2007 YAMAHA VENTURE MULTI PURPOSE Factory Service & Work Shop Manual
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Yamaha Phazer/Venture Lite service manual 2007-2011
This manual is comprised of a base manual, plus two additional supplement manuals for
the updates made to the Yamaha Phazer and Venture Lite over the years. Use the links
below or the bookmarks to the left to get to the manual that covers your model.
2007 models base manual
2008-2010 models supplement manual
2011 models supplement 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 informa-
tion 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 disas-
sembly and assembly procedures.
PZ50W, PZ50GTW, PZ50FXW, PZ50MW,
PZ50VTW, PZ50MPW
SERVICE MANUAL
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 lubrica-
tion 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 ........................................ 5-74
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
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$39.99
Upon purchasing this manual, you will receive a .PDF file containing an email address for further assistance. After contacting the provided email, you will receive a reply with a link to access the manual for your 2007 YAMAHA VENTURE MULTI PURPOSE.
This comprehensive manual covers every aspect of your machine, providing detailed instructions for tasks ranging from an oil change to a transmission swap. With hundreds of pages, it includes numerous illustrations to assist you and easy-to-understand text throughout.
The manual features a search function, allowing you to easily navigate its contents and print the necessary pages. It serves as a Factory Service Repair Manual, offering step-by-step guidance on maintenance and repair fundamentals, empowering owners to make informed decisions about their machine.
Whether you are a professional mechanic or a DIY enthusiast, this manual equips you with the knowledge required to effectively maintain and repair your vehicle. Our commitment to excellent customer service ensures your satisfaction with both the quality of the manual and our support.
