Yamaha TT500C 1976 User manual

.· .YAMAHA
.
TTSOO
OWNER'S MANUAL
'
•
. 1
1
1
1
.·
' . ,_ 583-28199-10 1
"-'"------ - ~..1 .,..., ~ . ----~- ~~- ~- ~-~- - -- ---:__.____ - -~- -_j

NOTICE
.
•'-
Yamaha
Motor
Company
is
confident
you
will
enjoy
vour
nèw
Yamaha
to
the utmost.
We
have made every
effort
to
provide you
with
a safe. well-engineered and
constructed product.
This
Owner's
Manual
will
acquaint
'you
with
severa! features and
maintenance procedures concerning your Yamaha. However.
if
you are
unf
amiliar
with
·the product.
or
the features
or
procedures
outli~ed
within
thi
s manual.
we
strongly urge you
to
consult
your
Authorized Yamaha Dea-
ler for additional information.
TT
500
C
OWNER
'S
MANUAL
FIRST
EDITION
AUGUST
1975
Ali Rights Reserved
by Yamaha
Motor
Comj1any Limited, Japan.
Printed
in
Japan
LIT-11626-00-20

FOREWORD
Yamaha's
TT
500
C
is
completely
new
model designed solely for the rigors
of
off
-road riding.
Each unit
is
assembled and checked according
to
the same rigorous
principles
as
our championship competition models.
This Owner's Manual
is
included
to
provide basic information for operation
and maintenance.
Additional information regarding major repairs can
be
found
within
the
TT
500
C Service Manual and various other information and training manuals
available from your Authorized Yamaha Dealer.
YAMAHA
MOTOR
CO
..
LTD.
SERVICE DEPARTMENT
INTERNATIONAL DIVISION
IWATA.
JAPAN

CONTENTS
FEATURES .... .. ........... ............. .. ................... .. .... .. ........... .. .......... .. .. 2
NOMENCLATURE .................... .. ........... .. ...... ........ . .. .. .. .. ... .. ...... .. ..... 4
SPECIFICATION .................. .......
.. ..... .. .. ................ .. . .. . .. . .. ................ 5
MACHINE IDENTIFICATION................. ..... .......... ...................... .. ..... 8
CONTROL FUNCTIONS........................
.. ......... .. ........ .. .......... .. .... .. ... 9
PRE-OPERATION CHECKS...........
.. ......... .... .. ................... ................ . 14
OPERATION .. .... .. ............ ... ........ ........... ............. .. .. .. .... ........... .. .... .. 16
PERIODIC MAINTENANCE AND MINOR REPAIR ............... .. ............. 20
CLEANING AND STORAGE ........ .. .... ............... .... ......... .... .. ..... .. .... .. 72
MI SCELLANEOUS ............. .............. .. ....... .. .................. .. ..............· .. . 75
CIRCUIT DIAGRAM .. .... ......... .... ............... .. ...... .. .. . ........ .. ........ 78

FEATURES
Aluminum cylinder construction
The
aluminum
cylinder has a special cast
liner
which
has superior heat dissipation
characteristics. Even during extended high
speed
operation
the engine operates ef-
ficiently and there is no significa
nt
loss
of
output.
Dry sump lubrication system
The dry sump system lubricates the engine
using a separate oil
tank
and feed
pump
.
After
lubricating the engine parts under
pressure. the oil is returned
to
the oil
tank
by
a scavenging pump. Consequently, loss and
overheating
of
oil is reduced because the oil
inside the crankcase is
not
agitated by the
crankshaft. Furthermore, the oil does
not
deteriorate
as
quickly
as
it
does in
ether
systems.
To make the machine
width
smaller. the oil
tank
is
built
in the frame. ln addition. the
ground clearance is made higher by the use
of
the dry sump system.
5-speed transmission
With
5-speeds.
power
is delivered efficiently
to the rear wheel, providing excellent perfor-
mance
for
ali operating conditions.
Starter eqlJipped carburetor
The carburetor on this vehicle has a separate
starter system. By merely operating the
starter (choke) lever a rich
mi
x
ture
is sllpplied
to
the engine
when
starting.
This makes starting easy even in cold
weather
.
Adjustable rear suspension
The rear spring preload can be adjusted
to
su
it
rider preference and riding conditions
-
2-

The
nitrogen/oil
type rear shock absorber has
improved the stability
of
the machine.
CAUTION:-----------
This
shock
absorber
is
filled
with
a
high
pressure
gas.
lt
should
be
handled
with
speci~l
care.
For
details,
refer
to
"Rear
Shock
Absorber"
on
page
63.
Lighting
equipment
As
opt
ions, headlight, taillight,
light
switch
and wire harness are available. A lighting
coil is mounted in the machine. For details,
see your Yamaha dealer.
- 3 -

