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Yamaha Books & Manuals
Road and Race Motorcycles
European Cafe Racer Specialists - Ducati, Laverda, Moto Guzzi, MV Agusta... Spare Parts and Restorations
| SR 500 1978-79 |  |
| 1978 | 1979 | |
| Model:
I.B.M. No. Frame I.D. and starting number Engine I.D. and starting number |
2J2 2J2-000101 2J2-000101 |
2J2-020101
2J2-020101 |
| Dimensions:
Overall length Overall width (standard) Overall height (standard) Wheel base Minimum ground clearance |
2,105 mm (82.9 in) 835 mm (32.9 in) 1,150 mm (45.3 in) 1,410 mm (55.5 in) 165 mm (6.5 in) |
|
| Weight:
Net weight |
163 kg (359 lbs) |
|
| Performance:
Climbing ability Minimum turning radius Braking distance |
30 deg 2,400 mm (94.5 in) 14 m (45.9 ft) at 50km/h (31 mph) |
| Description:
Engine type Engine model Displacement Bore x Stroke Compression Ratio Starting system Ignition system Lubrication system |
Air cooled 4-stroke, forward incline, single, S.O.H.C. 2J2 499 cc (30.45 cu. in.) 87 x 84 mm (3.425 x 3.307 in) 9.0 : 1 Primary kick starter C.D.I. Dry sump, trochoidal pump |
| Cylinder Head:
Combustion chamber type Combustion chamber volume (with BP7ES or N-7Y) Head gasket thickness |
Hemispherical 62.4 cc (3.81 cu. in.)
|
| Camshaft:
Cam drive type Camshaft bearing type (left) Camshaft bearing type (right) Cam chain type and No. of links |
Drive chain (right side drive) 6005C3 6005C3 (with groove) BF05M, 106L |
|
Cam dimensions: A (Cam Height) IN. A (Cam Height) EX. B (Base circle) IN. B (Base circle) EX. C (Cam lift) IN.
Intake open
Valve overlapIntake close Duration Exhaust open Exhaust close Exhaust duration |
required <allowable> 39.23 +or- .05 mm <39.08 mm> (1.5445 +or- .0020 in <1.5386 in>) 39.25 +or- .05 mm <39.10 mm> (1.5453 +or- .0020 in <1.5394 in>) 32.23 +or- .05 mm <32.08 mm> (1.2689 +or- .0020 in <1.2630 in>) 32.28 +or- .05 mm <32.08 mm> (1.2709 +or- .0020 in <1.2630 in>) 7.225 mm (.2844 in) 7.253 mm (.2856 in) <0.1 mm (.0039 in)> BTDC 44 deg
|
| Rocker arm and rocker shaft:
Rocker arm bearing dia. (I.D.) Rocker arm shaft dia. (O.D.) Clearance |
required <allowable>
12.00~12.02 mm <12.05 mm> (.4724~.4732 in <.4744 in>) 11.98~11.99 mm <11.96 mm> (.4714~.4720 in <.4709 in>) .01~.04 mm <.11 mm> (.0004~.0016 in <.0043 in>) |
| Valve, valve seat and valve guide:
Valve clearance (cold): IN. Valve clearance (cold): EX. No. of valves per cylinder: Valve head dia. (A): IN.
