Yamaha SR500 SR 500 1975-1983 Workshop Service Manual Repair

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The SR500, also known as the SR 500, is a classic motorcycle produced from 1975 to 1983. Renowned for its minimalist design and emphasis on rider engagement, the SR500 features...

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Tipo: Motorcycle

Proveedor:

SKU: 69986

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

Variantes de producto

Descripción

The SR500, also known as the SR 500, is a classic motorcycle produced from 1975 to 1983. Renowned for its minimalist design and emphasis on rider engagement, the SR500 features a 499 cc, 4-stroke, single-cylinder, air-cooled engine, delivering approximately 32-35 HP. Its robust, single downtube cradle frame and kickstart-only operation contribute to its authentic, classic riding experience. The SR500 is celebrated for its character, reliability when properly maintained, and its status as a cult classic, making it a popular choice for customization. This comprehensive workshop service manual provides detailed information for the SR500 models from 1975 through 1983. It covers routine maintenance, detailed repair and overhaul procedures for all major systems including the engine, fuel, ignition, transmission, clutch, chassis, braking, and electrical systems. The manual also includes troubleshooting guides, technical specifications, and wiring diagrams, offering professional technician-level detail for advanced DIY mechanics and owners. This resource is essential for maintaining the SR500's performance and ensuring its longevity.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

SR500

Model Alias:

SR 500

Product Name:

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

Generation

Covered Years:

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

👋 Introduction

Market Position

Target Audience:

Professional technicians, DIY mechanics, and SR500 owners seeking detailed service information.

Competitive Analysis

Manual Value Proposition:

Provides essential, accurate information for maintaining and repairing the Yamaha SR500, saving on dealership service costs.

Key Features

Instant Access:

Immediate download eliminates shipping costs and delays.

Print On Demand:

Ability to print specific sections for workshop use, keeping the digital original clean.

Accuracy Completeness:

Represents original manufacturer data, ensuring the highest level of accuracy.

📋 Manual Details

Coverage Areas

General Coverage:

Routine maintenance, repairs, troubleshooting, overhaul procedures, periodic maintenance charts.

Page Count

Estimated Page Count:

Hundreds of pages (as stated in product description)

Manual Type

Primary Manual Type:

Workshop Service Manual / Repair Manual

Secondary Manual Types:

Service Manuals, Workshop Manuals, Factory Service Manual, Full Service Repair Manual

Language

Language:

English

Format

Delivery Method:

Instant Download

File Format:

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine overhaul, disassembly, assembly, tuning, lubrication, cooling system (if applicable).

Fuel System:

Carburetor (Teikei Y20P or similar) tuning, maintenance, and repair, fuel tank, fuel lines.

Ignition System:

CDI ignition system, spark plugs, coils, timing.

Transmission Clutch:

Clutch operation, adjustment, replacement, transmission overhaul and maintenance (5-speed).

Chassis Frame:

Frame inspection, alignment, suspension (front forks, rear shock absorber) maintenance and overhaul.

Braking System:

Front disc brake system (caliper, master cylinder, rotor) and rear drum brake maintenance, adjustment, and overhaul.

Electrical System:

Wiring diagrams, lighting system, battery, charging system (alternator/stator, regulator/rectifier), starting system, instrumentation.

Exhaust System:

Exhaust pipe and muffler maintenance, inspection.

Wheels Tires:

Wheel bearing maintenance, tire pressure, spoke tension (for spoked wheels).

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, brake adjustments, spark plug checks, air filter cleaning/replacement.

Repair Instructions:

Step-by-step guides for all major component repairs and replacements.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting.

Overhaul Procedures:

Detailed instructions for complete engine, transmission, and suspension rebuilds.

Wiring Diagrams:

Comprehensive electrical system schematics.

Technical Depth

Depth Level:

Professional technician level, with sufficient detail for advanced DIY mechanics.

Diagnostic Capabilities:

Advanced diagnostics, including electrical system troubleshooting and component testing.

