Yamaha RD500 RD500LC 1984-1985 Workshop Service Repair Manual

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The Yamaha RD500LC, also known as the RZ500 in North America, is a legendary sportbike produced between 1984 and 1985. This 499cc, liquid-cooled, 2-stroke V4 engine motorcycle was engineered to...

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Typ: Motorcycle

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Art.-Nr: 66157

Stichworte: 1984 1985 Marine Motorcycle RD500 RD500LC Sterndrive Yamaha

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Beschreibung

The Yamaha RD500LC, also known as the RZ500 in North America, is a legendary sportbike produced between 1984 and 1985. This 499cc, liquid-cooled, 2-stroke V4 engine motorcycle was engineered to compete at the highest level, leveraging racing technology. It features an aluminum alloy twin-spar frame, dual front disc brakes, a rear disc brake, and advanced TCI front forks paired with a Monoshock rear suspension. Renowned for its potent mid-range power and aggressive top-end delivery, the RD500LC was a premium, high-performance machine that captured the spirit of 1980s motorcycle racing and remains a highly sought-after collector's item. This comprehensive workshop service repair manual provides detailed information for the Yamaha RD500LC (chassis codes 47X and 51X). It covers all aspects of maintenance, diagnostics, and repair, including in-depth procedures for the engine mechanicals, electrical systems, fuel system, cooling, transmission, suspension, brakes, steering, wheels, tires, and bodywork. The manual includes step-by-step instructions, detailed illustrations, diagrams, wiring schematics, and critical specifications such as torque values and fluid requirements. Its scope extends to routine maintenance, major repairs, and electrical system troubleshooting, making it an indispensable resource for owners and technicians aiming to maintain and restore this iconic motorcycle.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

RD500LC

Model Nickname:

RZ500 (North American designation)

Production Years Covered:

1984-1985

Codes

Chassis Code:

47X (RD500LC), 51X (RZ500)

👋 Introduction

Market Position

Positioning:

A premium, high-performance sportbike of its era, often referred to as a 'homologation special' for racing.

Competitive Analysis

Competitors:

Suzuki RG500 Gamma, Honda NS400R, Kawasaki KR-1S.

Key Features

Engine Configuration:

Liquid-cooled, 499cc, 2-stroke, V4 engine with reed valve induction.

Power Delivery:

Known for its potent mid-range power and aggressive top-end delivery.

Chassis Design:

Aluminium alloy twin-spar frame for rigidity.

Braking System:

Dual front disc brakes and a rear disc brake.

Suspension:

TCI (Tone-Controlled Ignition) front forks and a Monoshock rear suspension.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Workshop Service Repair

Secondary Coverage:

Troubleshooting, diagnostics, maintenance, repair

Page Count

Estimated Page Count:

Varies by specific print, but comprehensive coverage implies hundreds of pages.

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed disassembly, inspection, assembly, and tuning of the 2-stroke V4 engine.

Engine Electrical:

Ignition system, charging system, CDI, wiring diagrams, component testing.

Fuel System:

Carburetor overhaul, tuning, fuel tank, fuel lines, fuel pump.

Cooling System:

Radiator, water pump, thermostat, coolant flow diagrams.

Transmission:

Gearbox disassembly, inspection, repair, clutch operation and adjustment.

Suspension Front:

Front fork (TCI-equipped) disassembly, servicing, oil specifications, damping adjustments.

Suspension Rear:

Monoshock rear suspension servicing, linkage maintenance, shock absorber adjustments.

Brakes Front:

Disc brake system, caliper overhaul, pad replacement, bleeding procedures.

Brakes Rear:

Disc brake system, caliper overhaul, pad replacement, bleeding procedures.

Steering:

Handlebar assembly, steering head bearing maintenance and adjustment.

Wheels And Tires:

Wheel bearing maintenance, tire inspection, pressure recommendations.

Body And Frame:

Fairing removal, bodywork components, frame inspection.

Electrical System Component:

Lighting, instrumentation, switches, horn, battery maintenance.

Emission Control:

Information on emission control systems (if applicable to specific market variants).

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug servicing, lubrication points.

Troubleshooting:

Diagnostic flowcharts and common problem identification for engine, electrical, and chassis.

Major Repairs:

Engine rebuilds, transmission overhauls, suspension component replacement, carburetor synchronization.

Electrical Diagnosis:

Step-by-step electrical system troubleshooting using wiring diagrams.

Specifications And Torque:

Detailed torque values for fasteners, engine clearances, and fluid capacities.

