Introduction to Your Service Manual
This manual provides detailed instructions and specifications for the service, repair, and performance tuning of Yamaha XJ550 and FJ600 motorcycle models manufactured between 1981 and 1985. It is designed for both the professional mechanic and the do-it-yourself enthusiast, offering clear, step-by-step procedures to ensure proper maintenance and repair.
Familiarize yourself with the manual's layout and content before beginning any work on your motorcycle. Always prioritize safety and use appropriate tools and protective gear.
Image: Front cover of the Yamaha XJ550 & FJ600 Service, Repair, Performance manual. The cover features a motorcycle graphic and the title of the manual, indicating its comprehensive nature for these specific Yamaha models from 1981-1985.
Using This Manual Effectively
To maximize the utility of this service manual, it is recommended to:
- Review Safety Information: Always read the safety warnings and precautions at the beginning of each section before starting any procedure.
- Understand Terminology: Familiarize yourself with the technical terms and abbreviations used throughout the manual.
- Consult Diagrams and Illustrations: Detailed diagrams, exploded views, and photographs are provided to aid in understanding component locations and assembly sequences. Refer to these visuals frequently.
- Gather Necessary Tools: Ensure you have all required tools and equipment before beginning a task. Specialized tools are often noted.
- Follow Step-by-Step Procedures: Perform tasks in the order presented to avoid errors and ensure proper reassembly.
Service and Repair Procedures
This manual is organized into chapters covering various systems of the Yamaha XJ550 and FJ600. Each chapter focuses on specific components and provides comprehensive instructions for inspection, adjustment, removal, installation, and repair.
Key Areas Covered:
- Engine: Disassembly, inspection, repair, and reassembly of engine components, including cylinders, pistons, crankshaft, and valve train.
- Fuel System: Carburetor cleaning, adjustment, and synchronization; fuel tank and line maintenance.
- Electrical System: Wiring diagrams, troubleshooting electrical faults, testing components like the ignition system, charging system, and lighting.
- Chassis: Frame inspection, suspension (front forks, rear shock) service, steering head bearing adjustment, and wheel/tire maintenance.
- Brakes: Inspection, fluid replacement, pad replacement, and bleeding procedures for both front and rear brake systems.
- Transmission and Clutch: Adjustment, removal, inspection, and installation of clutch components and transmission gears.
Always refer to the specific chapter for the system you are working on for detailed instructions and torque specifications.
Troubleshooting Common Issues
A dedicated troubleshooting section is included to assist in diagnosing common motorcycle problems. This section typically provides symptom-based charts and diagnostic procedures to help identify the root cause of an issue.
When troubleshooting, start with the simplest checks and progressively move to more complex diagnostics. For example, if the engine will not start, first check fuel levels, battery charge, and spark plugs before disassembling major components.
Technical Specifications
This manual contains comprehensive technical specifications for the Yamaha XJ550 and FJ600 models, including:
- Engine Specifications: Bore, stroke, compression ratio, valve clearances.
- Torque Specifications: Essential for proper fastening of components.
- Fluid Capacities: Engine oil, fork oil, brake fluid types and volumes.
- Electrical Specifications: Battery voltage, fuse ratings, component resistances.
- Dimensions and Weights: Overall dimensions, dry weight, and other relevant measurements.
Always refer to the specific tables and charts within the manual for the most accurate and up-to-date specifications for your model year.
Publisher Information and Support
This service manual was published by Clymer Publications. For inquiries regarding the publication or content, please refer to the contact information provided within the manual itself or on the publisher's official website.
Publication Details:
- Publisher: Clymer Publications
- Publication Date: January 1, 1986
- Edition: 2nd Edition
- Print Length: 237 pages
- ISBN-10: 0892873728
- ISBN-13: 978-0892873722