Valve stem to guide clearance: EX. |
required <allowable>
.10 mm (.0039 in) .15 mm (.0059 in) 2 pcs 47 mm (1.85 in)
|
| Valve springs:
Free length: Inner Free length: Outer Spring rate: Inner Spring rate: Outer Installed length (valve closed): Inner
|
required <allowable>
45.3 mm <43.9 mm> (1.783 in <1.728 in>) 44.6 mm <43.3 mm> (1.756 in <1.703 in>) K1= 1.67, K2 = 2.12 [kg/mm] (K1 = 93.5, K2 = 119 [lb/in]) K1 = 3.60, K2 - 4.63 [kg/mm] (K1 = 202, K2 = 259 [Ib/in]) 38.0 mm (1.496 in) 40.0 mm (1.575 in) 12.2 kg (26.9 lb) 16.4 kg (36.2 lb) 28.0 mm (1.102 in) 30.0 mm (1.181 in) 33.4 kg (73.6 lb) 62.7 kg (138.2 lb) 3.1 mm (.122 in) 4.4 mm (0.173 in) 23.4 mm (.921 in) 32.9 mm (1.295 in) 1.97 mm (.0776 in) 1.97 mm (.0776 in) |
| Cylinder:
Material Bore size Taper limit
|
required <allowable>
Aluminum alloy with cast iron sleeve 87.00 ~87.02 mm <87.1 mm> (3.4252 ~3.4260 in <3.429 in>) <.05 mm> (<.0020 in>) <.01 mm> (<.0004 in>) |
| Piston:
Piston clearance Piston clearance measuring position (from piston skirt bottom) Piston pin bore size Piston pin outside diameter Piston pin length
|
required <allowable>
.050 ~ .055 mm (.0020 ~ .0022 in) 7.2 mm (.283 in)
|
| Piston ring:
Piston ring design: Top ring Piston ring design: 2nd ring Piston ring design: Oil ring Ring end gap (installed): Top ring Ring end gap (installed): 2nd ring Ring end gap (installed): Oil ring
Ring groove side clearance: 2nd ring Ring groove side clearance: Oil ring
|
required <allowable>
Plain ring Plain ring Oil ring with expander .3 ~ .5 mm <0.8 mm> (.012 ~ .020 in <.030 in>) .3 ~ .5 mm <.8 mm> (.012 ~ .020 in <.031 in>) .2 ~ .9 mm <1.0 mm> .04 ~ .08 mm <.15 mm> (.0016 ~ .0031 in <.0059 in>) .03 ~ .07 mm <.15 mm> (.0012 ~ .0028 in <.0059 in>) N.A. 87.25 mm (3.4350 in) 87.50 mm (3.4449 in) 87.75 mm (3.4547 in) 88.00 mm (3.4646 in) |
| Big end bearing:
Type Inside dia. x outside dia. x width Needle dia. x quality |
Needle bearing 34 x 42 x 24 mm (1.34 x 1.65 x .94 in) IKO 4 mm (.16 in) x 18 pcs KOYO 4 mm (.16 in) x 17 pcs. |
| Crankshaft:
Crankshaft assembly width (F) Crankshaft deflection ( D ) Connecting rod large end side clearance (C) Connecting rod small end deflection (P) Crank pin outside dia. x length
|
required <allowable>
74.95 ~ 75.00 mm (2.9508 ~ 2.9528 in) <.03 mm (.0012 in) or less> .35 ~ .65 mm (.0138 ~ .0256 in) .8 ~ 1.0 mm <2.0 mm> (.0315 ~ .0394 in <0.079 in>) 34 x 74 mm (1.34 x 2.91 in) 6306 SH2-9-C4 6307 SH2-9-C4 with special heat treatment SD-30-60-6 S-14-25-5.5 special |
| Clutch:
Clutch type Clutch push mechanism Primary reduction ratio and method Primary reduction gear back lash number Primary drive gear back lash number Primary driven gear back lash number Friction plate: Thickness/quantity Clutch plate: Thickness/quantity
Clutch spring: Spring set weight
|
required <allowable>
