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Yamaha PHAZER PZ50X, Supplementary Service Manual

The Yamaha PHAZER PZ50X Supplementary Service Manual is an indispensable resource for maintenance and troubleshooting, providing detailed instructions and diagrams. This comprehensive manual is available for free download at manualshive.com, ensuring that owners have access to the necessary information to keep their PHAZER PZ50X in peak condition.

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67

SPEC

CABLE ROUTING

N

Parking brake cable

O

Brake hose

P

Route the fuel tank breather 
hose along the frame rear cross 
member.

Q

Speed sensor coupler

R

Auxiliary DC jack (PZ50GT/
PZ50RT/PZ50MT) (optional)

S

Install the frame ground lead ter-
minal and the Rectifier/regulator 
using the same nut.

T

Sub-wire harness coupler

U

Left handlebar switch lead cou-
plers

V

Rectifier/regulator

W

Connect the wire harness cou-
pler to the Rectifier/regulator 
coupler shown in the illustration.

X

Crankshaft position sensor cou-
pler

Y

Fuel sender lead coupler

Z

Intake air pressure sensor cou-
pler

[

Headlight coupler

\

Intake air temperature sensor 
coupler

Summary of Contents for PHAZER PZ50X

Page 1: ...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 ...

Page 2: ...e 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 2007 by Yamaha Motor Corporation U S A 1st Edition November 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is express...

Page 3: ...gnificant 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 cou...

Page 4: ...rance D Engine speed E Special tool F Electrical data Ω V A Illustrated symbols G to R 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 brake fluid M Apply wheel bearing grease N Apply low temperature lithium soap based grease O Appl...

Page 5: ...RAL 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 ...

Page 6: ...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 5...

Page 7: ...pe PZ50VT Europe PZ50MP É PZ50GT Ê PZ50 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 Softe...

Page 8: ...urning the adjuster 1 With the adjuster fully turned lightly in direction a CAUTION Do not continue to turn the adjuster in direc tion a after it stops The shock absorber can be damaged and rebound damping force adjustments cannot be made Do not turn the adjuster in direction b more than 20 clicks Even if the adjuster is continu ally turned after 20 clicks there will be no change in the rebound da...

Page 9: ...ontinu 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 1 a b AIR PRESSURE ADJUSTMENT PZ50RT CAUTION The left and right shock absorber air pressure must b...

Page 10: ...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 inc...

Page 11: ...olls too much during cornering increase the air pres sure by 34 kPa 0 3 kgf cm 5 psi If the suspen sion is too firm and you want a more compliant ride decrease the air pressure by 34 kPa 0 3 kgf cm 5 psi Air pressure range 345 kPa 3 4 kgf cm 50 psi to 1 034 kPa 10 3 kgf cm 150 psi Recommended air pressure 483 kPa 4 8 kgf cm 70 psi REAR SUSPENSION Stopper band 1 Adjust Stopper band length CAUTION M...

Page 12: ...o 2 No 1 1 2 È È 1 1 2 No 4 No 3 No 2 No 1 É Choosing other settings CAUTION The standard settings work well under most general riding conditions The suspension can be adjusted to work better in one condition but only at the expense of another Keep this in mind when you adjust the suspension È PZ50 PZ50GT PZ50RT PZ50MT É PZ50VT PZ50MP È No 5 hole É No 4 hole shortest No 1 hole longest More weight ...

Page 13: ... Europe PZ50RT PZ50MT Europe PZ50VT Europe PZ50MP Spring seat distance Standard Shorter Longer Preload Harder Softer Length a Min 180 mm 7 09 in 190 mm 7 48 in Max 191 mm 7 52 in Spring seat distance Standard Shorter Longer Preload Harder Softer Length a Min 178 mm 7 01 in 188 mm 7 40 in Max 189 mm 7 44 in Spring seat distance Standard Shorter Longer Preload Harder Softer Length a Min 194 mm 7 64 ...

Page 14: ...bject the shock absorber assembly to flames or high heat which could cause it to explode É PZ50 PZ50GT USA Canada PZ50MT USA Can ada PZ50VT USA Canada Spring adjuster position 1 2 3 4 5 Preload Softer Harder Standard 1 É Rear side Turn the adjuster 1 to proper position WARNING Always adjust both spring preload left and right to the same setting Uneven adjustment can cause poor handling and loss of...

