Yamaha SR500 SR 500 1975-1983 Repair Service Manual

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Typ: Motorcycle

Anbieter:

Art.-Nr: 66346

Stichworte: 1975 1976 1977 1978 1979 1980 1981 1982 1983 Motorcycle Motorcycles SR Models SR500 Yamaha

Produktvarianten

Beschreibung

This workshop service manual covers the motorcycle produced between 1975 and 1983. The SR500 is celebrated for its robust single-cylinder, 4-stroke engine, classic styling, and engaging riding experience. Known for its reliability and torque, this model has become an icon, appealing to riders who appreciate mechanical purity and a connection to the road. Its straightforward engineering, featuring a kickstart-only system and air-cooled engine, contributes to its enduring appeal and classic motorcycle status. This comprehensive English-language manual is designed for mechanical technicians and owners seeking detailed guidance on maintaining and repairing the SR500. It includes complete repair and overhaul procedures for the engine, transmission, fuel, ignition, lubrication, exhaust, electrical, and bodywork systems. The manual also covers routine maintenance, diagnostic procedures, tune-ups, and the use of special tools. Safety is a key focus, with emphasis on proper precautions and the correct use of torque wrenches, ensuring that repairs are performed safely and effectively.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

SR500

Model Designation:

SR 500

Product Name:

Yamaha SR500 SR 500 1975-1983 Repair Service Manual PDF Download

Codes

Chassis Code Variant:

SR500

👋 Introduction

Market Position

Target User Profile:

Owners and DIY enthusiasts looking for professional-level repair and maintenance guidance for their Yamaha SR500.

Competitive Analysis

Manual Competitiveness:

Provides the depth of information typically found in authorized dealer service manuals, enabling owners to perform complex repairs and maintenance themselves, saving on labor costs.

Key Features

Information Reliability:

Stated to provide the most reliable information, mirroring dealer service department resources.

Value Proposition:

Aims to help owners get the best value from their SR500 by facilitating informed maintenance and repairs.

Safety Emphasis:

Highlights the importance of safety equipment and precautions, including the use of torque wrenches.

Warning Symbols:

Utilizes specific wording and symbols (WARNING, CAUTION, NOTE) to denote critical information.

📋 Manual Details

Coverage Areas

Covered Years:

1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983

Page Count

Page Count:

Manual Type

Manual Type:

Workshop Service Manual

Primary Audience:

Mechanical Technicians

Language

Language:

English

Format

File Format:

Delivery Method:

Electronic (Email)

📖 Manual Coverage

Systems Covered

Engine:

Complete repair and overhaul, including disassembly and assembly of engine components.

Transmission:

Complete repair and overhaul, including disassembly and assembly of transmission components.

Fuel System:

Detailed procedures for repair, adjustment, and diagnosis of the fuel system.

Ignition System:

Coverage of ignition system maintenance, troubleshooting, and repair.

Lubrication System:

Information on lubrication system maintenance and repair procedures.

Exhaust System:

Maintenance and repair procedures for the exhaust system.

Electrical System:

Comprehensive coverage of the electrical system, including wiring diagrams and component diagnosis.

Bodywork:

Procedures related to the body, including removal and installation of body panels.

Procedures Included

Routine Maintenance:

Detailed instructions for routine maintenance and servicing.

Diagnostic Procedures:

Step-by-step diagnostic procedures for identifying and resolving issues.

Repair Procedures:

In-depth repair procedures for all major vehicle systems.

Overhaul:

Detailed overhaul procedures for major mechanical components.

Assembly Disassembly:

Instructions for the assembly and disassembly of various components and systems.

Tune Ups:

Specific procedures for performing tune-ups on the Yamaha SR500.

Proprietary Components:

Includes instructions for proprietary components, referencing manufacturer guidelines.

Special Tool Usage:

References and illustrations for Yamaha-specific tools required for adjustments and repairs.

Technical Depth

Depth:

Comprehensive coverage suitable for professional technicians, covering everything from routine maintenance to complete engine and transmission rebuilds.

Diagnostic Focus:

Emphasizes special aspects of the product for accurate diagnosis and repair.

📊 Manual Specifications

File Format

File Format Type:

Searchability:

Assumed to be searchable text within the PDF, typical for professionally created manuals.

Print Quality

Printability:

Recommended Print Quality:

High-quality printout for clarity of diagrams and text.

