2007-2008 Yamaha Phazer Venture PZ50 models Service Manual

SERVICE MANUAL PZ50W PZ50GTW PZ50FXW PZ50MW PZ50VTW PZ50MPW LIT-12618-02-58 8GC-28197-10

NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha snowmobiles have a basic understanding of the mechanical con- cepts and procedures inherent in snowmobile repair. Without such knowledge, attempted repairs or service to this model may render it unfit and/or unsafe to use. Yamaha Motor Company, Ltd. is continually striving to improve all models manufac- tured by Yamaha. Modifications and significant changes in specifications or procedures will be for- warded to all authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. HOW TO USE THIS MANUAL Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the snowmobile opera- tor, a bystander, or a person inspecting or repairing the snowmobile. A CAUTION indicates special precautions that must be taken to avoid damage to the snowmobile. A NOTE provides key information that can make procedures easier or clearer. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all inspection, repair, assembly, and disassembly operations. In this revised format, the condition of a faulty com- ponent will precede an arrow symbol and the course of action required to correct the problem will follow the symbol, e.g., • Bearings Pitting/damage → Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section to facilitate correct disassembly and assembly procedures. PZ50W, PZ50GTW, PZ50FXW, PZ50MW, PZ50VTW, PZ50MPW SERVICE MANUAL ©2006 by Yamaha Motor Corporation, U.S.A. 1st Edition, July 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N.LIT-12618-02-58 WARNING CAUTION: NOTE:

ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Periodic inspection and adjustment 3 Chassis 4 Power train 5 Engine 6 Cooling system 7 Fuel injection system 8 Electrical 9 Specifications Illustrated symbols 0 to F are used to identify the specifications which appear. 0 Filling fluid A Lubricant B Tightening C Wear limit, clearance D Engine speed E Special tool F Ω, V, A Illustrated symbols G to O in the exploded diagram indicate grade of lubricant and location of lubrication point. G Apply locking agent (LOCTITE ® ) H Apply Yamabond No.5 ® I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply wheel bearing grease M Apply low-temperature lithium-soap base grease N Apply molybdenum disulfide grease O Use new one 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O GEN INFO INSP ADJ CHAS POWR TR ENG COOL FI – + ELEC SPEC T R . . LT 5 E G M B LS M New

INDEX GENERAL INFORMATION GEN INFO 1 PERIODIC INSPECTION AND ADJUSTMENT INSP ADJ 2 CHASSIS CHAS 3 POWER TRAIN POWR TR 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 FUEL INJECTION SYSTEM FI 7 ELECTRICAL ELEC 8 SPECIFICATIONS SPEC 9 – +

CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION............................ 1-1 FRAME SERIAL NUMBER ......................... 1-1 ENGINE SERIAL NUMBER ........................ 1-1 IMPORTANT INFORMATION .......................... 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY........................................... 1-2 ALL REPLACEMENT PARTS..................... 1-2 GASKETS, OIL SEALS, AND O-RINGS..... 1-3 LOCK WASHERS/PLATES AND COTTER PINS............................................................ 1-3 BEARINGS AND OIL SEALS ..................... 1-3 CIRCLIPS ................................................... 1-3 LOCTITE ® ................................................... 1-3 SPECIAL TOOLS ............................................. 1-4 FOR TUNE UP............................................ 1-4 FOR ENGINE SERVICE ............................. 1-4 FOR POWER TRAIN SERVICE ................. 1-7 FOR FUEL INJECTION SERVICE ............. 1-8 FOR ELECTRICAL SERVICE .................... 1-8 CHAPTER 2. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION............................................... 2-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM.............. 2-1 GENERAL MAINTENANCE AND LUBRICATION CHART .................................... 2-2 ENGINE ............................................................ 2-4 SPARK PLUGS........................................... 2-4 FUEL LINE INSPECTION ........................... 2-4 COOLING SYSTEM.................................... 2-5 VALVE CLEARANCE ADJUSTMENT ........ 2-7 THROTTLE BODY SYNCHRONIZATION ............................... 2-13 ENGINE IDLE SPEED ADJUSTMENT ..... 2-14 THROTTLE CABLE FREE PLAY ADJUSTMENT .......................................... 2-15 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK .................................... 2-16 COMPRESSION PRESSURE MEASUREMENT ...................................... 2-17 ENGINE OIL LEVEL INSPECTION .......... 2-19 ENGINE OIL REPLACEMENT ................. 2-20 CYLINDER HEAD BREATHER HOSE INSPECTION ............................................ 2-23 THROTTLE BODY JOINTS INSPECTION ............................................ 2-23 CHECKING THE AIR FILTER ELEMENT ................................................. 2-24 EXHAUST SYSTEM INSPECTION .......... 2-25 POWER TRAIN............................................... 2-26 SHEAVE OFFSET ADJUSTMENT ........... 2-26 DRIVE V-BELT.......................................... 2-28 ENGAGEMENT SPEED CHECK .............. 2-29 PARKING BRAKE ADJUSTMENT............ 2-29 BRAKE FLUID LEVEL INSPECTION ....... 2-30 BRAKE PAD INSPECTION....................... 2-31 BRAKE HOSE INSPECTION .................... 2-32 AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) .................................................. 2-32 DRIVE CHAIN ........................................... 2-33 TRACK TENSION ADJUSTMENT ............ 2-35 SLIDE RUNNER INSPECTION ................ 2-37 MAXIMIZING DRIVE TRACK LIFE ........... 2-37 CHASSIS ........................................................ 2-39 SKI/SKI RUNNER ..................................... 2-39 STEERING SYSTEM ................................ 2-39 LUBRICATION .......................................... 2-41 ELECTRICAL ................................................. 2-42 HEADLIGHT BEAM ADJUSTMENT ......... 2-42 BATTERY INSPECTION........................... 2-42 FUSE INSPECTION.................................. 2-48 TUNING .......................................................... 2-50 CLUTCH.................................................... 2-50 GEAR SELECTION................................... 2-55 FRONT SUSPENSION ............................. 2-61 REAR SUSPENSION................................ 2-63 CHAPTER 3. CHASSIS COWLINGS ...................................................... 3-1 PZ50/PZ50GT/PZ50FX/PZ50M .................. 3-1 PZ50VT/PZ50MP ........................................ 3-3 STEERING ........................................................ 3-4 PZ50W/PZ50GT/PZ50FX/PZ50M............... 3-4 PZ50VT/PZ50MP ........................................ 3-6 REMOVAL................................................. 3-10 INSPECTION ............................................ 3-10 INSTALLATION......................................... 3-11 SKI .................................................................. 3-14 PZ50/PZ50GT/PZ50FX/PZ50VT “USA/ Canada” .................................................... 3-14

PZ50VT “Europe”/PZ50MP ....................... 3-15 PZ50M ...................................................... 3-16 INSPECTION ............................................ 3-17 FRONT SUSPENSION ................................... 3-18 PZ50/PZ50FX/PZ50M............................... 3-18 PZ50GT/PZ50VT/PZ50MP ....................... 3-20 HANDLING NOTES .................................. 3-22 INSPECTION ............................................ 3-22 INSTALLATION ........................................ 3-23 CHAPTER 4. POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT ....... 4-1 REMOVAL .................................................. 4-3 DISASSEMBLY........................................... 4-3 INSPECTION .............................................. 4-4 ASSEMBLY................................................. 4-6 INSTALLATION .......................................... 4-9 SECONDARY SHEAVE ................................. 4-10 DISASSEMBLY......................................... 4-12 INSPECTION ............................................ 4-12 ASSEMBLY............................................... 4-13 INSTALLATION ........................................ 4-14 DRIVE CHAIN................................................. 4-15 REMOVAL ................................................ 4-16 INSPECTION ............................................ 4-16 INSTALLATION ........................................ 4-18 SECONDARY SHAFT .................................... 4-19 PZ50 ......................................................... 4-19 REMOVAL ................................................ 4-20 INSPECTION ............................................ 4-20 INSTALLATION ........................................ 4-20 SECONDARY SHAFT AND DRIVE CHAIN INSTALLATION ............................ 4-22 SECONDARY SHAFT AND REVERSE GEAR CASE................................................... 4-23 PZ50GT/PZ50FX/PZ50M/PZ50VT/ PZ50MP .................................................... 4-23 REMOVAL ................................................ 4-27 INSPECTION ............................................ 4-28 ASSEMBLY............................................... 4-28 INSTALLATION ........................................ 4-29 SECONDARY SHAFT AND DRIVE CHAIN INSTALLATION ............................ 4-30 BRAKE ........................................................... 4-31 BRAKE PAD REPLACEMENT ................. 4-33 BRAKE CALIPER DISASSEMBLY ........... 4-36 BRAKE CALIPER INSPECTION AND REPAIR ............................................ 4-36 BRAKE CALIPER ASSEMBLY ................. 4-37 BRAKE CALIPER INSTALLATION ........... 4-37 INSPECTION ............................................ 4-39 BRAKE MASTER CYLINDER ASSEMBLY ............................................... 4-39 INSTALLATION......................................... 4-39 SLIDE RAIL SUSPENSION............................ 4-40 PZ50/PZ50GT/PZ50FX/PZ50M ................ 4-40 PZ50VT/PZ50MP ...................................... 4-45 REMOVAL................................................. 4-51 INSPECTION ............................................ 4-51 ASSEMBLY ............................................... 4-51 INSTALLATION......................................... 4-55 FRONT AXLE AND TRACK ........................... 4-56 INSPECTION ............................................ 4-57 INSTALLATION......................................... 4-57 CHAPTER 5. ENGINE SEAT AND FUEL TANK................................... 5-1 PZ50/PZ50GT/PZ50FX/PZ50M .................. 5-1 BACKREST AND PASSENGER SEAT ........... 5-3 PZ50VT/PZ50MP ........................................ 5-3 RIDER SEAT AND FUEL TANK ...................... 5-5 PZ50VT/PZ50MP ........................................ 5-5 REMOVAL................................................... 5-7 INSTALLATION........................................... 5-8 EXHAUST PIPE AND MUFFLER ..................... 5-9 PZ50/PZ50GT/PZ50FX/PZ50M .................. 5-9 PZ50VT/PZ50MP ...................................... 5-10 INSTALLATION......................................... 5-11 OIL TANK ....................................................... 5-12 ENGINE ASSEMBLY ..................................... 5-13 HOSE AND LEADS................................... 5-13 ENGINE ASSEMBLY ................................ 5-15 REMOVAL................................................. 5-16 INSTALLATION......................................... 5-16 CAMSHAFTS.................................................. 5-18 CYLINDER HEAD COVER ....................... 5-18 CAMSHAFTS ............................................ 5-19 REMOVAL................................................. 5-20 INSPECTION ............................................ 5-21 INSTALLATION......................................... 5-25

