Yamaha PHAZER PZ50X Handbuch

SUPPLEMENTARY SERVICE MANUAL

PZ50X

PZ50GTX

PZ50RTX

PZ50MTX

PZ50VTX

PZ50MPX

LIT-12618-02-67 8GC-28197-11

PRINTED ON RECYCLED PAPER PRINTED IN U.S.A.

2007.10 CR

(E)

YAMAHA MOTOR CO., LTD.

2008

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and new data for

the PZ50X, PZ50GTX, PZ50RTX, PZ50MTX, PZ50VTX, PZ50MPX. For complete information, on

service procedures, it is necessary to use this Supplementary Service Manual together with follow-

ing manual:

PZ50W, PZ50GTW, PZ50FXW, PZ50MW, PZ50VTW, PZ50MPW SERVICE MANUAL:

8GC-28197-10 (LIT-12618-02-58)

PZ50X, PZ50GTX, PZ50RTX, PZ50MTX,

PZ50VTX, PZ50MPX

SUPPLEMENTARY SERVICE MANUAL

Corporation, U.S.A.

1st Edition, November 2007

unauthorized use without the written

permission of Yamaha Motor Corporation,

U.S.A. is expressly prohibited.

Printed in U.S.A.

P/N.LIT-12618-02-67

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 concepts 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.

This model has been designed and manufactured to perform within certain specifications in regard

to performance and emissions. Proper service with the correct tools is necessary to ensure that the

vehicle will operate as designed. If there is any question about a service procedure, it is imperative

that you contact a Yamaha dealer for any service information changes that apply to this model. This

policy is intended to provide the customer with the most satisfaction from his vehicle and to conform

to federal environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by

Yamaha. Modifications and significant changes in specifications or procedures will be forwarded 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 operator, 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 component 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 dis-

assembly and assembly procedures.

WARNING

CAUTION:

NOTE:

ILLUSTRATED SYMBOLS

(Refer to the illustration)

Illustrated symbols 1to 9are designed as thumb

tabs to indicate the chapter’s number and content.

1General information

2Periodic inspection and adjustment

3Chassis

4Power train

5Engine

6Cooling system

7Fuel injection system

8Electrical

9Specifications

Illustrated symbols 0to Fare used to identify the

specifications which appear.

Filling fluid

ALubricant

BTightening torque

CWear limit, clearance

DEngine speed

ESpecial tool

FElectrical data (Ω, V, A)

Illustrated symbols Gto Rin the exploded diagram

indicate grade of lubricant and location of lubrica-

tion point.

GApply locking agent (LOCTITE®)

HApply Yamabond No.5®

IApply engine oil

JApply gear oil

KApply molybdenum disulfide oil

LApply brake fluid

MApply wheel bearing grease

NApply low-temperature lithium-soap-based grease

OApply molybdenum disulfide grease

PApply silicone grease

QESSO beacon 325 grease or Aeroshell grease #7A

RUse new one

CDE

FGH

IJKL

MNO

PQR

GEN

INFO

INSP

ADJ

CHAS

POWR

ENG

COOL

FI –+

ELEC

SPEC

EGM

BLS 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

–+

PERIODIC INSPECTION AND

ADJUSTMENT

TUNING ................................................................1

FRONT SUSPENSION ...................................1

AIR PRESSURE ADJUSTMENT (PZ50RT) ...3

REAR SUSPENSION .....................................5

CHASSIS

COWLINGS ........................................................10

PZ50/PZ50GT/PZ50RT/PZ50MT..................10

STEERING..........................................................12

PZ50/PZ50GT/PZ50RT/PZ50MT..................12

FRONT SUSPENSION .......................................15

PZ50/PZ50RT/PZ50MT ................................15

PZ50GT/PZ50VT/PZ50MP ...........................17

INSTALLATION ............................................19

POWER TRAIN

SLIDE RAIL SUSPENSION................................20

PZ50/PZ50GT/PZ50RT/PZ50MT..................20

PZ50VT/PZ50MP..........................................24

ENGINE

SEAT AND FUEL TANK ....................................29

PZ50/PZ50GT/PZ50RT/PZ50MT..................29

BALANCER ........................................................31

REMOVAL ....................................................33

INSTALLATION ............................................33

FUEL INJECTION SYSTEM

THROTTLE BODY..............................................35

INJECTORS..................................................35

SPECIFICATIONS

GENERAL SPECIFICATIONS ...........................37

MAINTENANCE SPECIFICATIONS ..................41

ENGINE ........................................................41

POWER TRAIN.............................................46

CHASSIS ..................................................... 52

ELECTRICAL ............................................... 54

TIGHTENING TORQUE..................................... 57

ENGINE ....................................................... 57

POWER TRAIN............................................ 59

CHASSIS ..................................................... 61

GENERAL TORQUE SPECIFICATIONS .......... 63

DEFINITION OF UNITS ..................................... 63

CABLE ROUTING ............................................. 64

INSP

ADJ

FRONT SUSPENSION

PERIODIC INSPECTION AND

ADJUSTMENT

TUNING

FRONT SUSPENSION

Spring preload

1. Adjust:

•Spring preload

Adjustment steps:

•Loosen the locknut 1.

