1981MOTORCYCLE / MOTOCYCLETTE

OWNER'S MANUAL / MANUEL DUPROPRITAIRE

Model : TZ500H

5A0281991000 *5A0281991000*

murad

TZSOOH OWNER'S SERVICE MANUALFIRST EDITION, AUGUST 1980

ALL RIGHTS RESERVED BYYAMAHA MOTOR COMPANY, LIMITED,

JAPANPRINTED IN JAPAN

LIT-II626-02-69 5A0-28199-10

TZ500H ADDITIONAL INFORMATION AND CORRECTION

P. 4 Illustration

P. 14 Delete the "WARNING"

P. 22 The TZ5OOH Front fork spring has 3 slits on its endto distinguish from the TZSOOG Front fork spring.

Fork spring free length:

TZ500H: 428,6 mm (16.87 in)TZ500G: 425 mm (16,73 in)

P. 23 Rear shock spring rate

K - 6.34 kg/mm r '> K = 6.35 kg/mm

P. 34 Fork spring free length

42.5 mm (1.67 in) I :> 428.5 mm (16,87 in)Rear shock absorber free length

251 mm (9.88 in) I _> 198 mm (7.8 in)

Spring rate

6,0 kg/mm i _> 6.85 kg/mm (Option: 6.35 kg/mm)Rear wheel travel

130 mm (5.12 in) i _> 135 mm (5.31 in)

P. 35 Ignition coil Model/Manufacturer

CM61-2OP r _> CM61-2OCA

IMPORTANT NOTICE

This model is designed for roadrace use only. It is illegal to operate thismachine on any public street, road and highway. Know your local laws andregulations before operating this machine.

Particularly important information is distinguished in this manual by thefollowing notations:NOTE: A NOTE provides key information to make procedures

easier or clearer.CAUTION: A CAUTION indicates special procedures that must be fol-

lowed to avoid damage to the machine.WARNING: A WARNING indicates special procedures that must be fol-

lowed to avoid injury to a machine operator or person in-specting or repairing the machine.

CONTENTS

I. BASIC INSTRUCTION .................................................................. 1A. ENGINE MIXING OIL ..........................................................................1B. TRANSMISSION OIL ..........................................................................1C. COOLING WATER ...............................................................................1D. ENGINE BREAK-IN .............................................................................1

I1. PRE-OPERATION CHECKING ..................................................... 2III. MAINTENANCE ............................................................................. 2

A. MAINTENANCE SCHEDULE CHART ..............................................2B. ENGINE MAINTENANCE ...................................................................3

1. CLUTCH'..........................................................................................32. SHIFTER &TRANSMISSION .....................................................33. COUNTER SHAFT .........................................................................94. CARBURETOR ..............................................................................135, CRANKSHAFT ...............................................................................156. POWER VALVE .............................................................................177. COOLING SYSTEM ......................................................................208. LUBRICATION SYSTEM .............................................................21

C. CHASSIS MAINTENANCE ................................................................ 221. FRONT SUSPENSION .................................................................222. REAR SHOCKABSORBER .........................................................233. WHEELS .........................................................................................244. CHAIN ............................................................................................. 275. BRAKES ......................................................................................... 27

D. ELECTRICAL SYSTEM MAINTENANCE .........................................291. SYNCHRONISINGTHE RIGHTAND LEFT

CRAN KSHAFFT (Overhauling) ................................................... 292. IGNITION TIMING ADJUSTMENT ............................................303, ASSEMBLING THE CDI UNIT AND CDI MAGNETO .............314., ROTOR PULLER............................................................................31

IV. APPENDICES ................................................................................. 32A. SPECIFICATIONS ................................................................................32B, MACHINE STAND ............................................................................... 37

I. BASIC INSTRUCTION

A. ENGINE MIXING OIL _ /;;?

MIXINGRAT[ORECOMMENDEDOIL BREAK-IN RACE

BEL-RAYMC-1 20:1 30:1 /Drain plug Drain plug

FUEL TAN K CAPACITY:329.(8.45 US gal., 7.04 IMP gal.) C, COOLING WATER

--CAUTION:

Always mix a fresh batch of fuel the NOTE:

morning of the race and do not retain a Water in specific areas contains salt. Takemixed batch overnight, care so that the cooling system does not get

rasply.

B. TRANSMISSION OILD. BREAK-IN

RECOMMENDED OIL:BEL-RAY MC4 SAE 4OW or YAMALUBE 1. Prior to starting, fill tank with a break-in4-CYCLE OIL fuel/oil mixture and install the hotter

OIL CAPACITY: type spark plugs.OVERHAUL: 940 cm3 (31.8oz) 2, Allow engine to warm up. Check oper-EXCHANGE: 750cm 3 (25.6oz) ating controls (shifting, clutch, brake)(Add the same amount of oil as d_ained and engine stop button operation.off.) 3. Operate machine within 9,000 r/min

REPLACEMENT INTERVALS: and run about 30 miles (50 km}.AFTER BREAK-IN PERIOD 4, Remove the top end and inspect. Re-AFTER EVERYTHIRD move high spots on piston with No. 6OORACES grit, wet sandpaper.

