YAMAHA WR500

Read the truth behind the “1,000 WR500s made” myth.

YAMAHA WR500 specifications:


1. Model Identification
  • Model: WR500ZD
  • Model Code: 4AA1
  • VIN starting ('92 model): JYA4AAW0*NA000101
  • VIN starting ('93 model): JYA4AAW0*PA006101
  • Engine serial starting ('92 model): 4AA-000101
  • Engine serial starting ('93 model): 4AA-006101

2. General Specifications
  • Overall Length: 2,205 mm (86.8 in)
  • Overall Width: 845 mm (33.3 in)
  • Overall Height: 1,270 mm (50.0 in)
  • Seat Height: 985 mm (38.8 in)
  • Wheelbase: 1,505 mm (59.3 in)
  • Ground Clearance: 370 mm (14.6 in)
  • Wet Weight (oil + full fuel): 121.8 kg (269 lb)
  • Engine Type: Air-cooled 2-stroke, single cylinder, forward inclined, torque induction
  • Displacement: 487 cm³
  • Over 0.5mm: Real cc: 493cm³
    Over 1.0mm: Real cc: 499cm³
    Over 1.5mm: Real cc: 504cm³
    Over 2.0mm: Real cc: 510cm³
  • Bore × Stroke87 × 82 mm (3.43 × 3.23 in)
  • Compression Ratio: 6.64 : 1
  • Lubrication: Premix
  • Transmission Oil: Yamalube 4 (10W-30) or SAE 10W-30 SE
  • Periodic Oil Change: 0.75 L (0.66 Imp qt / 0.79 US qt)
  • Total Oil Capacity: 0.80 L (0.70 Imp qt / 0.85 US qt)
  • Air Filter: Wet foam element
  • Fuel Capacity: 13.0 L (2.86 Imp gal / 3.43 US gal)
  • Fuel Type: Premium unleaded RON 95+ (except AUS: unleaded only)
  • Carburetor: Mikuni VM38SS
  • Spark Plug: NGK B8EG, gap 0.5–0.6 mm (0.020–0.024 in)
  • Clutch: Wet multi-disc
  • Transmission: Constant-mesh 5-speed
  • Secondary Reduction: 50/14 (3.571)
  • Gear Ratios: 1st 29/15 (1.933) 2nd 24/16 (1.500) 3rd 22/18 (1.222) 4th 22/22 (1.000) 5th 20/24 (0.833)
  • Frame: Semi-double cradle
  • Caster / Trail28°15' / 128 mm (5.04 in)
  • Tires (with tube) Front 80/100-21 51M Rear 120/90-18 65M
  • Brakes: Front & Rear single disc (hydraulic)
  • Suspension: Front telescopic fork / Rear swingarm (New Monocross)
  • Wheel Travel: Front 300 mm (11.8 in) / Rear 310 mm (12.2 in)
  • Ignition: CDI Magneto
  • Generator: Flywheel magneto

3. Fuel & Oil Mixing
  • Recommended premix: Yamalube “R” (Racing 2-cycle oil) at 24 : 1
  • Alternatives: Castrol R30 or A747 at 20 : 1
  • Break-in mixture: 12 : 1 to 14 : 1

4. Maintenance Specifications – Engine
  • Cylinder head warp limit: < 0.03 mm (0.0012 in)
  • Cylinder bore: 87.00–87.02 mm
  • Taper limit: < 0.05 mm
  • Out-of-round limit: < 0.01 mm
  • Piston size / measuring point: 87.00 mm at 32 mm from bottom
  • Piston clearance: 0.080–0.085 mm (limit 0.1 mm)
  • Oversize pistons: 87.25 / 87.50 / 87.75 / 88.00 mm
  • Piston offset: 1.5 mm EX side
  • Piston ring: Keystone, B=1.5 mm, T=3.4 mm
    • End gap (installed): 0.35–0.50 mm
    • Side clearance: 0.03–0.05 mm
  • Crankshaft width “A”: 65.95–66.00 mm
  • Run-out limit: < 0.03 mm
  • Con-rod big-end side clearance: 0.25–0.75 mm
  • Small-end free play: 0.4–1.0 mm (limit 2.0 mm)
  • Clutch friction plates: 3.0 mm × 7 (limit 2.7 mm)
  • Clutch plates: 1.6 mm × 6 (warp limit 0.05 mm)
  • Clutch springs free length: 36.0 mm × 6 (limit 34.0 mm)
  • Carburetor (STD):
    • Main jet #440
    • Main air jet φ2.5
    • Jet needle 6F16-3
    • Needle jet Q-8
    • Cutaway 3.5
    • Pilot jet #40
    • Pilot air screw 1-1/2 turns out
    • Float height 19.1–21.1 mm
    • Fuel level 3–5 mm
  • Reed valve thickness: 0.42 mm
  • Valve stopper height: 8.4–8.8 mm
  • Valve bending limit: 0.6 mm

