Yamaha SR500 / SR400 — Example photo: beansoup_67, CC BY 2.0, Flickr

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Yamaha · Yamaha four-stroke single (XT/TT/SR 500 1976-)

SR500 / SR400

Library entry covers 1978-2021

31 factory 46 guideline

Published source

Yamaha 1978 SR500 Service Manual (Yamaha Motor Co.), Maintenance and Lubrication Chart pp.3-4

Factory service manual. Covers 1978 SR500 service manual (US), chart in km and mi.

77 items for a 1983 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Dry sump (separate oil tank)
Oil filtration: Mesh screens / strainers only
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1983 Yamaha SR500 / SR400

On the road: every 300 km

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Drive chain: check tension, clean and lube. Factory: Maintenance and lubrication chart pp.3-4: every 300 mi (500 km)

On the road: every 1,000 km

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

On the road: every 1,500 km

1 item

Walk-around: check nuts and bolts for vibration loosening

Pre-ride / on the road

Factory

Manual: Fittings and fasteners: tighten. Factory: Maintenance and lubrication chart pp.3-4: tighten before each trip as needed; lights and signals checked every 1,000 mi

On the road: every 1,600 km

1 item

Check road kit: plugs, points file, master link, tube patches, wire, tape

Pre-ride / on the road

Guideline

Every 1,500 km

6 items

Lights/signals: check operation, replace as required

Engine

Factory

Factory: Periodic maintenance chart p.3: at 500, 1,500 and 3,000 km initial, thereafter every 1,500 km (1,000 mi). (Read from the page images, ManualsLib Yamaha 1978 SR500 service manual pp.3-4.)
Clean / inspect air filter

Fuel and air

Factory

Manual: Air filter (dry): clean, replace as required. Factory: Maintenance and lubrication chart pp.3-4
Check battery electrolyte, top up with distilled water

Ignition and electrics

Factory

Manual: Battery: top up, check specific gravity and breather. Factory: Maintenance and lubrication chart pp.3-4
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch: check and adjust. Factory: Maintenance and lubrication chart pp.3-4
Check brake pads and discs

Brakes

Factory

Manual: Brake system (complete): check and adjust. Factory: Maintenance and lubrication chart pp.3-4: first at 300 mi
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Wheels and tires: check pressure, wear, balance. Factory: Maintenance and lubrication chart pp.3-4

Every 1,600 km or 6 months

1 item

Adjust rear drum brake and rod / cable linkage

Brakes

Guideline

Every 2,500 km or 6 months

1 item

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.

Every 3,000 km

9 items

Change engine oil

Engine

Factory

Manual: Engine oil: replace. Factory: Maintenance and lubrication chart pp.3-4: first at 300 mi
Change pedal shaft: apply lightly (lithium base grease)

Engine

Factory

Factory: Lubrication intervals chart: initial at 3,000 km (2,000 mi), thereafter every 3,000 km (2,000 mi). (Read from the page images, ManualsLib Yamaha 1978 SR500 service manual pp.3-4.)
Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance: check and adjust. Factory: Maintenance and lubrication chart pp.3-4: first at 300 mi and 2,000 mi; cylinder compression checked every 4,000 mi; cam chain tension every 3,000 mi
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plug: inspect, clean or replace. Factory: Maintenance and lubrication chart pp.3-4: first at 300 mi
Throttle grip/housing: apply lightly (lithium base grease)

Engine

Factory

Factory: Lubrication intervals chart: initial at 3,000 km (2,000 mi), thereafter every 3,000 km (2,000 mi). (Read from the page images, ManualsLib Yamaha 1978 SR500 service manual pp.3-4.)
Clean fuel tap filter / sediment bowl

Fuel and air

Factory

Manual: Fuel petcock: clean; flush tank as required. Factory: Maintenance and lubrication chart pp.3-4: first at 300 mi
Synchronize carburetors

Fuel and air

Factory

Manual: Carburetor: check and adjust. Factory: Maintenance and lubrication chart pp.3-4: first at 1,000 mi
Brake pedal shaft: apply lightly (lithium base grease)

