Refurbishing a 1980 Yamaha SR500

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rebelrider
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Refurbishing a 1980 Yamaha SR500

Post by rebelrider » Thu Aug 01, 2019 5:37 pm

Hi folks,

Thought I'd share my latest project. I've never owned or ridden a Yamaha before, but this one sort of fell into my lap, and I couldn't say no. So far it's been very nice to work on, and I think it will be roadworthy soon.
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When I went to pick it up, we had to drag it out of the carport because both wheels were seized. Turns out in was the brakes. We got the front brake removed, and dragged it onto the trailer so I could take it home. Once home, I had to get the back wheel to turn so I could get it off the trailer. After removing the wheel, I discovered the rear brake was seized, and in fact, the pads were adhered to the drum.
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Removing the shoes allowed me to rotate the wheel, but I had to get the bike off the trailer without brakes. I eventually got it off ok and had time to do a more thorough walk around.
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Here is a video I made as an introduction to the project:
Mike
Image2014 Ural M70 "Trogdor"
1987 Honda CMX250C "Rebel"
1979 Puch Moped "Wasp"
1971 Honda SL100

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Re: Refurbishing a 1980 Yamaha SR500

Post by Iron Maiden » Thu Aug 01, 2019 6:49 pm

That is a great bike.
I have the XT version.
Go for it! :lurker:

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Re: Refurbishing a 1980 Yamaha SR500

Post by rebelrider » Fri Aug 02, 2019 6:24 am

Here's the next video. Not a whole lot, but I've got the seat and the fuel tank off, and It turns out there was lots of rodent damage to the wiring. But I was able to start diagnosing the ignition system based on a PDF that I found on the internet.
Mike
Image2014 Ural M70 "Trogdor"
1987 Honda CMX250C "Rebel"
1979 Puch Moped "Wasp"
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Re: Refurbishing a 1980 Yamaha SR500

Post by VWK75S » Fri Aug 02, 2019 6:35 am

Mike,
Your really like a good project :shock:
John
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Re: Refurbishing a 1980 Yamaha SR500

Post by vetsurginc » Fri Aug 02, 2019 8:21 pm

Had a '76 XT. Great engine!
Doug
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Re: Refurbishing a 1980 Yamaha SR500

Post by rebelrider » Sat Aug 03, 2019 6:32 am

This has been a lot of fun to work on so far. Hopefully that trend continues!

Here you can see some of the wiring I had to repair:
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I think I complained in the last video that I couldn't find a decent wiring diagram. I finally found a faded black and white one that I'm sure actually goes with the bike. Of course I couldn't just leave it alone, so I re-drew it with thicker lines and in color:
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So this next video I did had a lot of audio problems, but I did the best I could with it. Got the turn signal switch working, and played a little with the battery.
Mike
Image2014 Ural M70 "Trogdor"
1987 Honda CMX250C "Rebel"
1979 Puch Moped "Wasp"
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Re: Refurbishing a 1980 Yamaha SR500

Post by rebelrider » Sun Aug 04, 2019 2:12 am

Got the air cleaner and carburetor off:
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Someone replaced the original air cleaner with a K&N oiled air filter. I suppose it was to get more horsepower, but I wonder if having less restriction in front of the carb will mess with the air/fuel mixture. I guess I'll find out when I get the thing running. I happen to have a cleaning and oiling kit from K&N, so fixing up the air filter won't be a problem.

Well, here is a video if me getting started with the carburetor disassembly:
Mike
Image2014 Ural M70 "Trogdor"
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Re: Refurbishing a 1980 Yamaha SR500

Post by INSUBORDINATOR » Sun Aug 04, 2019 1:39 pm

There is a lot of info on these online & an owners forum. I sold mine about 6 years ago. I ran a NEW Mikuni VM carburetor which seemed to help starting & general performance. Mine had several modifications to replace rusted out & worn parts. I sold mine to purchase a Royal Enfield with an "Electric Leg" - to help deal with my elderly legs. Both very fun Bikes to ride. The SR's handle great. Hope you enjoy it.
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Re: Refurbishing a 1980 Yamaha SR500

Post by rebelrider » Sun Aug 04, 2019 7:26 pm

So yours had a big ol' filter on it too. Well, I could be overthinking things then. I joined up with the SR400/SR500 forum. They've been helpful and supportive so far. :)
Mike
Image2014 Ural M70 "Trogdor"
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Re: Refurbishing a 1980 Yamaha SR500

Post by rebelrider » Mon Aug 05, 2019 4:19 am

I'm on an editing roll!

