Segment:
Dual-sport motorcycle, pioneering the 'thumper' segment with a focus on off-road capability and vintage appeal.
Competitors:
Honda XL500, Kawasaki KLR500 (later models), Suzuki DR500 (later models). The XT500 was often lauded for its torque and simple, robust design.
Features:
Kick-start only, large single-cylinder engine, strong low-end torque, spoked wheels, long-travel suspension, designed for both on-road and off-road use.
Covered Years:
1975, 1976, 1977, 1978, 1979, 1980, 1981
Type:
Workshop Service Manual / Repair Manual
Format:
PDF (Digital Download)
Engine:
Engine assembly, disassembly, tuning, lubrication, cooling system, fuel system (carburetor), exhaust system.
Transmission:
Clutch operation, gearbox disassembly and assembly, shift mechanism, lubrication.
Chassis:
Frame inspection and repair, suspension (front forks, rear shock absorbers), steering system, swingarm, wheel bearings.
Brakes:
Front disc brake system (caliper, master cylinder, fluid), rear drum brake system (shoe adjustment, linkages).
Electrical:
Ignition system (points, coil, spark plug), lighting system (headlight, taillight, turn signals), battery, charging system (stator, rectifier/regulator), wiring diagrams.
Fuel System:
Carburetor identification, disassembly, cleaning, adjustment (jetting, float level), fuel tank, petcock, fuel lines.
Maintenance:
Oil changes, filter replacement, spark plug checks, chain adjustment, brake adjustments, tire pressure checks, air filter cleaning/replacement.
Repair:
Engine rebuilds, transmission overhauls, carburetor rebuilding, brake system repairs, suspension component replacement, electrical component troubleshooting and replacement.
Troubleshooting:
Diagnostic procedures for common starting issues, running problems, electrical faults, and performance degradation.
Depth:
Comprehensive coverage from basic maintenance and adjustments to complete engine and transmission overhauls, including detailed component diagrams and specifications.
Engine Type:
Air-cooled, four-stroke, SOHC, single-cylinder
Displacement:
499 cc (30.45 cu in)
Bore X Stroke:
87.0 mm x 84.0 mm (3.43 in x 3.31 in)
Horsepower:
Approximately 30-32 hp @ 6,500 rpm (varies slightly by year/market)
Torque:
Approximately 27-28 lb-ft @ 5,000 rpm (varies slightly by year/market)
Carburetor:
Mikuni VM34SS (single, constant velocity)
Fuel Type:
Unleaded gasoline (min. 87 octane recommended)
Oil Capacity:
Approximately 2.0 liters (2.1 US qt)
Oil Type:
Yamalube 4 (or equivalent API SG, SAE 20W-40 or 10W-30 depending on climate)
Length:
Approximately 2,180 mm (85.8 in)
Width:
Approximately 830 mm (32.7 in)
Height:
Approximately 1,215 mm (47.8 in)
Dry Weight:
Approximately 147 kg (324 lbs)
Wet Weight:
Approximately 160 kg (353 lbs)
Fuel Tank Capacity:
11.0 liters (2.9 US gal)
Wheelbase:
1,415 mm (55.7 in)
Crash Safety:
N/A (Motorcycle, no standardized ratings as for cars)
Braking System:
Front: Disc brake; Rear: Drum brake.
Lighting:
Halogen headlight, taillight, brake light, turn signals.
Oil Change Interval:
Every 3,000 km (1,800 miles) or 6 months, whichever comes first.
Spark Plug Check Interval:
Every 3,000 km (1,800 miles)
Air Filter Cleaning Interval:
Every 3,000 km (1,800 miles), more frequently in dusty conditions.
Valve Clearance Check Interval:
Every 6,000 km (3,600 miles)
Chain Adjustment Interval:
Every 1,000 km (600 miles) or as needed.
Engine Oil Viscosity:
SAE 20W-40 or SAE 10W-30 (depending on ambient temperature)
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Fork Oil Type:
Yamalube Fork Oil (or equivalent SAE 10W)
Fork Oil Capacity:
Approximately 170-180 cc per fork leg (refer to manual for precise amount and level)
Common Problems:
Kick-starter mechanism wear, clutch cable adjustment, carburetor jetting sensitivity, potential for oil leaks from the engine case, electrical connections degradation over time.
Common Problems Details:
Owners often report difficulty starting due to the kick-start system if not properly maintained or initiated. Carburetor cleaning and proper jetting are crucial for optimal performance. The electrical system, particularly older wiring, may require inspection and repair.
Heritage:
Yamaha Motor Company's legacy in performance motorcycles, building on successful racing and street bike platforms.
Evolution:
Introduced in 1976, the XT500 was a groundbreaking dual-sport motorcycle. Its success paved the way for Yamaha's dominance in the off-road and dual-sport markets, leading to successors like the XT600 and Ténéré series.
Production Period:
1976-1981 (for the 500cc model covered by this manual). Later iterations of the XT line continued with larger displacements.
Manufacturing Location:
Japan
Industry Impact:
Widely recognized as an iconic dual-sport motorcycle that defined a generation. Praised for its ruggedness, torque, and versatility, making it a favorite for both adventure riding and desert racing.
Reviews:
Consistently receives high marks in vintage motorcycle reviews for its character and enduring design. Often cited in 'best dual-sport' lists from the 70s and 80s.
