Yamaha SR500 SR 500 1975-1983 Full Service Repair Manual

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Taper: Motorcycle

Distributeur:

UGS: 67734

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

Variantes de produits

Description

This manual covers the motorcycle, produced from 1975 through 1983. Known for its simple yet robust single-cylinder 4-stroke engine and classic styling, the motorcycle has garnered a reputation for reliability and is a popular platform for customization. Its design philosophy emphasizes a raw, engaging riding experience, making it a favorite among enthusiasts and a staple in the cafe racer and custom motorcycle scenes. The engineering quality reflects a commitment to durable and performance-oriented machines, offering a straightforward mechanical experience that appeals to riders seeking an authentic motorcycle connection. This comprehensive service repair manual provides detailed information essential for the maintenance and repair of your motorcycle. It covers all major systems, including the engine, fuel system, ignition, transmission, drivetrain, suspension, brakes, and electrical components. The manual includes routine maintenance procedures, in-depth troubleshooting guides, and step-by-step instructions for engine rebuilds and component overhauls. Technical specifications, wiring diagrams, and diagnostic procedures are also included, making this resource invaluable for professional technicians and experienced DIY mechanics alike. The English-language manual is presented in format, allowing for easy printing and accessibility for all users.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

SR500

Model Designation:

SR 500

Codes

Vin Decoder Prefix:

👋 Introduction

Market Position

Target Audience:

Professional motorcycle technicians, experienced DIY enthusiasts, and owners seeking comprehensive restoration and maintenance data for the Yamaha SR500.

Competitive Analysis

Value Proposition:

Provides the same in-depth information used by professional technicians, enabling users to perform virtually any repair or maintenance task on their SR500, saving time and money compared to shop labor.

Key Features

Clarity Of Instructions:

Features numbered instructions, detailed illustrations, and enlarged insets for precise component identification and procedural guidance.

Diagnostic Integration:

Combines troubleshooting guides with detailed wiring diagrams for efficient electrical system diagnostics.

Accessibility:

Instant download format eliminates shipping costs and delivery delays, making critical repair information immediately available.

📋 Manual Details

Coverage Areas

Model Years:

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

Page Count

Estimated Pages:

N/A (Digital PDF, typically extensive)

Manual Type

Type:

Full Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Detailed inspection, disassembly, assembly, troubleshooting, and repair of the SR500's single-cylinder engine.

Fuel System:

Carburetor (Mikuni VM series) overhaul, adjustment, fuel pump, fuel lines, and fuel tank maintenance.

Ignition System:

CDI (Capacitor Discharge Ignition) system diagnostics, spark plug specifications, timing adjustments, and component testing.

Transmission:

Clutch operation, gearbox disassembly and reassembly, gear inspection, and transmission oil specifications.

Drivetrain:

Chain drive maintenance, sprockets, and final drive lubrication.

Suspension:

Front fork overhaul, oil levels, seals, and rear shock absorber adjustment and replacement.

Brakes:

Front disc brake system (caliper, master cylinder, disc inspection, fluid flush) and rear drum brake adjustment.

Electrical System:

Wiring diagrams, lighting system, battery maintenance, charging system (alternator/stator), starter motor, and fuses.

Chassis And Frame:

Frame inspection, steering head bearing adjustment, and general chassis maintenance.

Bodywork And Trim:

Fuel tank, seat, fenders, and other body panels installation and removal.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustments, brake checks, tire pressure, and general lubrication schedules.

Troubleshooting:

Comprehensive troubleshooting guides for common starting, running, and electrical issues.

Engine Rebuild:

Detailed steps for complete engine disassembly, piston and cylinder inspection, valve adjustments, and reassembly.

Carburetor Tuning:

Step-by-step instructions for cleaning, rebuilding, and jetting the Mikuni carburetor for optimal performance.

Electrical Diagnostics:

Testing of ignition components, charging system output, and troubleshooting using wiring diagrams.

Suspension Overhaul:

Front fork seal replacement, damping rod inspection, and rear shock servicing.

Brake System Maintenance:

Bleeding procedures, pad replacement, and master cylinder seal replacement.

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and experienced DIY mechanics aiming for full restoration or advanced repairs.

Diagnostic Capabilities:

Detailed diagnostic procedures, including voltage, resistance, and continuity testing.

Rebuild Procedures:

Full engine and component rebuild instructions, including torque specifications and clearances.

📊 Manual Specifications

File Format

Format:

Print Quality

Printability:

Full Printable - All pages can be printed.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

Delivery

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader, WinRAR

Compatibility

Operating Systems:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, Air-cooled Single Cylinder

Displacement:

499 cc (30.4 cu in)

Bore X Stroke:

92.0 mm x 75.0 mm (3.62 in x 2.95 in)

Compression Ratio:

8.5:1 (typically, may vary slightly by year)

Valve Train:

SOHC (Single Overhead Camshaft), 2 valves per cylinder

Performance

Horsepower:

Approx. 32-34 HP @ 6,500 RPM (varies by year and market regulations)

Torque:

Approx. 28-30 lb-ft @ 5,000 RPM (varies by year)

Fuel System

Carburetor:

Mikuni VM34 (typically) or similar, single slide carburetor

Fuel Type:

Unleaded gasoline

Lubrication

Oil Capacity:

Approx. 2.4 liters (2.5 quarts) with filter change

Oil Type:

Yamaha recommends SAE 20W-40 or 10W-30 API SE or SF class motorcycle oil.

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Features

Clutch Type:

Wet, multi-plate

Final Drive:

Chain

📐 Dimensions

Weights

Dry Weight:

Approx. 171 kg (377 lbs)

Wet Weight:

Approx. 187 kg (412 lbs) (estimate)

🛡️ Safety Features

Ratings

Safety Features:

Robust braking system for its era, stable chassis design.

Active Features

Active Safety:

Effective front disc brake, responsive handling.

Passive Features

Passive Safety:

Steel tube frame, basic rider protection features.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Mechanical motorcycle of its era).

Driver Assistance

Driver Assistance Features:

N/A (Mechanical motorcycle).

Connectivity

Connectivity Features:

N/A (Mechanical motorcycle).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 km (1,800 miles) or 6 months, whichever comes first.

Valve Clearance Check:

Every 6,000 km (3,600 miles) or annually.

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after washing/riding in rain.

Spark Plug Replacement:

Refer to manual, typically every 10,000-15,000 km (6,000-9,000 miles).

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4, per manual recommendation.

Fork Oil:

Yamalube Fork Oil (or equivalent 10W or 15W, check manual for specific grade).

Known Issues

Kickstart Return Spring:

Can occasionally wear or break, leading to a non-returning kickstart lever.

Carburetor Tuning:

Mikuni VM series can be sensitive to altitude and air filter changes, requiring periodic adjustment.

Oil Leaks:

Common with aging motorcycles; often from valve cover gasket, pushrod seals, or base gasket.

Ignition Coil:

Can fail over time, affecting spark.

📚 Vehicle History

Brand Heritage

Heritage:

Yamaha's reputation for building reliable and performance-oriented motorcycles, particularly known for their Thumper engines.

Model Evolution

Evolution:

The SR500 was developed as a simple, robust, and stylish single-cylinder motorcycle, drawing inspiration from classic British designs while incorporating Japanese engineering. It served as a platform for customization and was popular for its raw, visceral riding experience.

Production

Production Period:

1978-1999 (with variations across markets and specific models like SR400).

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Street Credibility:

Highly regarded in the custom and cafe racer scene for its minimalist design and customization potential.

Ratings

Reliability Rating:

Generally considered robust and reliable when properly maintained, a testament to Yamaha's build quality of the period.