CYLINDER HEAD........................................... 5-28 REMOVAL ................................................ 5-29 INSPECTION ............................................ 5-29 INSTALLATION ........................................ 5-30 VALVES AND VALVE SPRINGS ................... 5-32 REMOVAL ................................................ 5-33 INSPECTION ............................................ 5-34 INSTALLATION ........................................ 5-38 A.C. MAGNETO ROTOR AND STARTER CLUTCH ......................................................... 5-41 REMOVAL ................................................ 5-42 INSPECTION ............................................ 5-43 INSTALLATION ........................................ 5-44 OIL PAN AND OIL PUMP .............................. 5-46 REMOVAL ................................................ 5-49 INSPECTION ............................................ 5-49 INSTALLATION ........................................ 5-50 BALANCER .................................................... 5-52 REMOVAL ................................................ 5-54 INSPECTION ............................................ 5-55 INSTALLATION ........................................ 5-55 CRANKCASE ................................................. 5-58 CRANKCASE............................................ 5-58 CONNECTING RODS AND PISTONS ..... 5-59 CRANKSHAFT.......................................... 5-60 REMOVAL ................................................ 5-61 INSPECTION ............................................ 5-63 INSTALLATION ........................................ 5-73 CHAPTER 6. COOLING SYSTEM RADIATOR AND HEAT EXCHANGER............ 6-1 INSPECTION .............................................. 6-3 INSTALLATION .......................................... 6-4 THERMOSTAT ................................................. 6-5 INSPECTION .............................................. 6-6 INSTALLATION .......................................... 6-6 WATER PUMP.................................................. 6-8 DISASSEMBLY......................................... 6-10 INSPECTION ............................................ 6-10 ASSEMBLY............................................... 6-11 INSTALLATION ........................................ 6-12 CHAPTER 7. FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM ............................. 7-1 WIRING DIAGRAM ..................................... 7-2 ECU SELF-DIAGNOSTIC FUNCTION ....... 7-4 SELF-DIAGNOSTIC FUNCTION TABLE.... 7-4 TROUBLESHOOTING CHART................... 7-6 DIAGNOSTIC MODE .................................. 7-7 TROUBLESHOOTING DETAILS .............. 7-14 OIL PRESSURE SWITCH ........................ 7-28 INTAKE AIR TEMPERATURE SENSOR ................................................... 7-28 THROTTLE BODY.......................................... 7-29 INJECTORS .............................................. 7-30 INSPECTION ............................................ 7-31 PRESSURE REGULATOR OPERATION ............................................. 7-31 INSPECTION AND ADJUSTMENT .......... 7-32 CHAPTER 8. ELECTRICAL SWITCH INSPECTION ..................................... 8-1 SWITCH INSPECTION ............................... 8-1 INSPECTING A SWITCH SHOWN IN THE MANUAL ............................................. 8-1 IGNITION SYSTEM .......................................... 8-2 CIRCUIT DIAGRAM.................................... 8-2 TROUBLESHOOTING ................................ 8-4 IGNITION SPARK GAP .............................. 8-6 IGNITION COIL ........................................... 8-6 CRANKSHAFT POSITION SENSOR ......... 8-7 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) .................................................... 8-8 ENGINE STOP SWITCH ............................ 8-9 THROTTLE SWITCH .................................. 8-9 MAIN SWITCH .......................................... 8-10 ELECTRICAL STARTING SYSTEM .............. 8-11 CIRCUIT DIAGRAM.................................. 8-11 TROUBLESHOOTING .............................. 8-12 STARTER MOTOR ................................... 8-14 CHARGING SYSTEM ..................................... 8-19 CIRCUIT DIAGRAM.................................. 8-19 TROUBLESHOOTING .............................. 8-20 BATTERY.................................................. 8-21 A.C. MAGNETO ........................................ 8-21

