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Yamaha SR500 SR 500 1975-1983 Workshop Service Repair Manual

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The Yamaha SR500, produced from 1978 to 1983, is celebrated for its robust single-cylinder engine and timeless design. As a road-going evolution of competition bikes, it embodies simplicity and mechanical...
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Yamaha SR500 SR 500 1975-1983 Workshop Service Repair ManualYamaha SR500 SR 500 1975-1983 Workshop Service Repair ManualYamaha SR500 SR 500 1975-1983 Workshop Service Repair ManualYamaha SR500 SR 500 1975-1983 Workshop Service Repair Manual
The Yamaha SR500, produced from 1978 to 1983, is celebrated for its robust single-cylinder engine and timeless design. As a road-going evolution of competition bikes, it embodies simplicity and mechanical engagement, making it a beloved model for enthusiasts and customizers alike. Its 499cc, air-cooled, four-stroke engine, paired with a 5-speed transmission and a wet, multi-disc clutch, delivers a torquey and responsive riding experience. The SR500 is noted for its reliability and classic styling, earning it a place as a significant model in esteemed motorcycle heritage. This comprehensive workshop service repair manual provides in-depth coverage for all aspects of the Yamaha SR500, from basic maintenance to complete overhauls. It details procedures for engine mechanical and electrical systems, fuel and emission controls, clutch, transmission, driveshaft, suspension, steering, and braking systems. The manual includes troubleshooting guides, wiring diagrams, and step-by-step instructions for component repair and reassembly, making it an indispensable resource for owners and technicians. Its detailed illustrations and factory-authorized information ensure accurate and efficient maintenance and repair, preserving the integrity and performance of your SR500.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
SR500
Model Years Covered:
1975-1983
Codes
Product Name:
Yamaha SR500 SR 500 1975-1983 Workshop Service Repair Manual PDF Download
👋 Introduction
Market Position
Positioning:
A fundamental resource for owners and mechanics of the iconic Yamaha SR500, emphasizing its classic design and single-cylinder simplicity.
Competitive Analysis
Value Proposition:
Offers comprehensive, in-depth technical information at an affordable price, enabling cost-effective maintenance and repair.
Key Features
Features:
Detailed illustrations, step-by-step instructions, troubleshooting guides, and electrical schematics.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Service and Repair
Page Count
Estimated Page Count:
Refer to actual manual for exact count (typically 300-500 pages for this era of comprehensive manuals)
Manual Type
Type:
Workshop Service Repair Manual / Factory Service Manual
Language
Language:
English
Format
Format:
PDF (Downloadable)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full coverage including disassembly, inspection, repair, and reassembly of all engine components.
Engine Electrical:
Detailed diagnostics, troubleshooting, and repair of ignition, charging, and starting systems.
Fuel System:
Carburetor service, fuel pump diagnostics, and fuel line maintenance.
Emission Control:
Information pertaining to emission control systems as applicable to the model years.
Clutch System:
Service and adjustment of the clutch mechanism.
Transmission:
Disassembly, inspection, and repair of the manual transaxle.
Driveshaft Axle:
Service and inspection of the final drive mechanism.
Suspension:
Front fork and rear shock absorber service, adjustment, and overhaul.
Steering System:
Handlebar and steering head bearing maintenance.
Brake System:
Front and rear brake caliper service, hydraulic system maintenance, and bleeding procedures.
Body Exterior:
Body panel removal, installation, and cosmetic repairs.
Body Interior:
Seat removal and related interior components.
Body Electrical:
Wiring diagrams, lighting systems, switchgear, and accessory electrical components.
Restraint System:
Information relevant to rider safety and any applicable restraint systems.
Procedures Included
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, chain adjustments, and general tune-ups.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and uncommon issues.
Repair:
Step-by-step instructions for component removal, repair, and installation across all vehicle systems.
Rebuilds:
Comprehensive procedures for complete engine, transmission, and suspension overhauls.
Wiring Diagrams:
Detailed electrical schematics for accurate diagnosis and repair of electrical faults.
Technical Depth
Depth:
Complete, from basic maintenance and adjustments to full engine rebuilds and complex electrical troubleshooting.
