Many technical problems to be solved
"First, the heavy pistons gave us countless problems. They seized up and were punched. Cylinder and head development was as difficult. We even had a cylinder that broke in the middle.
At that time we didn't even try balancer systems, although we had many problems with broken crankshaft bearings as well.
The con-rod had no big end bearing but was turning on a needle bearing that needed a low pressure lubrication. We did make this choice instead of using a one-piece forged crankshaft with assembled connecting rod because it allowed us to build a much more compact engine and was also cheaper to produce due to its vertically split crankcase."
"In the end all our technical problems delayed the roll out by more than one year. But we had succeeded, XT was now more reliable than a big single 4-stroke had ever been! Although it was over-square with a bore and stroke of 87 x 84 mm, (all British bikes were long stroke), we obtained the real character of a big thumper. The two-valve head gave a flat torque curve while the smaller flywheel allowed the engine to rev up as easily as we wanted. Dry sump and short stroke also allowed for better ground clearance and a more compact engine than former British bikes ever had."
Rollout in 1975 in US
The first XT 500 was shown at the US dealer convention in September 1975. Europeans had to wait till the summer of 1976 before they could press their boots against the heavy kick-starter.
The XT 500 was an instant success and was produced until 1990. It laid the ground for the later range of XT bikes ranging from 125 cc (XT 125) to 750 cc (XTZ 750) and contributed largely to Yamaha's image.
The XT proved it's performance and reliability by winning the first big African rallies, which were on the rise in the late seventies. It started with Paris-Abidjan-Nice and then the godfather of all rallies, the famous Paris-Dakar, which confirmed the supremacy of the XT 500. In France alone, 62.000 XT 500's were sold from 1976 to 1990.