Second half of the carburetor teardown:


A bit short. It seems I forgot to record a few things getting taken apart. Oh well. :lol:
Mike
Image2014 Ural M70 "Trogdor"
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Re: Refurbishing a 1980 Yamaha SR500

Post by INSUBORDINATOR » Mon Aug 05, 2019 10:35 am

You might want to buy a big harbor freight SONIC BATH type SONAR CLEANER. Best way I know to get corrosion out of carb parts & internal passages etc. All come out looking like new.
Although on 2 occasions I've just purchased new Mikunis instead, recently for my Ural. Because I'm old - & may not have future use for a sonar cleaner. At your age I'd probably get my use out of it.
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Re: Refurbishing a 1980 Yamaha SR500

Post by rebelrider » Tue Aug 06, 2019 4:56 am

This is the first carb I've cleaned with the ultrasonic cleaner. I'm pretty happy with the results. :)

This next vid is fixing the kill switch:
Mike
Image2014 Ural M70 "Trogdor"
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Re: Refurbishing a 1980 Yamaha SR500

Post by rebelrider » Wed Aug 07, 2019 6:11 am

I finally got the bar-end mirrors off that weird handlebar. Unfortunately, they didn't really survive. But I didn't want to reuse them anyway.
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Also got the gas tank emptied. Pretty nasty fuel!
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I don't remember if I mentioned it, but after repairing the wiring, all the 12V stuff started working except a couple burnt out bulbs, and the rear brake switch. Well I found the issue:
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Turns out there's a spring from the switch that should be attached to a tab on the brake lever that was disconnected. Now it works just fine. So just a couple light bulbs, and some general cleaning, and the 12V side of things should be done!

I've also got the fuel valve taken apart and cleaned. Man that was a mess! But it looks practically new now. The only thing that absolutely must be replaced is the o-ring that goes with the diaphragm. But I'll be looking for a rebuild kit anyway. Seems the SR500s had more than one type of fuel valve, so I've got to make sure I buy the right one.
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For folks interested in a video of all this:


This should be the last video with the audio issue. I believe I've finally got it fixed. :)
Mike
Image2014 Ural M70 "Trogdor"
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1979 Puch Moped "Wasp"
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Re: Refurbishing a 1980 Yamaha SR500

Post by rebelrider » Mon Aug 12, 2019 9:17 pm

I got to go camping with my neighbors this weekend, so no actual progress.
But I did get a video edited:


I discovered that the speedometer is toast.
Image

But I found a good deal on eBay for a replacement.
Mike
Image2014 Ural M70 "Trogdor"
1987 Honda CMX250C "Rebel"
1979 Puch Moped "Wasp"
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Re: Refurbishing a 1980 Yamaha SR500

Post by rebelrider » Wed Aug 14, 2019 4:30 am

Here's a video on a few updates, and refurbishing the main switch. I fast forwarded for brevity.


The tachometer, fortunately, is in good shape. So is the wiring for the lights behind it. Just a couple of lightbulbs that need replacing.
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I decided that as long as I'm cleaning up rusty stuff, may as well do the headlight bucket too.
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The bucket and the two gauge lower covers turned out really good.
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The main switch was surprisingly easy to take apart. I got it all cleaned up and put back together.
Image
Image
Mike
Image2014 Ural M70 "Trogdor"
1987 Honda CMX250C "Rebel"
1979 Puch Moped "Wasp"
1971 Honda SL100

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