📊 Manual Specifications

File Format

File Type:

Print Quality

Printability:

Full Printable

Viewability:

Zoom IN/OUT functionality

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Software Requirements

PDF Reader:

Adobe PDF Reader

Extraction Tool:

WinRAR

Compatibility

Operating Systems:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, single-cylinder, air-cooled

Displacement:

499 cc

Bore X Stroke:

87.0 mm x 84.0 mm

Compression Ratio:

8.4:1 (typical for early models, may vary)

Performance

Horsepower:

Approx. 32-35 HP @ 6,000 RPM (depending on model year and tuning)

Torque:

Approx. 39-42 Nm @ 5,000 RPM (depending on model year and tuning)

Fuel System

Carburetor Type:

Single Teikei Y20P (or similar model dependent specification)

Fuel Type:

Unleaded gasoline

Lubrication

Oil Type Specification:

Yamaha recommends SAE 20W-40 SE grade oil (or equivalent API SE, SF, SG).

Oil Capacity:

Approx. 2.4 Liters (including filter, with oil change)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Optional

Optional Transmission:

N/A (SR500 was exclusively 5-speed)

Features

Clutch Type:

Wet, multi-plate

Final Drive:

Chain drive

Maintenance

Transmission Oil Type:

Yamalube SAE 80 API GL-4 or equivalent

Transmission Oil Capacity:

Approx. 0.7 Liters

📐 Dimensions

Exterior

Length:

Approx. 2185 mm

Width:

Approx. 810 mm

Height:

Approx. 1165 mm

Wheelbase:

Approx. 1445 mm

Weights

Dry Weight:

Approx. 170 kg (varies slightly by year)

Wet Weight:

Approx. 184 kg (with fluids)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle safety is typically not rated by agencies like NHTSA)

Active Features

Braking System Type:

Front: Disc; Rear: Drum

Lighting:

Halogen headlamp, tail lamp, turn signals

Passive Features

Frame Construction:

Steel single downtube cradle frame

💡 Technology Features

Infotainment

Infotainment System:

N/A (Minimalist design, focus on mechanicals and riding experience).

Driver Assistance

Driver Assistance Features:

N/A (No electronic rider aids like ABS, traction control)

Connectivity

Connectivity Features:

Instrumentation

Dashboard Features:

Analog speedometer, analog tachometer, neutral indicator, high-beam indicator, turn signal indicators.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 km or 6 months (whichever comes first), depending on usage and conditions.

Spark Plug Check Interval:

Every 3,000 km or 6 months.

Valve Clearance Check Interval:

Every 6,000 km or 12 months.

Carburetor Sync Adjust Interval:

As needed, or every 6,000-12,000 km, or if engine performance degrades.

Fluid Specifications

Engine Oil Viscosity:

SAE 20W-40 SE

Brake Fluid Type:

DOT 3 or DOT 4 (check specific year specification, typically for front disc brake master cylinder).

Fork Oil Type:

Yamaha Fork Oil 10W or equivalent (check manual for exact viscosity and volume per fork leg).

Known Issues

Common Wear Items:

Clutch plates, valve guides/seals, carburetor jets/float needle, kickstart mechanism wear, stator/rotor failures, charging system components.

Typical Problems:

Difficulty starting (due to kickstart), carburation issues, oil leaks from the pushrod seals, electrical system gremlins on older units.

📚 Vehicle History

Brand Heritage

Manufacturer Focus:

Yamaha Motor Company, known for its diverse range of motorcycles and musical instruments, with a strong reputation for innovation and performance.

Model Evolution

Sr500 Heritage:

The SR500 was designed as a minimalist, classic-styled motorcycle, emphasizing simplicity, torque, and rider engagement. It was a revival of the single-cylinder thumper ethos.

Key Innovations Sr500:

Single-cylinder engine with counterbalancer, kickstart-only operation (a deliberate choice for simplicity and classic feel), leading axle front forks.

Production

Production Period:

1978–1999 (though this manual covers up to 1983 models)

Major Market Entry:

🏆 Awards & Recognition

Recognitions

Motorcycle Reputation:

Highly regarded for its character, reliability (when maintained), and classic appeal. Often considered a cult classic and a great platform for customization.

Ratings

Customer Satisfaction:

Generally high for owners who appreciate its vintage feel and mechanical simplicity. Prone to issues if neglected.

Certifications

Manual Quality:

Official Yamaha factory service manual content, ensuring high standards of technical accuracy and completeness.