5. Check entire unit [or' loose or miss--WARNING: adjusted fittings/controls/fasteners.1. The oil drain plug should be torqued Change gear oil. Retighten each

to specification and be sequred bolt/nut. If metallic dust is found ex-against loosening be use of locking cessive, check the transmission gearwire. case.

2. Check oil level before every runnin! 6. Remove break-in fuel, Refill with 15:1of engine. (or 30:1 ) operation fuel.

NOTE:DRAIN PLUG TORQUE: After replacing the crankshaft assembly,

22 Nm cylinder, or piston, perform the above opera-(2,0_ 2.5 m-kg, 14,5,_ 18 ft-lb) tions, except 5,

7, After the break-in period, check the fol-lowing items:

-1-

a. Engine b ChassisOil leakage All fittings and fasteners

Water leakage Cracking of chassis, rear armsReplacegear oil Forkoil leakageIgnition timing Steering head free playAll fittings and fasteners Lever/pedal free play

Condition o[ disc pad wear.

II. PRE-OPERATION CHECKING

Check the operation of Y.P.V.S, and specifiedchecking items.

III. MAINTENANCE

A. MAINTENANCE SCHEDULE CHARTC: CHECKR: REPLACEA: ADJUSTT : TIGHTEN

ENGINEEVERYRACE EVERYTHIRD REMARKS

1 PISTON C R2 PrSTONRING R3 CYLINDER& Y.P.VS. VALVE C REPLACEEVERY5 RACES4 CRANKSHAFT5 CLUTCH C,A

YAMALU BE4-CYCLEOIL6 TRANSMISSION C.R.lOlL) BEL-RAY MC4 4OW7 Y,PV S. LINKAGE &

VALVEJOINT C,TS IGNITION A9 SILENCER T

CHASSISEVERYRACE EVERYTHIRD REMARKS

10 DRIVE CHAIN A11 FRONTFORK C,T R (OIL) YAMAHA FORKOIL lOwt. 30wt12 REARSHOCK ABSORBER C,A,T13 SWINGARM C.T14 WHEELS C,T15 SPOKES T16 SPACERFLANGE T

17 FRAME BOLTS . (EVERYSEASON) (APPLYLOCKINGAGENT), _r,,18 SEAT FH-flNG BOLTS T

--2--

@@ @

B, ENGINE MAINTENANCE

1. Clutch 3) Hold the push cam lever by turning thea. Mechanism adjustment adjuster on the crankcase as illustrated,1) Loosen the adjuster lock nut on the pre- turn the adjuster in on the pressure

ssure plate and turn the adjuster out. plate until resistance is felt. Tighten the2) Turn the adjuster on the lever holder in, lock nut,

/ On The crankcase I

On the pressure plate

/

Push cam lever

Adjuster

--3--

4) Adjust the clutch lever free play byturning the adjuster on the lever holder.

b, Maintenance

Apply locking agen

I "-

I x

['"- 'hx I

//

Clutch bc_s- "-.

Torque: 8.0m-kg _ /Make sure the oil groove faces

toward the out side ofthe engine,

t ush rod

Oil BallPush crown bush

-4-

Clutch plate thickness: 2.0 mm (O.087 in)Quantity: 6

Friction plate thickness: 3,0 mm (0.12 in)Quantity:7 _ _e(___/

// 1!

-6-

Transmission gear ratioThe following gear sets are contained in the packing to allow the rider to change the gear ratiosaccording to the circuit conditions

Drive DrivenGear

Part name Remarks No, e[ Part name Remarks No of ratioteeth teeth

I st pinion gearLO (Main axle( 13 1st wheel gear B Two grooves 33 2.538

(same as STD)

1st pinion gear -- 13 1st wheel gear -- 32 2.4611st STD (Main axial1 st pinion gear

HI (Main axle DI One groove 14 1st wheel gear O One groove 33 2.357gnd pinion gear

LO (same as eTD) -- 16 2nd wheel gear B TWO grooves 31 %9372nd

STD 2nd pinion gear -- 16 2nd wheel gear -- 30 1 875

HI 2nd pinion gear D One groove 16 2nd wheel gear D One groove 29 1812

3rd pinion gearLO (same as STD) 20 3rd wheel gear B Two gr_ves 32 1600

3rd STD 3rd pinion gear -- 20 3rd wheel gear -- 31 1550

HI 3rd pinion gear D One groove 18 3r wheel gear D One groove 27 1.500

4th STD 4th pinion gear -- 20 4th wheel gear -- 27 1 350

5th STD 5Ih pinion gear 23 5th wheel gear - 28 1 217

6th STD 6th pin{on gear -- 24 6th wheel gear -- 27 1 125

--CAUTION:

placed by another set, check the N 3.

clearance between the geardOgSso as more lilly U _i :3 utch

and gear tooth patterns, and ifnecessary, make an adjustment. A

2. The 1st wheel gear should be instal-led that illustrated, the Hchamfered side faces the mating procketgear. 3rd 4th

3. Be careful so that the 3rd and 4th Becarefulwheel gear mounting positions arenot reversed. Install the 3rd wheelgear on the sprocket side and the4-th on the clutch side.

