04/10/2025
Instead of building a serious motocross bike, in 1976 Yamaha released the TT500 designed for casual trail riders. However, the bike proved quite successful for aftermarket companies like White Brothers, Powroll, and Protec. They responded with accessories to increase power, reduce weight, and improve suspension.
Frame builders like C&J, Dick Mann, Champion, and Dallas Baker soon developed lightweight frame kits that could accommodate the standard TT500 engine and components. While these aftermarket parts helped the Yamaha TT500 as an off-road bike, they failed to make it competitive in motocross.
That would change when two-time 500 World Champion Sten Lundin began working with four-time 250 World Champion Torsten Hallman to build a prototype model using a Husqvarna frame and a used TT500 engine. Yamaha would not send a 1976 TT500 to Sweden because it wasn’t sold there. Lundin’s next step was to have USA-based Profab make a lightweight chromoly frame, which Lundin mated to a special aluminum swingarm, state-of-the-art Fox AirShox and Simons forks. The project bike was dubbed the HL500, combining the first letters of Hallman and Lundin. The whole package hit the scale at 247Lb and had nearly 11 inches of wheel travel front and rear.
In late 1976, Torsten Hallman approached Yamaha about having two-time 500cc World Champion Bengt Aberg race the HL500 in the 1977 500cc World Championships. The Yamaha race team said no, but Torsten Hallman went over their heads and got approval. The HL500 was a huge media success. Bengt Aberg finished ninth in the 1977 World Championship and even won a moto in Luxembourg.
After its excellent results in 1977, a machine identical to the winning characteristics in Luxembourg was marketed in a small series in 1978 and called the HL500, H for Hallman and L for Lundin, the two creators of the yamaha 500. With a chrome-molybdenum steel frame, and a De Carbon rear shock absorber, Production version of the HL500 was lightweight, weighing 253 Lb.
Intrinsically less powerful than the YZ, which produced over 50 hp, the 38 hp HL compensated for this lack of power with greater efficiency. Pierre Karsmakers, a Dutch amateur four-stroke racer, distinguished himself in GP riding the HL, winning the 1980 US GP in Carlsbad, as well as the national championship and the one reserved for four-stroke motorcycles in the United States.
The Yamaha race team elected not to support the project in 1978, but Yamaha Europe commissioned the Norton factory to build 400 complete HL500s to sell in 1978–1979 in Europe only (you can tell the 1979 from the 1978 by its banana swingarm). The production HL500s used lots of stock Yamaha parts, including the forks, but it did come with Ohlins shocks.
In the USA, the HL500 was only offered as a kit bike. Torsten Hallman Racing, now Thor, had Profab build 100 frame kits of its Hallman “TT500 Aberg Replica.” The Hallman Racing HL500 frame kit with swingarm and necessary hardware sold for $1000 in 1978. When you added in the cost of a donor TT500, Simons or YZ forks, Ohlins or Fox shocks, gas tank, seat and other parts, you rang up a $3000 investment. The wheels from a YZ or a TT500 could be used, while the alloy gas tank had to be borrowed from a YZ125C.
The HL500 was never a huge sales success for Yamaha, but the press it received helped sell a lot of XT and TT off road bikes in the late seventies for the brand. The HL500 is an interesting footnote from an era dominated by two-strokes. It was an idea about twenty years ahead of its time. In 1997 Yamaha would pick up the torch laid down by the HL500 and lead a four-stroke revolution that would change motocross in the new millennium.