•Turn the spring seat 2in or out.

PZ50GT

PZ50MT “Europe”

PZ50VT “Europe”/PZ50MP

•Turn the adjusting ring 3to the proper position.

PZ50/PZ50MT “USA/Canada”/PZ50VT “USA/

Canada”

ÈPZ50MT “Europe”/PZ50VT “Europe”/PZ50MP

ÉPZ50GT

ÊPZ50/PZ50MT “USA/Canada”/PZ50VT “USA/Can-

ada”

Spring seat

distance

Standard

Shorter ←→

Longer

Preload Harder ←→

Softer

Length a

Min.

172 mm

(6.77 in)

182 mm

(7.17 in)

Max.

182 mm

(7.17 in)

Spring seat

distance

Standard

Shorter ←→

Longer

Preload Harder ←→

Softer

Length a

Min.

215 mm

(8.46 in)

225 mm

(8.86 in)

Max.

226 mm

(8.90 in)

Spring seat

distance

Standard

Shorter ←→

Longer

Preload Harder ←→

Softer

Length a

Min.

205 mm

(8.07 in)

215 mm

(8.46 in)

Max.

216 mm

(8.50 in)

Spring adjuster

position 12345

Preload Softer ←→

Harder

Standard 1

INSP

ADJ

FRONT SUSPENSION

CAUTION:

Be sure that the left and right spring preload are

the same.

WARNING

These shock absorber contain highly pressur-

ized nitrogen gas.

Do not tamper with or attempt to open the

shock absorber assemblies.

Do not subject the shock absorber assemblies

to flames or high heat, which could cause it to

explode.

Rebound damping force adjustment (PZ50GT)

The rebound damping force can be adjusted by

turning the adjuster 1.

* With the adjuster fully turned lightly in direction a

CAUTION:

•Do not continue to turn the adjuster in direc-

tion aafter it stops. The shock absorber can

be damaged and rebound damping force

adjustments cannot be made.

•Do not turn the adjuster in direction bmore

than 20 clicks. Even if the adjuster is continu-

ally turned after 20 clicks, there will be no

change in the rebound damping force.

•Be sure to stop the adjuster at a position

where there is a click.

Adjuster

position

20 clicks out 12 clicks out 3 clicks out

Minimum Standard Maximum

Turns out b* ←→

Turns in a

Rebound

damping

force

Soft ←→

Hard

INSP

ADJ

FRONT SUSPENSION/

AIR PRESSURE ADJUSTMENT (PZ50RT)

Compression damping force adjustment

(PZ50GT)

The compression damping force can be adjusted

by turning the adjuster 1.

* With the adjuster fully turned lightly in direction a

CAUTION:

•Do not continue to turn the adjuster in direc-

tion aafter it stops. The shock absorber can

be damaged and compression damping force

adjustments cannot be made.

•Do not turn the adjuster in direction bmore

than 12 clicks. Even if the adjuster is continu-

ally turned after 12 clicks, there will be no

change in the compression damping force.

•Be sure to stop the adjuster at a position

where there is a click.

Adjuster

position

12 clicks out 7 clicks out 2 clicks out

Minimum Standard Maximum

Turns out b* ←→

Turns in a

Compres-

sion damp-

ing force

Soft ←→

Hard

AIR PRESSURE ADJUSTMENT (PZ50RT)

CAUTION:

The left and right shock absorber air pressure

must be set to the same setting. Uneven set-

tings can cause poor handling and loss of sta-

bility.

This snowmobile is equipped with FOX shock

absorbers as standard equipment.

The air pressure of the shock absorbers can be

adjusted using the shock absorber pump 1

included with your snowmobile.

INSP

ADJ

AIR PRESSURE ADJUSTMENT (PZ50RT)

Adjustment steps:

WARNING

Support the snowmobile securely on a suitable

stand before adjusting the shock absorbers.

CAUTION:

Make sure that there is no load on the shock

absorbers and that they are fully extended

before making any air pressure adjustments.

1. Place the snowmobile on a level surface and

apply the parking brake.

2. Lift the front of the snowmobile onto a suitable

stand to raise the skis off the ground.

3. Remove the air valve cap 1from the shock

absorber.

4. Install the hose connector 2of the shock

absorber pump onto the air valve of the shock

absorber and tighten it approximately six turns

until the pressure registers on the pump gauge.

CAUTION:

Do not overtighten the connector onto the air

valve as this will damage the connector seal.

NOTE:

If the shock absorber has no air pressure, the

gauge reading will be zero.

5. To increase the air pressure, operate the pump

a few times. The pressure should increase

slowly. If the pressure increases rapidly, check

to make sure that the pump is properly con-

nected and tightened onto the air valve. To

decrease the air pressure, push the black bleed

valve button 3.

NOTE:

To allow pressure to escape from the pump and the

shock absorber, push the button halfway down and

hold it. To allow only a small amount of pressure to

escape, push the button all the way down and

quickly release it.

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