )

cu.in

16.387

cc "cm )

pt (US liq)

0.4732

lit (liter)

qt (US liq)

0.9461

lit (liter)

gal (US liq)

3.785

lit (liter)

MISC.

lb/in

0.017855

kg/mm

psi (lb/in )

0.07031

kg/cm²

Fahrenheit (°C)

5/9(°F-32)

Centigrade (°F)

DEFINITION OF TERMS:

m-kg

=

Meter-kilogram(s) (usually torque)

9

=

Gram(s)

kg

=

Kilogram(s) (1,000 grams)

lit

=

Liter(s)

km/lit

=

Kilometer(s) per liter (fuel consumption)

cc

=

Cubic centimeter(s) (cm³) (volume or capacity)

kg/mm

=

Kilogram(s) per millimeter (usually spring compression rate)

kg/cm²

=

Kilogram(s) per square centimeter (pressure)

> Pressure feed

• Splashed

Part to be tightened

Part name

Thread size

Q'ty

Tightening torque

Remarks

m-kg

ft-lb

ENGINE:

Cam shaft cap

Bolt

M6x 1.0

24

1.0

7.2

Tighten in 3-stages

Cylinder head {cam chain)

Stud bolt

M6X1.0

4

0.5

3.6

Apply oil

Cylinder head (Exhaust pipe)

Stud bolt

M6x 1.0

8

1.0

7.2

Apply oil

Cylinder head

Stud bolt

M8X1.25

2

1.5

11.0

Apply oil

Cylinder head

Nut

M8X1.25

2

2.0

14.5

Cylinder head

Cap nut

M8x 1.25

12

2.2

16.0

Apply oil

Spark plug

M12x1.25

4

2.0

14.5

Cylinder head cover

Bolt

M6X1.0

12

1.0

7.2

Tachometer gear housing

Bolt

M6x 1.0

1

1.0

7.2

Cylinder

Stud bolt

M8X1.25

1

1.6

11.0

Apply oil

Cylinder (YICS blind plug)

Plug

M12x 1.25

2

2.2

16.0

Cylinder and crankcase

Nut

M8x 1.25

1

2.0

14.5

Cylinder head and cylinder

Nut

M6 x 1.0

4

1.0

7.2

Cam chain (front & rear)

Connecting rod and rod cap

Nut

M7 x 0.75

8

2.5

18.0

Camshaft and sprocket

Bolt

M7x1.0

4

2.0

14.5

Cam chain tensioner stopper bolt

Bolt

M6x1.0

1

0.6

4.3

Cam chain tensioner case and cylinder

Bolt

M6x 1.0

1

1.0

7.2

Cam chain tensioner case and cylinder

Nut

MB x 1.0

1

1.0

7.2

Cam chain tensioner lock nut

Nut

M8x1.25

1

0.9

6.5

Crankcase

Plug

MIOxl.25

1

1.0

7.2

Rotor housing and pump cover

Screw

M6x 1.0

1

0,7

5.1

Oil pump ass'y and crankcase

Screw

M6x1.0

3

0.7

5.1

Strainer housing and crankcase

Bolt

M6x 1.0

2

1.0

7.2

Strainer cover and crankcase

Bolt

M6x1.0

12

1.0

7.2

Filter cover and crankcase

Union bolt

M20x 1.5

1

1.5

11.0

Strainer cover

Plug

M14X1.5

1

4.3

31.0

Carburetor joint and Cylinder head

Bolt

M6x 1.0

8

1.0

7.2

Air filter

Screw

M5 x 0.8

4

0.5

3.6

Air filter

Bolt

M6 x 1.0

3

0.7

5.1

Exhaust pipe and cylinder head

Nut

M6x1.0

8

1.0

7.2

Exhaust pipe joint

Bolt

M8x1.25

6

2.0

14.5

Muffler

Bolt

M10x 1.25

2

2.5

18.0

Muffler protector

Bolt

M10x1.25

1

2.5

18.0

Muffler protector

Screw

M6x 1.0

2

i °:⁷

5.1

Crankcase

Stud bolt

M8x1.25

12

1.3

9.5

Apply oil

Crankcase (upper and lower)

Bolt

M8xl.25

11

2.4

17.5

Apply oil

Crankcase (upper and lower)