NOMENCLATURE
Right side view
Left side view
1. Rear shock absorber
7.
Front number plate
1.
Full petcock
2. Se at
8. Exhaust pipe 2. Carburetor
3. Right side cover
(Number plate) 9. Oil fi/ter cover 3. Drive chain
4. Fuel tank 10. Rear brake pedal
4. Side stand
5.
Fuel tank cap 11. Kick pedal
5. Shift lever
6.
Engine oil tank cap 12. Foot rest
-4-

SPECIFICATIONS
NOTICE:
----------------------------------------------------------
Some data in
this
manual
may
become
out-
dated
due
to
improvements
made
to
the
machine in the future.
If
there
is
any ques-
GENERAL
SPECIFICATIONS
Dimension:
Overall len
gth
Overall
wi
dth
Overall hei
ght
.Wheelbase
Model
Min
imum road clearance
Net
weight
Minimum
turning radius
Engine:
Type
Engine model
Cylinder
Displacement
tian
concerning this manual.
consult
your
nearby Yamaha dealer.
TT500C
2.110
mm
(83.1 ins)
935
mm
(36.8
ins)
1.120mm(44.1
ins)
1.420
mm
(55.9
ins)
215
mm
(8.5 ins)
119
kgs
(262
lbs)
2.100
mm
(82
.7 ins)
4 stroke. single over head cam. gasoline
583
Single cylinder
499
cc
(30.4
cu. in)
-
5-

Mode!
TT500C
Bore and Stroke
87 x 84 mm (3.425 x 3. 307
ins)
Compression ratio
9.0
Starting system Kick starter system
Ignition system Flywheel magneto
Gasoline tank capacity 8.5 lits (2
24 US gal)
Engine oil
quantity
2.5 lits (2.6 US.qt) Periodic oil change:
2.0 li ts (2.1 US.qt)
Lubricating system Dry sump
Spark plug BP7ES
NGK
Carburetor
VM34SS MIKUNI
Air cleaner Oiled, foam rubber
Tra~smission:
Primary reduction system Gear
.....
~
Primary reduction ratio
2.566 (77/ 30)
Secondary reduction system Chain
Secondary reduction ratio
3.466 (52 /15)
Clutch Wet.
multi-disc type
Gear box type Constant mesh, 5-spe
ed for ward
' ' • Operation system Left
foot operation
Gear ratio: First
2.357 (33/14)
Second 1.
555 (28/18)
Th i rd
1. 190 (25 / 21)
Fourth 0.
916 (22/24)
- 6-

Madel
TI500C
Fifth 0.777 (21/27)
Steering: Caster
59° 50'
Trail 134 mm (5.28 ins)
Tire size: Front 3.
00-21 -4PR
Re ar
4.60 -18-4PR
Suspension: Front Telescopic fork
Re ar
Swing arm
S
hock absorber: Front Coil spring, oil
damper
Re ar Coil spring, nitrogen/oil damper
Frame Semi-double cradle .
.. ~ ·
- 7 -

MACHINE
IDENTIFICATION
Frame number
The frame
number
is stamped on the right
side
of
the steering head pipe.
Engine number
The engine seriai
number
is stamped
into
the
elevated
part
of
the
right
rear section
of
the
engine.
NOTE:----
--
--------------------
The first three digits
of
these numbers are for
mode! identifications; the remaining digits
are the
unit
production number. The
two
seriai numbers are usually identical
but
they
. may sometimes be 2
or
3 numbers apart.
1.
Frame
number
1. Engine
number
-
8-

CONTROL
FUNCTIONS
Engine stop button
The engine stop
butten
is located on the left
handlebar. Push and hold
to
turn engine off.
Fuel
tank
and petcock
The fuel
tank
incorporates a threaded plastic
tiller cap.
The fuel
petcock
is
located on
the
rear left-
side
of
the fuel
tank
. Turn the
petcock
lever
to
the
vertical position and fuel
will
flow
to
the carburetor. Turn lever
to
the horizontal
position
to
shut
off
fuel supply
to
the car-
buretor.
- 9 -
1. Engine stop
button
r
1. Fuel tank cap 2. Petcock

Front brake lever
The
front
brake lever is located on the right
handlebar; pivot
it
toward
the handlebar
to
activate the
front
brake.
Rear brake pedal
The rear brake pedal is on the right side
of
the motorcycle and activates the rear brake
through a link rod.
Decompression lever
When
this lever is squeezed. the exhaust
valve is forced open so the compression
pressure can be reduced. This
allows
you
to
move the piston just past the compression
stroke before kick starting. See page 17 for
proper operating procedure.
1. Brake lever 2. Brake pedal
1. Decompression lever
-10 -

Throttle
The
throttle
is the positive-return type, and
is
located on the
right
handlebar.
Kick crank
The kick starter crank is located on the right.
rear side
of
the engine.
NOTE:--------------------------
When
starting the engine use
the
decompression lever.
Clutch lever
The clutch lever is located on the
left
handlebar and disengages or engages the
clutch. Pivot the clutch lever
toward
the
handlebar
to
disengage the clutch and
release
the
lever
to
engage the clutch. The
lever should be pulled rapidly and released
slowly
for
smooth
starts.
-11-
CD
/
1. Clutch lever