LIGHTING SYSTEM ....................................... 8-22 CIRCUIT DIAGRAM.................................. 8-22 TROUBLESHOOTING .............................. 8-24 BULB(S) .................................................... 8-26 HEADLIGHT BEAM SWITCH ................... 8-26 HEADLIGHT RELAY................................. 8-27 LOAD CONTROL RELAY ......................... 8-27 SIGNAL SYSTEM........................................... 8-28 CIRCUIT DIAGRAM.................................. 8-28 TROUBLESHOOTING .............................. 8-30 BRAKE LIGHT SWITCH ........................... 8-38 DRIVE POSITION SWITCH AND REVERSE POSITION SWITCH (PZ50GT/PZ50FX/PZ50M/PZ50VT/ PZ50MP) ................................................... 8-38 DC BACK BUZZER (PZ50GT/PZ50FX/ PZ50M/PZ50VT/PZ50MP) ........................ 8-38 COOLANT TEMPERATURE SENSOR .... 8-39 OIL LEVEL SWITCH ................................. 8-40 FUEL SENDER ......................................... 8-40 SPEED SENSOR...................................... 8-41 KNOCK SENSOR ..................................... 8-41 GRIP WARMER SYSTEM .............................. 8-42 CIRCUIT DIAGRAM.................................. 8-42 TROUBLESHOOTING .............................. 8-44 GRIP AND THUMB WARMER ................. 8-46 GRIP/THUMB WARMER ADJUSTMENT SWITCH .................................................... 8-46 PASSENGER GRIP WARMER (PZ50VT) .................................................. 8-47 PASSENGER GRIP WARMER SWITCH (PZ50VT) .................................................. 8-47 PASSENGER GRIP WARMER RELAY (PZ50VT/PZ50MP) ................................... 8-48 COOLING SYSTEM (PZ50M/PZ50VT/PZ50MP) ............................. 8-50 CIRCUIT DIAGRAM.................................. 8-50 TROUBLESHOOTING .............................. 8-52 RADIATOR FAN MOTOR ......................... 8-53 RADIATOR FAN MOTOR RELAY ............ 8-53 DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/PZ50FX/PZ50M/PZ50VT/ PZ50MP) ......................................................... 8-54 CIRCUIT DIAGRAM.................................. 8-54 TROUBLESHOOTING .............................. 8-56 GEAR MOTOR ......................................... 8-57 GEAR MOTOR RELAY 1.......................... 8-58 GEAR MOTOR RELAY 2.......................... 8-58 GEAR MOTOR RELAY 3.......................... 8-59 CHAPTER 9. SPECIFICATIONS GENERAL SPECIFICATIONS.......................... 9-1 MAINTENANCE SPECIFICATIONS................. 9-5 ENGINE ...................................................... 9-5 POWER TRAIN ......................................... 9-10 CHASSIS .................................................. 9-16 ELECTRICAL ............................................ 9-18 TIGHTENING TORQUE.................................. 9-21 ENGINE .................................................... 9-21 POWER TRAIN ......................................... 9-23 CHASSIS .................................................. 9-25 GENERAL TORQUE SPECIFICATIONS ....... 9-27 DEFINITION OF UNITS .................................. 9-27 CABLE ROUTING .......................................... 9-29

1-1 GEN INFO GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number 1 is located on the right-hand side of the frame (just below the front of the seat). ENGINE SERIAL NUMBER The engine serial number 1 is located on the left-hand side of the crankcase. NOTE: Designs and specifications are subject to change without notice. MACHINE IDENTIFICATION

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2007-2008 Yamaha Phazer Venture PZ50 models Service Manual

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