-7-

4th (P) 3rd (PI 4Ih {PI3rd tP) 4th{P_ 3rd (Pi

m (O.OiinJ

i

4th (W) more than 05 mm (OOZin) more t mm(002 n)

(p) : Pinion gear(W) : Wheel gear

-8--

r--_o o-ring

Be caroful not to loss the0 ring far oil delivery line.

--CAUTION: 3. Counter ShaftWhen the 6th pinion gear has been re- a. Disassemblingplaced, check that the clearance be- For counter shaft removal, proceed astween the shim and pinion gear is 0.05 follows:

0.1 mm (0.002 ~ 0.004 in). If not, 1) Remove the transmission gearmake a shim adjustment, assembly and breaker shaft assembly.

2) Remove the lock nuts for primary drivegear and breaker drive gear.

3) Move the counter shaft to the right and

_.._h piniongear the driven gear to the left, Now the gearholder can be removed.

005 _ 0.1 mm 4) Remove the breaker drive gear and col-lar.

$h__'_ 5) Move the counter shaft to the left until

it stops.6) Remove the primary drive gear.7) Pull out the counter shaft from the

crankcase right.8) Remove the driven gear out of the

crankcase.

-9-

b. Reassembling

Primary drive gear

Counter shaft

Driven gear

Breaker driven gear

"h""N

No4 crank

C D.I rotorNo3 crank

Collar

Breaker drive gear

No.2 crank

No. 1 crank

-10-

1) Install the driven gear to the crankcase 6) Fit the gear holders in the groovesas illustrated, around the counter shaft, move the

driven gear to the right, and lock thegear holders,

_ _ 7) Be sure to lock the breaker drive gearoo ' t_ holding bolt and the primary drive gear

\'_____ o_ lock nut by bending the two sides ofthe)ock washer___,asshown.

2) Install the counter shaft to the F__crankcase from right side of the case.

3) Pull the countershaft to the left side ofthe crankcase then install the primarydrive gear to the counter shaft.

NOTE:The driven gear has a punch mark on its NOTE:right-side and the counter shaft has a punch The breaker drive gear holding bolt andmark on its splined portion. Be sure to align primary drive gear lock nut should bethese marks when assembling, tightened once to specification and loosened,

and retightened again to specification.

4) Move the counter shaft to the right untilit stops. TORQUE:

5) Install the collar and breaker drive gear BREAKER DRIVE GEAR:on the left part of the counter shaft. 100 Nm

NOTE: (9.5,-_ 10,5 m-kg, 70_ 75 ft-lb)PRIMARY DRIVE GEAR:The breaker drive gear has a punch mark on

100 Nmits outer side, and the counter shaft has apunch mark on its splieed portion. (9.5 _ 10,5 m-kg, 70 _ 75 fi-lb)

c. Positional relation between crank gearand breaker drive gear (For ignition tim-ing)

_'_ Punchmark 1) Align the crank pins on both right and

__//_ leftcrankgearsandbringthemtomesh

with the driven gears.2) Install cylinders, Nos. 2 and 3, and bring

the piston to TDC,3) Align the keyway with the drilled mark

in the crankcase 4, and install the case4.

-11-

Crank gear[____

?v _ Breaker driven gear

Driven gear Crankcase 4

d. Crankcase tightening order

FWD

--12--

4. Carburetor

a. Power jet operation range

Throttle openingSetting part name

0 1/8 1/4 1/2 3/4 7/8 1/ 1

Main Jet

Powerjet

FLOW CURVEConventional carburetor

///j/.._ With power jet carburetor

cc/min _'_--_ (Main jet _- Power jet)

t -T'Flow of main jet

FLOW 0 FFUEL

Flow of power jet

7,500 10.500 r/min

ENGINE REVOLUTION

b. Adjustment1 ) Full throttle setting

Engine revolution rangeNecessary setting

Max revolution 8,000 _ 9,000 r/rain1 RICH RICH Smaller MJ

2 RICH GOOD Smallerpowerjet3 RICH LEAN Larger MJ and smaller power jet

Mixture 4 LEAN RICH Larger power jet and smaller MJcondition

LEAN GOOD Larger power letLarger MJ or power let should be so

6 LEAN LEAN selected that power output is larger inthe mid-speed range.

-13-

2) Partial settingsPartial settings follow the determinationof the full throttle settings and thesecan be performed by usual procedure.