Wet, multiple disc type Inner push, cam axle type 77/30 (2.566), spur gear 148 ~ 150 21.79 +0 -.04 mm (4 Teeth) 52.71 +0 -.04 mm (9 Teeth) 2.8 mm <2.5 mm> /8 pcs. (.110 in <.098 in> /8 pcs.) 1.2 mm /7 pcs. (.047 in /7 pcs.) <.05 mm (.0020 in)> 41.2 mm <40.0 mm> /6 pcs. (1.622 in <1.575 in> /6 pcs.) 19.8 x 6 kg/25 mm (43.7 6 lb/.984 in) 1.22 kg/mm (68.3 lb/in) .10 ~ .21 mm (.004 ~ .008 in) <.2 mm (.0079 in) or less> Needle bearing (17-21.5-15) x 2 pcs. SD-17-28-6 |
| Transmission:
Type Gear ratio: 1st Gear ratio: 2nd Gear ratio: 3rd Gear ratio: 4th Gear ratio: 5th Bearing type: Main axle (Left) Bearing type: Main axle (Right) Drive axle (Left) Drive axle (Right) Drive axle (Left) Secondary reduction ratio and method |
Constant mesh. 5 speed 33/14 (2.357) 28/18 (1.555) 25/21(1.190) 22/24 (0.916) 21/27 (0.777) Needle bearing (20-32-12) 4205 6305 special Needle bearing (20-36-12) SD-35-62-10 44/16 (2.750), chain |
| Shifting mechanism:
Operation system Shifting type Oil seal type: Change lever |
Return type, left foot operation Guide bar type, cam drum system SDO-14-24-6 |
| Kick starter:
Type Oil seal type Kick axle |
Ratchet type SD-25-35-7 |
| Compression release:
Type Lever free play Oil seal type |
Manual, wire linked cam axle type 2 mm (.079 in) SD-12-17-2.5-2NR |
| Air cleaner:
Type/quantity |
Dry foam rubber / l pc. |
| Carburetor:
Type and manufacturer I.D. mark Main jet (M.J.) Airjet (A.J.) Jet needle: Clip position (J.N.) Needle jet (N.J.) Cutaway (C.A.) Pilot jet (P.J.) Mixture screw turns out Starter jet (G.S.) Float height Idling engine speed |
VM34SS MIKUNI 2J200 #300 #80 6FL25-2 P-8 3.5 #25 Preset #50 23.5 +or- 1 mm (.925 +or- .039 in) 1100 r/min |
| Lubrication:
Transmission gear and engine sump oil Quantity Type engine oil
Oil pump: Housing depth (delivery) Oil pump: Housing depth (scavenger) Oil pump: Rotor diameter Oil pump: Rotor thickness (delivery)
Side clearance Tip clearance Check valve opening pressure
|
required <allowable>
Total amount: 2.4 lit (2.5 US.qt) (2.11 Imp. qt) Periodic oil change: 2.0 lit (2.1 US.qt) (1.76 Imp. qt) Exchange with oil filter: 2.1 lit (2.2 US.qt) 1.85 IMP.qt) Yamalube 20W / 40 motor oil or equivalent Trochoidal pump 40.65 ~ 40.68 mm <40.85> (1.6004 ~ 1.6016 <1.6083 in>) 4.03 ~ 4.06 mm <4.09 mm> (.1587 ~ .1598 in <.1610 in>) 18.03 ~ 18.06 mm <18.09 mm> (.7098 ~ .7118 in <0.7122 in>) 40.53 ~ 40.56 mm <40.50 m> (1.5957 ~ 1.5968 in <1.5945 in>) 3.98 ~ 4.00 mm <3.95 mm> (.1567 ~ .1575 in <.1555 in>) 17.98 ~ 18.00 mm <17.95 mm>) .09 ~ .15 mm <.35 mm> (.0035 ~ .0059 in <.0138 in>) .03 ~ .08 mm <0.14 mm> (.0012 ~ .0031 in <.0055 in>) .07 ~ .12 mm <.35 mm> (.0028 ~ .0047 in <.00138 in>) .18 kg/cm2 (2.56 lb/in2) 1.0 kg/cm2 (14.2 lb/in2) Paper type |
Chassis specification (Top)
| Frame:
Frame design |
Tubular steel semi double cradle |
| Steering system:
Caster Trail Steering head ballbearings: Upper race
Lock to lock angleLower race |
27.5 deg (62.5 deg) 117 mm (4.6 in) 22 pcs. 3/16 in
|
| Front suspension:
Type Front fork cushion travel Front fork spring:
Inner tube outside diameter
|
Telescopic forks 150 mm (5.9 in) 445 mm (17.52 in)
35 mm (1.38 in)
|
| Rear suspension:
Type Damper type Rear shock absorber travel Rear wheel travel Rear shock absorber spring: Free length Set length (soft position) Wire dia. x winding dia. Spring constant Swing arm free play (limit)
|
required <allowable>
Swing arm Coil spring, oil damper 80 mm (3.15 in) 110 mm (4.33 in) 216.5 mm (8.52 in)
|
| Fuel tank:
Capacity Fuel grade |
12 lit (3.2 US.Gal) (2.6 IMP.gal) Regular gasoline |
| Wheel:
Type Tire size and pattern: Front Tire size and pattern: Rear Rim type: Front Rim type: Rear Rim runout (limit): Front/Rear Rim hopping (limit): Front/Rear Bearing type: Front wheel (Left) Front wheel (Right) Rear wheel (Left) Rear wheel (Right) Oil seat type: Front wheel ( Left) Front wheel (Right) Meter gear Rear wheel (Left) Rear wheel (Right) Secondary drive chain: Type Number of links Chain pitch Chain free play |
required <allowable>
Casting wheel 3.50-S19-4PR. lug type 4.00-S18-4PR. lug type 1.85-19 / Aluminum 2.15-18 / Aluminum <2 mm> (<.08 in>) <2 mm> (<.08 in>) 6303ZZ
..................
DID 50 HDSS
|
| Brakes:
Type Disc size (Outside dia x thickness) Front Rear Disc wear/limit Disc pad thickness Pad wear limit (Minimum thickness) Master cylinder inside dia. Caliper cylinder inside dia. Brake fluid type |
Hydraulic disc type 298 x 5 mm (11.73 x .02 in)
|
Electrical Specifications (Top)
| Voltage | 12V |
| Ignition system:
C.D.I. Model/Manufacturer Pulser coil resistance High speed (White/Red-Black) Low speed (White/Green-Black) Charge coil resistance High speed (Red-Brown) Low speed (Brown-Black) Ignition timing: Ignition advancer: Advance type Advance angle Advance starting engine speed Full advance engine speed Ignition coil: Model/manufacturer Spark gap Primary winding resistance Secondary winding resistance Spark plug: Type Spark plug gap C. D.I. unit: Model/Manufacturer |
required <allowable>
032000-045 / NIPPON DENSO 16 ohm +or- 30% at 20 deg C(68 deg F)
334 ohm +or- 30% at 20degC (68 deg F)
Electrical
029700-468 / NIPPON DENSO
BP-7ES (NGK) N- 7Y (Champion)
070000-035/NIPPON DENSO |
| Charging system:
AC. magneto: Model/Manufacturer Rotor puller thread size Output Stator coil resistance White-Yellow
White-White |
032000-045 / NIPPON DENSO
M27 x P 1.0 14.5V-11A / 5000 r/min .73 ohm +or- 30% at 20 deg C (68 deg F)
|
| Rectifier/regulator:
Model/Manufacturer (Rectifier) Type Capacity Withstand voltage (Regulator) Type Regulating voltage Allowable amperage Battery: Model/Manufacturer Capacity Charging rate Specific gravity |
SH235 / SHINDENGEN I.C. type. three phase full wave
I.C. type
12N7-3B / G.S.
|
| Lighting system:
Headlight type: Bulb wattage/Quantity: Headlight
Taillight Brake light Flasher light Turn indicator light Meter light High beam indicator light Neutral indicator light |
Sealed beam 12V, 50W/40W x 1
|
| Horn:
Model/Manufacturer Winding resistance Amperage Flasher relay: Type Model/Manufacturer Flasher frequency Capacity |
CF-12 / NIKKO HORN 1.24 ohm +or- 10% at 20 deg C (68 deg F) 2.5A Condenser type
|
| Fuse:
Rating |
20A |
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