Bolt

M6x1.0

23

1.2

8.5

Apply oil

Generator cover and crankcase

Bolt

M6x1.0

3

1.0

7.2

Bearing cover plate (crankcase right)

Bolt

M6x1.0

2

1.0

7.2

Bearing cover plate (crankcase left)

Screw

M6x 1.0

2

1.0

7.2

Use LOCKTITE

Clutch cable holder

Screw

M6x1.0

1

1.0

7.2

Crankcase cover

Bolt

M6x1.0

13

1.0

7.2

Crankcase (Main gallary blind plug)

Plug

M20x1.5

2

1.2

8.5

Apply oil

Clutch pressure plate

Bolt

M6x 1.0

5

0.8

5.8

Clutch boss

Nut

M20x 1.0

1

7.0

50.5

Drive sprocket

Bolt

M6x1.0

2

1.0

7.2

Cam shift

Screw

M5 x 0.8

1

0.7

5.1

Use LOCKTITE

Stopper plate

Bolt

M6x1.0

1

1.0

7.2

Change pedal

Bolt

M6x 1.0

1

1.0

7.2

A.C. Generator

Bolt

M10x1.25

1

3.5

25.5

A.C. Generator (brush)

Screw

M6x1.0

2

0.8

5.8

A.C. Generator (rotor)

Bolt

M8 x 1.25

1

2.4

17.5

Pick up coil base

Screw

M6X1.0

2

0.8

5.8

Timing plate

Screw

M6 x 1.0

1

0.8

5.8

Starter motor

Bolt

M6x1.0

2

1.0

7.2

Neutral switch

Screw

M5x0.8

3

0.3

2.2

Use LOCKTITE

Oil level gauge switch

Bolt

M6x 1.0

2

0.7

5.1

Handle crown & Steering shaft

Bolt

M14 P1.25

1

5.4

39.0

Handle crown & Inner tube

Nut cap

M8 PI .25

1

2.0

14.5

Handle crown&Handlebar holder

Bolt

M8 PI .25

4

2.0

14.5

Under bracket & Inner tube

Bolt

M12 P1.25

2

3.8

27.5

Front wheel shaft

Nut Castle

M14 P1.5

1

10.5

76.0

Front wheel Axle pinch bolt

Nut salf locking

M8 PI.25

2

2.0

14.5

Pivot shaft

Nut

M14 P1.5

1

9.0

65.0

Rear wheel shaft

Nut castle

M14 P1.5

1

10.5

76.0

Sprocket wheel

Nut

M10 P1.25

6

6.2

45.0

Rear shock absorber (Upper)

Nut cap

M10 P1.25

2

3.0

21.5

Rear shock absorber (Lower)

Bolt

M10 P1.25

2

3.0

21.5

Footrest

Bolt

M12 P1.25

2

7.0

50.5

Tension bar & Brake plate

Bolt

M8 P1.25

2.0

14.5

Tension bar & Rear arm

Bolt

M8 P1.25

2.0

14.5

Camshaft lever & Camshaft

Bolt

M6 P1.0

0.9

6.5

Brake disc & Hub (Front)

Bolt

M8 P1.25

12

2.0

14.5

Lock washer

Master cylinder & Brake hose (Front)

Bolt union

M10 P1.25

2.6

19.0

Brake hose & Joint

Bolt union

M10 P1.25

2.6

19.0

Caliper & Brake hose

Bolt union

M10 P1.25

2.6

19.0

Caliper & Front fork (Front)

M10 P1.25

4.5

32.5

CaMper bleed screw (Front)

M8 P1.25

0.6

4.3

Front fender

Bolt

M8 P1.25

1.0

7.2

Master cylinder cap

Screw

M5 P0.8

2

0.18

1.3

Muffler bracket & Frame

Bolt

M10 P1.25

4

4.2

30.5

Muffler brakcet & Muffler (rear footrest)

Bolt

M10 PI .25

2

4.5

32.5

Master cylin Master cylinder bracket

Bolt

M6 P1.0

2

0.9

6.5

Steering shaft & Ring nut

Nut

M25 P1.0

1

3.8

27.5

Brake pedal & Brake shaft

Bolt

M6 P1-0

1

0.9

6.5

Sensor & Fuel tank

Bolt

M6 P1.0

4

0.5

3.6

Rear arm end & rear arm

Bolt

M6 P1.0

2

0.6

4.3