3) Standard carburetor setting

TYPE VM34SS STARTERJET #80I.D MARK 5AO00 FLOATHEIGHT 33_+ I mmMAIN JET #320 (13 _+0.04 in)POWERJET #80NEEDLEJET N-6JET NEEDLE 6BOG1-3CUTAWAY O0PILOTJET #0AIRSCREW 0(TURNS OUT)

NOTE:Install the throttle valve with the cutawayfacing toward the engine.

ENGINESIDE

--WARNING:Take care not to loosen and removecontraction adjuster "B", or the highpressure oil Will spurt out.For adjustment, don't back it out morethan 2 turns from the tightened position.

-14-

5. Crankshaft

a) Crank center bearing removal & instal-lation

How to remove Holdingspring

1)Remvethehldingspringfrmthebe-_Oaringgroove.2) The holding spring is screwed in. To re-

move, screw it out counterclockwise.

Screw in position

I

--15-

and slip the holding springs over the1) Assemble two holding springs and labyrinth seal. and fit them in the bear-

place them on the labyrinth seal. ing groove. Apply a liberal amount of oil2) Install the bearing on the crankshaft, to the bearing roller.

b, Crank gear lock washer

_Crank .._

gear

Cutoff the projecting part

--16--

c. Crank gear installatienThe crank gear has a punch mark on its

crank pin and press-fit the gear over theshaft.

6. Power Valve

O

Torque: 2.0 m-kg

--17-

a. Connecting joint installation NOTE:1) As illustrated, assemble the joint and The valve joint bolts should be once tighten-

install, ed hard and check the circular marks on the2) Install :the cylinders on the crankcase, valve shafts left by the bolts. If the circular

starting with the left one, and each time marks have no broken line. apply NEJI-LOCKeach cylinder is installed, check that the to the bolts and tighten hard.valve can be turned lightly by hand.The cylinder bolts should be tightened

NOTE:When connecting the valve with the joint, besure that the valve is not reversed.

b. YPVS valve adjustment3) If any valve is stiff to turn, turn the joint 1) Valve opening adjustment

90 as shown and reinstall the joint, a) Loosen the stopper screw on each valvejoint.

b) Fully open the No. 4 cylinder valve.c) With the No. 4 cylinder valve fully op-

ened, open the other cylinder valves as

_ _ __ wide as possible and tighten thestOp-perscrews,d) Loosen the lever stopper bolt and turn

the valve shaft so that when the ex-haust valve in the cylinder whose valvetiming is the latest (the valve head pro-jects into the exhaust port) is fully opened, the punch mark on the governor

The valve joint is secured to the valve shaft lever aligns with the center of theby two bolts at any position. (On the preced- governor cover hole.

As a result of this modification, it is advisablenot to remove the valve joint when removingthe cylinder for better operation efficiency.When the cylinder has been replaced, tern- _- _

porarily tighten the valve joint bolts and after (_I_'--/__ -i""_

making sure that the valve moves lightly,apply NEJI-LOCK to the bolts and tighten.

1. Governer cover 3, Governer lever 5 Stopper bolt2 Punch mark 4, Valve shaft

-18-

e) After this adjustment, check that whenthe governor is sat to the full-open po- Oblong holesition, all exhaust valves are fully op- (_. _ _.-J_) /_-..ened.

NOTE:1, When fully opening a valve, be sure to

turn it from the full-closed position tothe full-open so that the joint becomes

tight. _ _,_2, Perform steps a) to d) while assembling

the engine, and perform the procedurein e) after mounting the engine on theframe.Never forget to do this check whenever Push-starting of the engine:the engine is re-mounted, Turn the governor arm (2) to the left and

hook the lever (3) on to the pin (4), and2) Adjustment of full-opening and closing the engine compression pressure (in the

of valves cylinder head) decreasesand startinga) Make an adjustment by moving the ad- the engine becomes easy.

justing bolt in the oblong hole so that When the engine speed reaches 9,000when the governor arm is turned in the r/rain or so, the governor is auto-direction of D until it stops, the punch matically restored to the original state,mark on the governor lever aligns with

the center of hole B in the governor I,-r-CAUTION:when the Icover, i except push-starting engine,

b) Turn the adjusting bolt so that when the ldo not hook the lever (3) onto the pin Igovernor arm is set free. the punch J(4). It may fatigue the spring faster. Imark on the governor lever aligns withthe center of hole A in the governorcover.

c. GovernorNever attempt to disassemble ortamper with the governor, or engineperformance will be greatly impaired. Itis manufactured under strict qualitycontrol and assembled delicately at thefactory, requiring precision adjustment.

-19-

7. Cooling Systema. Water pump

?