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, 4-stroke, SOHC

Displacement:

499 cc (30.4 cubic inches)

Bore X Stroke:

90.0 mm x 78.0 mm (3.54 in x 3.07 in) - *Typical for this model, confirm with manual*

Compression Ratio:

Approx. 8.4:1 - *Confirm with manual*

Performance

Horsepower:

Approx. 32-33 hp at 6,500 rpm - *Specific figures may vary by year/market, manual will clarify*

Torque:

Approx. 28.7 lb-ft at 5,000 rpm - *Specific figures may vary by year/market, manual will clarify*

Fuel System

Carburetor:

Single Mikuni VM34SC (or similar Mikuni model) - *Manual will specify exact model and jetting*

Fuel Type:

Unleaded gasoline

Lubrication System

Oil Type:

Yamalube SAE 20W-40 or equivalent motorcycle oil - *Manual will provide specific viscosity and API service classification*

Oil Capacity:

Approx. 2.0 liters (2.1 US qt) - *Manual will confirm capacity and filter change amount*

Cooling System

Cooling Method:

Air-cooled

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-disc

Features

Drive Type:

Chain drive

📐 Dimensions

Weights

Dry Weight:

Approx. 171 kg (377 lbs) - *Confirm with manual for specific year/trim*

Wet Weight:

Approx. 185 kg (408 lbs) - *Confirm with manual for specific year/trim, includes fluids*

Fuel Tank Capacity:

17 liters (4.5 US gallons) - *Confirm with manual*

🛡️ Safety Features

Ratings

Safety Features Overview:

The manual emphasizes safety precautions and the use of proper equipment, such as torque wrenches, indicating a focus on safe repair practices.

Active Features

Braking System Front:

Single disc brake - *Manual will detail specifications and maintenance*

Braking System Rear:

Drum brake - *Manual will detail specifications and maintenance*

Passive Features

Lighting System:

Coverage of headlight, taillight, and turn signal system maintenance and repair.

💡 Technology Features

Infotainment

Infotainment System:

Not applicable. The SR500 is a classic motorcycle focused on mechanical engagement, with no electronic infotainment systems.

Driver Assistance

Electronic Aids:

None. This is a purely mechanical motorcycle with no electronic rider aids.

Connectivity

Connectivity Features:

Not applicable. This motorcycle predates modern connectivity features.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 km (2,000-3,000 miles) or 6 months, whichever comes first - *Manual will provide definitive schedule*

Spark Plug Replacement:

Recommended at 10,000-15,000 km (6,000-9,000 miles) - *Manual will specify plug type and gap*

Valve Clearance Adjustment:

Typically at 5,000-10,000 km (3,000-6,000 miles) - *Crucial for single-cylinder engines, manual is essential for correct procedure and specs*

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4 - *Manual will specify exact type and replacement interval*

Transmission Oil Type:

Yamalube SAE 80W API GL-4 or equivalent - *Manual will provide specific type and capacity*

Known Issues

Common Issues Overview:

While generally robust, common areas of attention can include carburation tuning, occasional electrical gremlins (especially on older, unrestored models), and wear on wear-prone components like clutch plates or cam chains. The manual is critical for addressing these.

Kickstarter Reliability:

The SR500 famously features a kickstart-only system, which requires specific technique. The manual will provide guidance on its operation and maintenance.

📚 Vehicle History

Brand Heritage

Yamaha Motorcycles Legacy:

Yamaha has a long history of producing reliable and performance-oriented motorcycles, with the SR series being a significant part of their heritage, known for its classic styling and robust engineering.

Model Evolution

Sr500 Development:

The SR500 was introduced as a more road-oriented, single-cylinder machine, a contrast to the sportier twin-cylinder models, appealing to riders who appreciated simplicity, torque, and a classic riding experience. It was developed to cater to a growing segment of riders seeking a traditional motorcycle feel.

Production

Production Period:

1978-1999 (though this manual covers the initial 1975-1983 period, which includes the early and most popular iterations of the SR500 and its international variants).

Key Markets:

The SR500 was popular in North America, Europe, and Japan, with variations in specifications and styling across different markets.

🏆 Awards & Recognition

Recognitions

Model Reputation:

The Yamaha SR500 is highly regarded for its reliability, classic aesthetics, and strong torque, making it a popular choice for customization and a classic motorcycle icon.