5. Maintenance Specifications – Chassis
  • Front fork travel: 300 mm
  • Fork spring free length: 480 mm
  • Spring rate (STD): 3.9 N/mm (0.39 kg/mm)
  • Fork oil capacity: 505 cm³
  • Oil level: 120 mm (from top of inner tube, fully compressed, no spring)
  • Oil grade: Front Fork Oil “01”
  • Rear shock travel: 129 mm
  • Spring free length: 260 mm
  • Installed length (STD): 240 mm
  • Spring rate (STD): 48.0 N/mm (4.8 kg/mm)
  • Gas pressure: 1,000 kPa (10 kg/cm² / 142 psi); range 700–1,300 kPa
  • Swingarm free play limits: End <1 mm, Side <0.3 mm
  • Drive chain: 520V6 / Daido, 117 links + joint
  • Chain slack: 30–60 mm (1.2–2.4 in)
  • Front disc: 230 × 3.0 mm (wear limit 2.5 mm)
  • Front pads: 4.4 mm (limit 0.8 mm)
  • Rear disc: 220 × 4.5 mm
  • Rear pads: 4.7 mm (limit 1.0 mm)
  • Brake fluid: DOT 4
  • Brake lever free play: 10–20 mm (at lever end)
  • Brake pedal height: 10 mm below footrest top
  • Clutch lever free play: 2–3 mm (at pivot)
  • Tire pressure (cold): 100 kPa (1.0 kg/cm² / 14 psi)
  • Rim run-out limit: Vertical & lateral <2.0 mm

6. Electrical Specifications
  • Ignition timing: 1.9–2.1 mm (0.075–0.083 in) / 16° BTDC at 2,000 rpm
  • CDI Magneto: F003T20672 / Mitsubishi
    • Source coil: 279–341 Ω (Brown–Black)
    • Pickup coil: 11.2–13.6 Ω (White/Red–Black)
  • CDI Unit: F08T01472 / Mitsubishi
  • Ignition coil: F6T537 / Mitsubishi
    • Primary: 0.26–0.36 Ω
    • Secondary: 3.5–4.7 kΩ
    • Min spark gap: 6 mm

7. Torque Specifications (Key Values)Engine
  • Spark plug: 25 Nm (18 ft·lb)
  • Cylinder head nuts: 22 Nm
  • Cylinder nuts: 35 Nm
  • Crankcase: 12 Nm
  • Primary drive gear: 115 Nm
  • Clutch boss: 75 Nm
  • Drive sprocket: 75 Nm
  • Magneto rotor: 85 Nm
  • Oil drain bolt: 20 Nm
Chassis
  • Handle crown / outer tubes: 23 Nm
  • Steering stem nut: 115 Nm
  • Handlebar holders (upper): 23 Nm / (lower): 40 Nm
  • Front axle: 59 Nm
  • Rear axle: 115 Nm
  • Pivot shaft: 85 Nm
  • Engine mounting (upper/lower): 64 Nm
  • Front/rear caliper mounts: 23 Nm
  • Brake disc bolts: 12 Nm
  • Spoke nipples: 6 Nm
General ISO torque (standard fasteners)
  • 6 mm: 6 Nm
  • 8 mm: 15 Nm
  • 10 mm: 30 Nm
  • 12 mm: 55 Nm
  • 14 mm: 85 Nm
  • 16 mm: 130 Nm
Steering ring-nut procedure: Tighten to ~38 Nm, loosen 1 turn, then retighten to 4 Nm.

8. Key Adjustments
  • Clutch lever free play: 2–3 mm
  • Throttle free play: 3–5 mm
  • Pilot air screw: 1-1/2 turns out
  • Chain slack: 30–60 mm (check at tightest point)
  • Front fork rebound (STD): 6 clicks out
  • Front fork compression (STD): 8 clicks out
  • Rear shock preload (installed length): 240 mm (range 237–260 mm)
  • Rear rebound (STD): ~8 clicks out
  • Rear compression (STD): ~11 clicks out

9. Setting / Optional PartsCarburetor
  • Main jets: #430 / #440 (STD) / #450
  • Pilot jets: #35 / #40 (STD) / #45
  • Throttle valves: 2.5 / 3.0 / 3.5 (STD)
  • Needle jets: Q-6 / Q-8 (STD) / R-0
Front fork springs
  • STD 0.390 / Soft 0.380 / Hard 0.400
Rear shock springs
  • STD 4.8 / Soft 4.6 (green) / Hard 5.0 (red)
Sprockets
  • Drive: 13T / 14T (STD) / 15T
  • Driven: 44T / 46T / 48T / 50T (STD) / 52T