&

NOTE:1. Pack the oil seal lip with grease. I_ _t_[ _2. When installing oil seals on the water

pumpshaft, take care not to reverse the _(_ _voil seal positions, Wind a vinyl tape 1 or inyltape2 turns around the shaft to protect thelip against damage.

b. Radiator _,.w_Cooling liquid capacity: 2.3Radiator cap valve opening pressure:

0.9 kg/cm 2

-20-

8. Lubrication System

LUBRICATION CHART

4 EACH GEAR(MAIN AXLE) J

IMA'"A'EBEAR'"_I---_ 'c"AH"As_u""E")s.ow""' I D"'V"AXLE""A"'"GIt

-21 -

NOTE:1. The pump rotor should be so installed

.

3. Do not deform or damage the Next, remove the plug (rubber valvecylinder in any way. Cylinder assembly) on the cylinder bottom. Beforedamage will result in poor damping removal, check the gas pressure with theperformance, checking gauge.

4. Handle it with great care, for a scoreor scratch in the piston rod sliding --WARNING:portion will cause oil leakage. To dispose of a damaged or worn out

5. Never remove the plug on the shock absorber, take the unit to yourcylinder bottom. Injury may result. Yamaha dealer for this disposal pro-

cedure.

This chock absorber is capable of independ- NOTE:ant damping force adjustment for expansionand contraction {see below). Make sure the fuel tank does not contact theFor expansion, adjust at "A" and for contrac- rnonocross suspension.tion at "B".

Absorber specificationsStroke: 65 mm (2,6 in)

i Overall length (from eye to eye):HARD _.,'_ 626 mm (24.6 in)

(__ 183 _ 195 mm (7.2 _-' 7.6 in)SOFT Initial setting length:

187.5 mm (3.4 in)

(_ _ _OOFT Free length: 198 mm (7.8 in)Torque:A 30 Nm (3.0 m-kg, 22 fi-lb)

--WARNING: B 90 Nm (9.0 m-kg, 65ft-lb)Take care not to loosen and removecontraction adjuster "B", or the high A rear absorber spring which is a little harderpressure oil will spurt out. than standard is available as option. ApplyFor adjustment, don't back it out more your Yamaha dealer,

than 2 turns from the tightened position. - P/No. 5A0-22212-10 1/

Notes on disposal (Yamaha dealers 0nly) The optional spring is painted yellow at itsGas pressure must be released before dis- end for identification.posal of shock absorber,At first, insert the injection needle to the Parts contained in the cartenrubber valve on the cylinder bottom, Most of Rear shock spring (HARD)gas pressure can be released by this pro- (yellow painted)cedure. K: 634 kg-m

--WARNING:Wear eye protector to prevent eyedamage from escaping gas pressure.

-23 -

3. Wheels b. Interchangeability of rear wheela. Interchangeability of front wheel The TZ750 rear wheel assembly is not

For the TZ500, the TZ750 wheel (spoke useable for the TZ500, but the TZSO0wheel, Campangolo cast wheel) is de- spoke wheel is useable for the TZ750.signed to be used, whether it is an As shown below, the TZ750assembly (including the wheel bearing, Campangolo cast wheel can be used forbrake disc, etc.) or not. the TZ500, provided that the TZSO0 ad-However. the TZSO0 brake disc is pro= aptor (indicated by shaded areas) isvided with a slit. attached to the wheel.

TZ500106 mm 80 m m(4.13 in) (3 14 in)

126mm 120mm[4,9 in) (472 in)

TZ750 89 mm 80 mm(3.50 in) (3,14 in)

_268 mm

113mm ll3mm(444 in) (44-4 ini

-24 -

Torque: 8.5 m-kg

//. -//

""(_/_ _ Torque: 7 m-kg: Be sure to apply locking agent.C._//_ _ When replace the sprocket wheel,

./_.__(_ check and retighten as necessary

._;_'. j_J_' fl / Never use copper wire.

-25-

Rear wheel assembly diagram1) Sprocket ass'y

I f 1-35T 4A0-25435-00

SPROCKET 1-36T 4A0-25436-00_-37T 409-25437-00_-38T 409-25438-00

C[ c: _-39T 409-25439 ODL-40T 409-25440-00

-- HEXAGON SOCKET HEAD BOLT (5 pcs/unit)SPROCKET SPACER (1 pc/unit)SELF LOCKING NUT (5 pcs/unit)

*The sprocket should be replaced in the form of the above assembly,

2) Adaptor parts on the sprocket side (excluding thesprocketassembly)

FLANGE SPACER 1 (1 pc/unit)SOCKET HEAD BOLT (5 pcs/unit)

{APPLY LOCKING AGENT)

SPROCKET WASHER (2 pcs/unit)SPROCKET SHAFT NUT{1 pc/unit)

I--CIRCRIP (1 pc/unit)

WHEEL SHAFT COLLAR I1 pc/unit)

SPROCKET DAMPER {5 pcs/unit)

REAR ARM

3) Adaptor parts on the disc side

BRAKE DISC (1 pc/unit)-- LOCK WASHER (3 pcs/unit)

HEXAGON BOLT (6 pcs/unit)

-DISC BRACKET, 2 (1 pc/unit)1 ! * SHAFT COLLAR. 2 (1 pc/unit)

.J

'*Be sure to install this collar before installing the disc bracket.

