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Old 02-16-2010, 12:26 PM   #1
XTwarrior OP
My bike is older than me
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Joined: Jul 2007
Location: Allentown PA
Oddometer: 281
Thumb The XT550 Thread: Info, Stories and Mods Inside!

Hello all! For those of you lucky people out there to own arguably the most superior motorcycle ever , I'm sure you have at one time wanted to find a safehaven where you can share your XT550 stories, what companies still make mod parts for this bike, what you can customize or swap from different bikes, and general information that may be somewhat hard to find without calling your local dealership or knowing somebody. Alteast I know I do! So here is that thread, on this wonderful forum, for just that! I mean, it isn't fair the XT500 and XT600 have their own thread, right?!

I'm going to keep the first post for informational purposes and reference so searching will be far easier. I've quite often tried to search for information on this bike and found it hard or impossible to find, so hopefully this will be your one stop information spot! Post up your stories and projects, whether it be just an OEM restoration or full custom!

Also, don't hesitate to PM me information to update or post it in this thread! The point is to share what you can to better the XT550 community!

Yamaha XT550 General Information and Specifications:
Years of Production: 1982 to 1983
Category: Dual Purpose / Enduro
Displacement: 558 CCM (or 34.05 cubic inches)
Cam type: (OHC)
Cylinders: 1
Stroke: 4 stroke
Horsepower: 38 HP at crank @ 6,500 RPM's
Compression Ratio: 8.5:1
Bore x Stroke: 92MM x 84MM
Valves: 4
*Stock clearances:
Intake: 0.08mm
Exhaust: 0.15mm
Fuel Control: Carburated (2-stage)
OEM Carb settings:
*Main Jet Primary Carb: 125
*Main Jet Secondary Carb: 125
*Pilot Jet Primary Carb: 48
*Needle Jet Primary Carb: V00
*Needle Jet Secondary Carb: 00
*Jet Needle clip Primary Carb - 5C33 fixed
*Jet Needle clip Secondary Carb: 4A70 fixed
*Slide Cutaway: 4.5
*Float Level: 26mm with a tolerance of + or - 2.5mm
*Fuel Level: 6mm with a tolerance of + or - 1mm
*Idle RPM: 1,200 RPM's
*Max CO2: 7%
*Max HC: 500PPM
*Set CO: 5.5%
Type of cooling: Air Cooled
Gearbox: 5 speed; 1 down 4 up.
Drive Type: Chain (Link size: 520 / Links: 98)
Front Sprocket Size: 15 tooth
Rear Sprocket Size: 42 tooth
Dry Weight:
Wet Weight: 145 Kilograms -or- 320 Lbs.
Front Tire: 3.00/21
Front Rim: 1.60/21
Rear Tire:4.60/18
Rear Rim: 2.15/18
Front Axle Diameter: 15MM
Rear Axle Diameter: 17MM
Front Brake System: Expanding Drum Brakes
Rear Brake System: Expanding Drum Brakes
Front Suspension: 38MM Air adjustable Fork tubes; 10 weight oil OEM. 369CC's of oil PER fork when serviced.
Fork Spring Rates: Free Length 21.87 Inches / Outside Diameter 1.45 inch. (unconfirmed)
Rear Suspension: Nitrogen and Oil charged shock; non-adjustable and non-rebuildable.
Rear Spring Rate:
Top Speed: 92 MPH reported...downhill...with a headwind.
Fuel Capacity: 3.17 Gallons
Oil Type: OEM recommends 20W40
Oil Capacity: Dry - 2200cc / Oil and Filter Change - 1900cc -OR- 65 ounces / Oil Only - 1800cc

Yamaha XT550 Service Intervals:
Valve Clearance: Check every 2,500 miles
Spark PLugs: Check every 2,500 miles; Replace every 5,000 miles
Crankcase Hose: Check every 5,000 miles; replace if cracks formed
Fuel Hose: Check every 5,000 miles; replace if cracks formed or leaks
Exhaust System: Check every 2,500 miles for leaks or bad gaskets.
Idle Speed: Check every 2,500 miles; adjust cable free play if necessary
Decompression System: Check every 2,500 miles (after valve clearance adjustment)
Change Oil: Every 2,500 miles; factory recommends 20w40.
Change Oil Filter: Every 5,000 miles; Make sure to check downtube strainer at the same time!
Change Air Filter: Every 2,500 miles; wash and oil type foam filter
Check Brakes: Every 2,500 miles; adjust free play or replace shoes if necessary
Check Clutch: Every 2,500 miles and adjust any freeplay
Check Drive Chain: Every 500 miles; adjust for 2.4" - 2.8" of play
Check Control and meter cables: Every 2,500 miles lubricate and adjust
Lubricate Pivot Shafts: Apply lithium grease lightly every 5,000 miles.

Yamaha XT550 Manuals, Flyers, and Useful Sites:
Stock Axle Diameters of Popular UJM Bikes (Link)
XT550 DIY CDI (rough English but do-able):
Stock Fork tube Diameter reference list:
XT550 Service Manual: (Thanks to NetJustin for his work!)

Yamaha XT550 Aftermarket Parts Manufacturers (both OEM replacement and high performance):
Clark Gas Tank:
SuperTrapp Aluminum Exhaust:
Hyperpak CDI Ignition (Wayne Gum; sold only on Ebay but work great!):
K&N High Flow Filter:
WP Suspension front fork springs(Pro line):
Works Suspension rear Monoshock (direct replacement!):

Yamaha XT550 Swappable Parts From other bikes:
Small thread with useful info on XT/TT600 engine swaps:
Swapped front end with KLR650 (38 MM fork versions)
Swapped Front end with Yamaha Tenere 1VJ.
Engine Swap; XT/TT600 into XT550 frame compatiability and issues:

Yamaha XT550 Tips and Tricks:
Changing and reading the motor oil in your XT550: (Link)

Yamaha XT550 Projects:
XTwarrior's Quasimotard:

Remember; please let me know if you have any information to add, the more the better!

(This post will be updated regularly with new info as it comes in)
2006 SV650 Nudie/ZX14 shock/Delkevic 225mm silencer/Fender Elminiator
1983 XT550 Projecto!

XTwarrior screwed with this post 04-06-2010 at 01:26 PM
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