./
Starter lever (choke lever)
When
cold the engine requires a richer fuel
mixture
for starting. A separate starter cir-
cuit.
which
is controlled by
the
starter lever.
supplies this
mixture
.
Push the lever
down
to
open the
circuit
(for
starting) and pull
it
up
to
close the circuit.
Shift lever
The transmission
shift
lever is located on
the
lefthand side
of
the machine directly in
front
of
the rider's
foot
rest. The
shift
mechanism
is
of
the ratcheting type and controls gear
selection for the 5-speed transmission.
-
--
-·
---
1.
Starter
lever (Choke lever)
1. Shift lever
-
12
-

Rear shock absorber
The rear suspension should be adjusted
to
fit
the load. speed and raad-conditions.
Turn
it
to
change the spring rate.
Soft
..
................
..
A
2 (
5 positions)
Stiff
....
..
........
..
....
E
-13-

PRE-OPERATION CHECKS
Before using this motorcycle please check the following points:
Item Routine Page
Fuel tank Check gas level
/top -o ff as required 9,15
Brakes Check operation/adjustment
27,28
Clutch Check
operation/adjustment
28
Engine oil Check
oillevel/top-off as required
15,34
Drive chain Check
alignment/adjustment/lubrication
52~54
Sprk plug
After break-in check color/cond'n
33
Throttle Check for proper
throttle cable operation
32.54
Decompression lever Check
for proper cable free play 15
Air filter Foam type -
must be clean and damp w/oil always
49~51
Wheels and tires Check pressure/runout/spoke tightness/ax le nuts
67~69
Fittings/fasteners Check ali - tighten as necessary -
NOTE: -- -- ---- -- ------ ---------- ------ -------- -- ------------ -- ----
Pre-operation checks should be made each time the machine is used. Such an inspection can
be thoroughly accomplished in a very short time; and the added safety it assures is more than
worth the time involved.
-14-

Fuel
Make sure there
is
sufficient fuel in
the
tank.
Recommended gasoline:
Premium gasoline
(90
octane)
Fuel tank capacity:
8.5
lit
(2.24
U.S.gal.)
Engine
oil
Make sure the engine oil
is
at the specified
leve
l.
Add
oil
as
necessary.
Recommended oil:
1.
Yamalube
4-cycle
oil
Oil quantity:
2. SAE
20W/40
type
"SE"
motor
oil (more
than
15°C,
59°F)
3. SAE 1
OW/30
type
"SE"
motor
oil
(below
15°C,
59
°F
)
2.5
lits
(2.6
US
.qt), periodic
Oil change:
2.0
lits (2.1 US.qt)
-
15-
Brake
lever
and
brake
pedal
Check for correct play in the brake lever and
pedal and make sure
they
are
working
properly. Check the brakes
at
low
speed
shortly
after
starting out.
Clutch
lever
Check for correct play in the clutch lever and
make sure the lever operates properly.
Throttle
grip
Turn the
throttle
grip
to
see
if
it
operates
properly and
if
the play is normal. Make
certain the
throttle
springs closed
when
released.
Decompression
lever
Check for correct play in the
decomp
. lever
and make sure the lever operates properly.
Tires
Check the tire pressure. (Normal riding)
FRONT
0.9
kg
/cm
2
(13 psi)
REAR
1.1
kg
/cm
2
(15
psi)

OPERATION
CAUTION:
-
--
------
- -
Before
riding
this
motorcycle,
become
thoroughly
familiar
with
ali
operating
contrais
and
their
function.
Consult
your
Yamaha
dealer
regarding
any
control
or
function
you
do
not
thoroughly
understand
. .
Starting
a
cold
engine
WARNING:--
-
--
----
- -
If
the
proper
starting
procedure
(using
the
decompression
lever) is
not
followed,
the
engine
could
kick
back
causing
injury
to
the
rider.
1.
Turn the fuel
pet
c
ock
ta
"ON".
2. Open
the
carburetor starter
jet
(choke)
by
pushing
dawn
on the lever and
com
-
pletely close the
throttle
grip.
WARNING:
-
---
-
---
- -
This
model
is
designed
for
off-road
use
only.
lt
is
not
equipped
with
U.S.
Government
approved
lighting,
mirrors,
horn
or
directional
signais.
ln
most
instances,
it
is
illegal
to
ride
this
model
(either
day
or
night)
on
any
public
street
or
highway.
-1
6 -

3. By
slowly
depressing the kick pedal. find
the compression stroke.
NOTE:--------------
--
------
When
considerable resistance
of
the
kick pedal is felt, the engine is on the
compression stroke.
4. Squeeze the decompression lever, and
depress the kick pedal
slowly
to
the
position
shawn
in the figure. This ad-
vances the engine
just
beyond the com-
pression stroke.
5.
Release the decompression lever, and
allow
the kick pedal to return
to
its
home position.
-
17-