-26 -

., Chain Chain free play adjustment To check the chain play. the machine must stand vertically with its both wheels on the ground and without rider on it.

CHAIN FREE PLAY: 5 mm (0.2 in)

CHAIN TYPE: DID 50 HDS NO. OF LINKS: 99 + Joint

5. Brakes

r

Torque: 5 m kg

"-.. ~@ i r - / "7 r-.

~L... "J'l

L >Torque: 5 m-kg

,~.f,.,/Torque: 1.2 m-kg

Torque: 3 m-kg

PAD THICKNESS: 4.5 mm (O.17 in) WEAR LIMIT: 0.5 mm (0.02 in)

-27 i

Torque: 5 m-kg I _./

h

Torque: 5 m-kg _'__ %`""/

lorque 3 m-kg

PADTHICKNESS: 4,5 mm (O.17 in)WEAR LIMIT; 0.5 mm (O.O2in)

Brake pedal free play adjustmentWhen making this ad)ustment, bleed thebrake fluid line first and add brake fluid.

ADJUSTERMAX. LENGTH: I13.5 mm (0.53 in)

IO5 in)

--28--

D. ELECTRICAL SYSTEM b. Align the right and left crank pins, andMAINTENANCE place the crankshaft in the crankcase,

1. Synchronizing the Right and Left and install the pistons (for cylindersCrankshaft (Overhauling) Nos. 2 and 3) and cylinder head, Next,

When the right crankshaft or drive gear install a dial gauge,has been replaced, both crankshafts c. Bring the No, 2 cylinder piston to 1.40must be synchronized, To synchronize, mm (0.0551 in) BTDC.proceed as follows: I

a Install labyrinth seals, bearings, oil IGNITION TIMING: Iseals, etc. on both crankshafts, and pre- 1.40 _+0.07 mm (0.0028 in) BTDCss-fit the drive gear, When press-fittingthe drive gear over the shaft, be sure to d. With the piston at this position, read thealign the pin hole in the crankshaft with dial gauge installed in the No. 3 cylinder.the punch mark on the drive gear. 1) The dial gauge reading should be 1.33

1.47 mm (0.0523 _ 0.0520 in).2) If the dial gauge reading is 1.19 _ 1.32

mout the right side crankshaft. Next, turnthe drive gear to the right so that itspunch mark position shifts 8 splines onthe crankshaft, and press-fit the gearAs a result, the center line of the toothcomes off the center line of the crankpin, and the piston shifts 0,14 mm(O.O055 in) off TDC.

D, rivegear Centerofcrankplrl CenterofteelhDrill mark

\ //// i_ i

_ Ciankpill (No3)

;,_ -_J' J' ' X 1-umirlg d,recbo, ,Crankshaft

of engme

-29-

3) If the dial gauge reading is 1.18 mm(0.0465 in) off TDC.

4) If the dial gauge reading is 1.48 _ 1.62 the right so that the piston moves 0.15mm (0.0583 _ 0.0637 in) BTDC, shift mm (0.0591 in) toward TDC.the drive gear punch mark 5 splines to

5) If the dial gauge reading is 1.63 mm NOTE:(0.0642 in) BTDC or more, shift the The keyway is covered by the rotor holdingdrive gear punch mark 10 splines to the washer, and therefore a mark indicating theright so that the piston moves 0.30 mm keyway position should be put on the rotor.(0.0118 in) toward TDC.

3. Bring the No. 2 cylinder piston to 1.42. Ignition Timing Adjustment mm (O.0134 in) BTDC and read the No.Before adjusting the ignition timing, syn- 3 cylinder piston position. Next, calcu-ehronize both right and left crankshafts, late the average reading of the No. 2

1. Bring the pistons in cylinders, Nos, 2 and No. 3 cylinders, and bring theand 3, to TDC. piston at this position.

2. Align the rotor keyway with the drilled 4, Align the timing mark on the rotor withmark in crankcase 4- (magneto case), the mark (central) on the stator.and install the magneto case in thecrankcase.

-30-

Ma rk on crat~c~se 4

Keyway position mark

I I I I IL

3. Assembling the CDI Unit and CDI Magneto

If either the CDI unit or the CDI magneto assembly has to be replaced, then replace them as a set, The rotor, stator and unit have a five-digit number indicating the production No, Always use these of the idential number as a set If not, it is necessary to make an ig- nition timing adjustment while checking engine output at high speeds in actual run- ning.