Brakes

Factory

Factory: Lubrication intervals chart: initial at 3,000 km (2,000 mi), thereafter every 3,000 km (2,000 mi). (Read from the page images, ManualsLib Yamaha 1978 SR500 service manual pp.3-4.)
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Control and meter cables: lubricate. Factory: Maintenance and lubrication chart pp.3-4: throttle grip housing, brake and change pedal shafts every 2,000 mi

Every 4,500 km

1 item

Cam chain: check/adjust chain tension

Final drive

Factory

Factory: Periodic maintenance chart p.3: check at 500 km (300 mi); at 4,500 km (3,000 mi), thereafter every 4,500 km (3,000 mi). (Read from the page images, ManualsLib Yamaha 1978 SR500 service manual pp.3-4.)

Every 5,000 km or 12 months

11 items

Check engine mounting bolts and plates

Engine

Guideline
Clean oil strainers / mesh screens

Engine

Guideline

Often done with every oil change on old machines.
Check throttle cable(s) free play and return

Fuel and air

Guideline
Adjust clutch pushrod / clutch adjuster

Primary and gearbox

Guideline
Check chain guard, chain oiler (if fitted), rear chain case

Final drive

Guideline
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering damper (friction or hydraulic)

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline

Every 6,000 km

4 items

Cylinder: check compression

Engine

Factory

Factory: Periodic maintenance chart p.3: initial at 3,000 km (2,000 mi), thereafter every 6,000 km (4,000 mi). (Read from the page images, ManualsLib Yamaha 1978 SR500 service manual pp.3-4.)
Replace oil filter

Engine

Factory

Manual: Oil filter element: replace; oil strainer: clean. Factory: Maintenance and lubrication chart pp.3-4: first at 300 mi and 2,000 mi
Check / set ignition timing

Ignition and electrics

Factory

Manual: Ignition timing: adjust as required. Factory: Maintenance and lubrication chart pp.3-4: first check at 2,000 mi
Change fork oil

Front end

Factory

Manual: Front forks: drain and refill. Factory: Maintenance and lubrication chart pp.3-4

Every 6,500 km or 12 months

2 items

Replace spark plugs

Engine

Guideline
Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 8,000 km or 2 years

1 item

Check cylinder head bolt torque

Engine

Guideline

Air-cooled iron and alloy engines can lose head bolt tension; follow your manual's sequence and whether it is done hot or cold.

Every 9,500 km or 12 months

5 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 9,500 km or 2 years

1 item

Check engine breather and oil return

Engine

Guideline

Every 12,000 km

4 items

Speedometer gear housing: inspect thoroughly/pack moderately (lithium base grease)

Engine

Factory

Factory: Lubrication intervals chart: thereafter every 12,000 km (8,000 mi). (Read from the page images, ManualsLib Yamaha 1978 SR500 service manual pp.3-4.)
Check steering head bearing adjustment

Front end

Factory

Manual: Steering bearings: inspect and repack. Factory: Maintenance and lubrication chart pp.3-4: speedometer gear housing at the same interval
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Rear arm pivot shaft: grease. Factory: Maintenance and lubrication chart pp.3-4
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings: grease (do not over-pack). Factory: Maintenance and lubrication chart pp.3-4

Every 16,000 km or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 16,000 km

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 19,500 km or 2 years

1 item

Replace air filter element

Fuel and air

Guideline

Every 24,000 km or 5 years

1 item

Inspect clutch plates and springs

Primary and gearbox

Guideline

Every 24,000 km

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 32,000 km or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

5 items

Master cylinder and caliper cylinder oil seals: replace (NOTE 2)

Engine

Factory

Factory: As printed: On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
Inspect fuel tank for rust, sealer failure, leaks

Fuel and air

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hoses: replace. Factory: Maintenance and lubrication chart pp.3-4: every four years, or if cracked; caliper and master cylinder seals every two years
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

No interval set

3 items

Brake fluid level: check

Brakes

Factory

Factory: As printed: Normally check the brake fluid level and add the fluid as required.
Brake fluid: replace (NOTE 1)

Brakes

Factory

Factory: As printed: When disassembling the master cylinder or caliper cylinder, replace the brake fluid.
Brake hoses: replace (NOTE 3)

Brakes

Factory

Factory: As printed: Replace the brake hoses every four years, or if cracked or damaged.

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.