Target Audience:
Suitable for both the experienced professional mechanic and the enthusiastic do-it-yourself owner.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Fully printable pages
Zoom Functionality:
Zoom IN/OUT capability for detailed viewing
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Requirements
Software Requirements:
Adobe PDF Reader, WinZip (for extraction if compressed)
Compatibility:
All Versions of Windows & Mac
Delivery
Delivery Method:
Instant Download
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, SOHC, Air-cooled Single Cylinder
Displacement:
499 cc (499cc)
Bore X Stroke:
90.0 mm x 78.0 mm (3.54 in x 3.07 in) - specific to SR500
Performance
Horsepower Approximate:
Approximately 32-34 hp @ 6500 rpm (Varies slightly by year and market)
Torque Approximate:
Approximately 39-40 Nm @ 5000 rpm (Varies slightly by year and market)
Fuel System
Carburetor:
Typically a Mikuni VM34-131 or similar single, constant-velocity carburetor.
Fuel Type:
Unleaded gasoline (minimum octane rating as per manual)
Ignition System
Ignition Type:
CDI (Capacitor Discharge Ignition)
Lubrication System
Oil Type:
Yamaha recommends API SE or SF, SAE 20W-40 or 10W-30 motorcycle specific oil. Consult manual for exact specifications.
Oil Capacity:
Approximately 2.0 liters (2.1 US qt) with filter change. Consult manual for exact capacity.
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh, sequential transmission
Features
Clutch Type:
Wet, multi-disc, cable-operated
Fluid Type
Transmission Oil:
Yamalube Gear Oil or equivalent API GL-4, SAE 80W motorcycle transmission oil. Consult manual for exact specification.
📐 Dimensions
Exterior
Length:
Approx. 2,170 mm (85.4 in) (Varies slightly by year)
Width:
Approx. 800 mm (31.5 in) (Varies slightly by year)
Height:
Approx. 1,160 mm (45.7 in) (Varies slightly by year)
Weights
Dry Weight:
Approx. 173 kg (381 lbs)
Wet Weight:
Approx. 187 kg (412 lbs) (with all fluids)
🛡️ Safety Features
Ratings
Safety Features:
Focus on rider control, braking performance, and the inherent stability of its design.
Active Features
Braking System:
Front: Single Disc Brake, Rear: Drum Brake (early models) or Disc Brake (later models). Specific caliper and master cylinder details are in the manual.
Passive Features
Lighting:
Halogen headlamp, tail/brake light, and turn signals.
💡 Technology Features
Infotainment
Infotainment System:
N/A (This is a classic motorcycle designed for mechanical engagement, not modern electronics.)
Driver Assistance
Rider Assistance:
N/A (Focus is on rider skill and mechanical feedback.)
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Recommended every 3,000 km (1,800 miles) or 6 months. Consult manual for precise interval and oil quality requirements.
Spark Plug Maintenance:
Check and gap every 3,000 km (1,800 miles). Replace as needed. Consult manual for specific plug type and gap.
Air Filter Maintenance:
Inspect and clean every 3,000 km (1,800 miles), replace as needed.
Chain Maintenance:
Lubricate and adjust chain tension every 1,000 km (600 miles).
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4, high-temperature glycol-based brake fluid. Consult manual for exact type and replacement interval.
Fork Oil:
Yamalube Fork Oil G10 or equivalent. Capacity and level are critical for proper front suspension performance. Consult manual for specific quantities.
Known Issues
Common Problems:
Kick-start reliability (due to mechanism design), carburetor tuning, and occasional electrical gremlins common in vintage motorcycles. The manual provides solutions for these.
📚 Vehicle History
Brand Heritage
Yamaha Legacy:
Yamaha Motor Company, established in 1955, has a rich history in motorcycle manufacturing, renowned for performance, innovation, and reliability.
Model Evolution
Sr500 Lineage:
The SR500 was introduced as a road-going version of Yamaha's successful off-road competition bikes, emphasizing a simple, robust, and torquey single-cylinder engine and traditional styling.
Production
Manufacturing Period:
1978-1983 (international markets), with various iterations and improvements during its production run.
Production Location:
Primarily Japan
🏆 Awards & Recognition
Recognitions
Model Recognition:
The SR500 is highly regarded for its enduring simplicity, reliable engine, and classic styling, making it a popular choice for custom builds and classic motorcycle enthusiasts.
Certifications
Manual Certification:
Represents factory-authorized repair and service information, providing authoritative guidance.
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