MARKING POSITION

4. Rotor Puller The rotor puller for this model is available at the Yamaha parts departments. I P/No.: 90890-01260

--31-

IV. APPENDICES

A. SPECIFICATIONSEngine

Bore and stroke 56 x 507 mm (2.205 x 1,996 in)Displacement 499 cm_(3047 cuPn)Engine type Water cooled, 2-stroke piston valve with Y.P.V SCompressionratio 7.9: 1Lubricating system:

Engine Mixedgasoline:15: 1 -- Castrol R30, Yamalube R30:1 -- BeI-RayMC-1

Transmission Dry sump (Trochoid pump)Cylinder head volume with spark plug (N-84G) 12.2 cm _

Head gasket material Silicone rubber

Cylinder:Material All aluminum alloyb,_er material Porous chrome plated

PistonPiszon clearance 0,035 _ O,045'mm (0,0014 _ 0.0018 inl

Measunng point 10 mm (04 in) from piston bottomPiston off-set 1 mm (0.04 in) off-set to Ex. side

Piston ring:Ringdesign PlainrigRingendClap 04_ 05 mm(OO16_ 0019 in)Ring groove side clearance 0 03 _ 007 mm (0.OO12_ 0.0027 in)

Crankshaft:Crank width (A) 167 mm (6.57 ml

O 0(F) 53.5 -005 mm (2.10_0002 in)

Crankshaft deflection (A) 0.03 mm max. (O.O012 in)Checking position:

Big end side clearance (Ct 0.25 _ O.75 mm (0.01 ._ 0.O3 in)

IC)---

_. lA)

Crankoilseal(L&R) SW38 62--6.5Clutch:

Type On/multi-discPrimary reduction ratio 47/22 (2.136)Friction plate Q'ty 7Thickness/Wearlimit 3 mm/2.7 mm (O.12 in/0.11 in)Clutch plate Q'ty 6Thickness/Warp limit 2 mm/O.O5 mm (0 08 in/O.OO2 _n)

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Cllutch spring Q'ty 6Free length/_,Near limit 383 mm/38 O mm (1 51 in/1.49 in)Spring rate 1.31 kg/mmClutch housing thrust clearance 0.12 _ 0.41 mm (0005 _ 0,016 in)Push rod bending limit 02 mm (0 008 in)

Transmission:Type Constant mesh, 6 speed, returnGear ratio 1st 32/13(2461)

2nd 30/16 (1875)3rd 31/20 (1,550)4th 27/20 (1350]5th 28/23 (1 217]6th 27/24 (1,125)

Transmission oil quantity Total: 940 cm _(000 IMP.qt)Exchange: 750 cm 3 (000 IMP qt)

Type (Bel-ray MC-4) SAE 40WBearing type: Main axle (L) {22 x 36 x 17]

(R) 5205Drive axle (L) 5206

(R) (25 x38 x 16)Drwe axle oil seal type (L) SD40 x 62 x 6

Secondary reduction ratio 36/17 (2 117)Shifting mechanism:

Oilsealtype S12x22x5Carburator:

Type and manufacturer VM34SS/M JKUNII.D. mark 5AO00Main let (M.J) #320Power jet #80Jet needle-clip position (J,N.) 6BDG 1-3Needlejet (N,J.) N-6Cutaway (C.A.) 0Pilot jet (P,J,) 0Air screw tums out (A.S.) 0Starter jet (G.S.) #80Float height 33 +_1 mm I1.3 _+0,04 in)

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Chassis

Frame Tuubular steel double cradle

Steering:Caster 275Trail 108mm(4.25in)Head pipe bearing type Taper roller bearing

Front suspension:Type Telescopic folkDamper type Coil spring, and oil damperForktravel 130mm(5 12in)Front fork spring, free length 42.5 mm (16.7 in)

spring rate 0,60 kg/mmFork oil quantity 160 cm a(169 US qt., 140 IMP qt.)

type GlO(SAE#10)Oilsealtype SW36--48 105

Rem suspension:Type Swinging arm [Monocross suspension)Damper type Coil spring, Gas oil damperRear shock absorber spring:

Freelength 251mm(9.88in) .Spnng rate 6,0 kg/mmRear shock absorber travel 66 mm (2,56 in)Rear wheel travel 130 mm (5.12 in)Swing arm length 470 mm (18.5 in)

deflection (rear and) 0 _ 1,0 mm (0 _ 0.04 in)free play (pivot shaft) 0.1 _ 0.2 mm (0.004 _ 0.008 in)

Pivot shaft-bearing type N BX-2530ZFuel tank:

Capacity 31.51(000IMP.qt)Wheels:

Tire size ( F} 3.25-- 18(R) 400/5.75 18

Manufacturer SUMITOMOModel F, KR-IO4/R KR-133Pressure:

Front 1.8 kg/cra z (1.8 bar)Rear 2.1 kg/em 2 (2.1 bar)

Rimsize(F) 2,50 18(R) 3.50--18

Run out (vert):Front-limit 07 mm (0.027 in)RearJimit 0.7mm(0.027in)

Bearing type and size:Front wheel (L) 6303Z

(fi) 6303ZRear wheel {L) 6204Z

(R) 6204ZZDrive chain:

Type DID50HDSNumber of links 99 + JOINTChain pitch 15.875 mm (0625 in)Free play 5 mm (0.2 in)

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Brakes (Front and Rear):Type {F) Disk brake, dual

(R) Disk brake, singleDisk O.D. (F) 6298 x 5 mm (11.7 x 0.2 m)

(R) d_218 x 5 mm (86 x 0.2 in)Pad dis

Tightening torque

Item Tightening torque

Engine:Cylinderhead MS 1.9_ 2 1m-kgSpark plug M14 2.0_ 2.5 m-kgCylinder (Nut) M8 1.9 _, 2.1 rn-kgPrimary drive gear (Nut, Lock) M24 9.5_ 10.5 m-kgClutch boss (Nut, Lock) M20 4.5 _ 5.0 m-kgClutch spring {Bolt, Flange) M6 0,8 _ 1.0 m-kgDrive sprocket (Bolt) M20 5.0 N 5 5 m-kgChange pedal (Bolt) M6 0.8 _ 1.0 m-kgGenerator (Rotor, Nut) M12 4.0_ 4.5 m-kg

(Staler, Bolt) M6 0,8 _ 1.0 m-kgCrarlk gear (Bolt, Hex ) M14 4.5 _ 5.0 m-kgBreaker gear (Bolt) M14 9.5,_ 10.5 m-kgCrankcase(Nut) M8 1,8_ 2.2m kg

Chassis:Engine mounting bolt:

Front upper MIO 3.7_ 5.8 m-kgRear under M 10 3.7 _ 5.8 m-kgRear under M10 3.7 _ 5.8 m-kg

Engine mount stay M8 2.3 _ 3.7 m-kgHandle crown:

Steering shah M14 7.3 _ 11.7 m-kgInner lube M8 1.5 _ 2.0 m-kg

Front fork:Capbolt M28 1 5_ 3.0m-kgUnder bracket and Innter tube MB 1.5 _ 2.0 m-kg

Steering shaft M 10 1.8 -_ 2.0 m-kgCylinder complete M8 2.0 _ 2.6 m-kgFront wheel axle M14 7.0_ IO.O m-kgFront wheel axle holder MS 1,5 _ 2.3 m-kgPivot shaft M16 8.0_ 14-0 m-kgSprocket spacer MIO 4,9 _ 7.8 m-kgRear wheel axle M18 12.0_ 180 m-kgSprocket wheel M 10 49 _ 7,8 m-kgRear suspension and frame MB 23 _ 3.7 m-kgSuspension upper bracket and extension M 18 7 _ 10 m-kgFoot rest M6 1.0 ,_ 1.6 m-kgBrake disc (F) MB 2.0 _ 3.2 m-kg

(R) M8 2.3_ 3.7m-kgDisc bracket M6 0.8 ,_ 1.4 m-kgBrake hose bolt (AIl) MIO 1.4_ 1.8 m-kgCaliper bracket M 10 3,7 _ 5.8 m-kgBleed screw MS 0.4 '_ 0,7 m kg

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B. MACHINE STAND

The following diagram indicates the machine stand for the TZ500. It can be used for the TZ250and 350, if partically modified.

305 _:_

M6 bolt

....... 400

Q* tB 8

. __/'_'_ Section C-C_-view

Or_

.. I

UNIT: mrnD D-view

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Yamaha Motor Canada Ltd.480 Gordon Baker RoadToronto, ON M2H 3B4

OWNER'S SERVICE MANUAL FOR TZ500HNOTICETABLE OF CONTENTSBASIC INSTRUCTIONENGINE MIXING OILTRANSMISSION OILCOOLING WATERENGINE BREAK-IN

PRE-OPERATION CHECKINGMAINTENANCEMAINTENANCE SCHEDULE CHARTENGINE MAINTENANCECLUTCHSHIFTER & TRANSMISSIONCOUNTER SHAFTCARBURETORCRANKSHAFTPOWER VALVECOOLING SYSTEMLUBRICATION SYSTEM

CHASSIS MAINTENANCEFRONT FORKSREAR SHOCK ABSORBERWHEELSCHAINBRAKES

ELECTRICAL SYSTEM MAINTENANCESYNCHRONISING THE RIGHT AND LEFT CRANKSHAFT (Overhauling)IGNITION TIMING ADJUSTMENTASSEMBLING THE CDI UNIT AND CDI MAGNETOROTOR PULLER

APPENDICESSPECIFICATIONSMACHINE STAND