Technical Depth

Depth:

Comprehensive; suitable for both DIY enthusiasts and professional mechanics.

Detail Level:

Step-by-step instructions, detailed illustrations, diagrams, and wiring schematics.

📊 Manual Specifications

File Format

Format:

Features:

Zoom IN/OUT capability, searchable text (if OCR'd).

Print Quality

Printability:

Fully Printable

Binding Type

Binding:

Digital (PDF)

Paper Type

Digital Format:

Electronic document optimized for viewing and printing.

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, V4, liquid-cooled

Displacement:

499 cc (30.45 cu in)

Bore X Stroke:

54.0 mm x 54.5 mm (2.13 in x 2.15 in)

Compression Ratio:

7.2:1 (approximate)

Valve Mechanism:

Reed valve induction

Performance

Horsepower Rating:

Approx. 87 hp @ 9,500 rpm (European spec, may vary by market)

Torque Rating:

Approx. 68 Nm (50 lb-ft) @ 8,000 rpm (approximate)

Top Speed:

Approx. 220 km/h (137 mph)

Fuel System

Carburetors:

4 x Mikuni VM26SS or similar, butterfly-valve type with T.C.I. control.

Fuel Type:

Unleaded gasoline (Premium unleaded recommended), 2-stroke oil pre-mix or Autolube system.

🔧 Transmission

Standard

Type:

6-speed constant mesh

Optional

Availability:

N/A (Standard 6-speed manual)

Features

Clutch Type:

Wet, multi-disc

📐 Dimensions

Exterior

Length:

Approx. 2155 mm (84.8 in)

Width:

Approx. 745 mm (29.3 in)

Height:

Approx. 1210 mm (47.6 in)

Wheelbase:

Approx. 1440 mm (56.7 in)

Weights

Dry Weight:

Approx. 193 kg (425 lbs)

Wet Weight:

Approx. 206 kg (454 lbs)

Fuel Capacity:

21 liters (5.5 US gal)

🛡️ Safety Features

Ratings

Crash Test Data:

N/A for motorcycles of this era. Focus is on rider protection through design and maintenance.

Active Features

Braking:

Dual front discs and single rear disc provide strong stopping power for the era.

Handling:

Rigid frame and advanced suspension contribute to stable handling characteristics.

Passive Features

Lighting:

Dual headlights for improved visibility.

💡 Technology Features

Infotainment

Features:

N/A (This is a 1980s sportbike, no modern infotainment systems).

Driver Assistance

Features:

N/A (This is a 1980s sportbike, no modern driver assistance systems).

Connectivity

Features:

N/A (This is a 1980s sportbike, no modern connectivity features).

Engine Management

Ignition System:

Yamaha Computer Controlled Ignition (TCI) with electronic advance and retard, often with power valve control.

🔧 Maintenance

Service Intervals

Oil Change Engine:

Refer to manual; typically every 3,000-5,000 km or annually.

Spark Plugs:

Inspection every 2,000-3,000 km, replacement as needed (e.g., NGK B8ES, BR8ES, or equivalent).

Chain Lubrication Adjustment:

Every 500-1,000 km, or as per manual's recommendation.

Fluid Specifications

Engine Oil Type:

High-quality 2-stroke motorcycle oil (e.g., Yamalube 2R or equivalent).

Coolant Type:

Ethylene glycol based coolant, diluted with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Fork Oil Type:

Specific viscosity fork oil as per manual (e.g., SAE 10W).

Known Issues

Engine Carbon Buildup:

Common in 2-stroke engines, requiring periodic decarbonization of exhaust ports and power valves.

Carburetor Synchronization:

Crucial for smooth running due to four carbs; requires periodic checks.

Electrical Connections:

Age-related degradation of wiring and connectors can lead to intermittent electrical issues.

Power Valve Sticking:

Carbon buildup can cause power valves to stick, affecting performance.

📚 Vehicle History

Brand Heritage

Yamaha Legacy:

Yamaha has a strong heritage in two-stroke performance and racing, particularly with its 'R' series sportbikes.

Model Evolution

Development Context:

Developed to compete with other manufacturers' V4 500cc 2-stroke sportbikes, leveraging Yamaha's Grand Prix racing technology.

Design Philosophy:

Concentrated on delivering immense power and sharp handling, mirroring its racing counterparts.

Production

Production Period:

1984-1985. Considered a relatively short production run but highly impactful.

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Historical Acclaim:

Highly regarded as one of the most potent and exciting 500cc two-strokes of its era, a homologation special for racing.

Collectible Status:

It is now a highly sought-after collector's item among motorcycle enthusiasts.