Page 15: ...fter it stops The shock absorber can be damaged and damping force adjustments cannot be made Do not turn the adjuster in direction b more than 20 clicks Even if the adjuster is continu ally turned after 20 clicks there will be no change in the damping force Be sure to stop the adjuster at a position where there is a click Adjuster position 20 clicks out 11 clicks out 1 click out Minimum Standard M...

Page 16: ...t panel 1 3 Air filter case cover 1 4 Headlight cover 1 5 Left side panel 1 6 Right side panel 1 7 Left side cover 1 8 Right side cover 1 9 Left lower cover 1 10 Right lower cover 1 11 Headlight coupler 2 12 Headlight assembly 1 13 Cylinder 2 intake air pressure sensor cou pler 1 Disconnect 7 5 4 12 6 18 19 19 3 10 2 8 17 16 11 15 13 14 8 Nm 0 8 m kg 5 8 ft lb È È È È È 9 1 PZ50RT 20 ...

Page 17: ...er 1 Disconnect 16 Cylinder head breather hose 1 Disconnect 17 Oil tank breather hose 1 Disconnect 18 Air filter case assembly 1 19 Air filter case assembly pad left and right 2 20 Intake air pressure sensor hose 2 For installation reverse the removal proce dure 7 5 4 12 6 18 19 19 3 10 2 8 17 16 11 15 13 14 8 Nm 0 8 m kg 5 8 ft lb È È È È È 9 1 PZ50RT 20 ...

Page 18: ... meter coupler 1 6 Multi function meter 1 7 Multi function meter bracket 1 8 Steering pad 1 PZ50GT PZ50RT PZ50MT 9 Plastic band 2 10 Thumb warmer lead coupler 1 Disconnect 11 Engine stop switch coupler 1 Disconnect 12 Throttle switch coupler 2 Disconnect 13 Grip warmer lead connector 2 Disconnect 14 Grip thumb warmer adjustment switch lead coupler 1 Disconnect 25 23 Ê 19 20 21 É Ì 18 17 22 12 5 11...

Page 19: ...linder holder 1 22 Master cylinder assembly 1 NOTE After installing all parts refer to CABLE ROUTING to check the cable and lead rout ings 23 Handlebar holder 2 24 Handlebar 1 25 Steering joint 1 For installation reverse the removal proce dure 25 23 Ê 19 20 21 É Ì 18 17 22 12 5 11 13 10 14 13 15 16 24 9 4 9 8 6 3 7 1 Ë Ë 3 2 È LT 2 È LT 4 16 Nm 1 6 m kg 11 ft lb Ë 10 Nm 1 0 m kg 7 2 ft lb 15 Nm 1 ...

Page 20: ...14 CHAS STEERING 1 Install For PZ50RT Wind deflector bracket holder 1 Wind deflector bracket 2 NOTE Align the end of the wind deflector bracket with the punch mark a on the handlebar 2 1 a ...

Page 21: ...rber 1 PZ50 PZ50MT USA Canada 2 Shock absorber 1 PZ50RT 3 Shock absorber 1 PZ50MT Europe 4 Collar 2 PZ50 PZ50MT 5 Bushing 4 PZ50 PZ50MT 6 Tie rod 1 Disconnect 7 Steering knuckle 1 8 Upper arm ball joint 1 9 Upper arm 1 10 Bushing 2 11 Stabilizer holder 1 12 Bushing 1 New 5 5 4 4 10 11 12 9 10 16 16 16 15 14 13 17 7 6 8 1 90 Nm 9 0 m kg 65 ft lb Ë 45 Nm 4 5 m kg 32 ft lb Ê 65 Nm 6 5 m kg 47 ft lb Ì...

Page 22: ... arm 1 16 Bushing 4 17 Lower arm ball joint 1 For installation reverse the removal proce dure New 5 5 4 4 10 11 12 9 10 16 16 16 15 14 13 17 7 6 8 1 90 Nm 9 0 m kg 65 ft lb Ë 45 Nm 4 5 m kg 32 ft lb Ê 65 Nm 6 5 m kg 47 ft lb Ì Ì Ì É É É Ê Ì Ê Ê È Ë Ê 28 Nm 2 8 m kg 20 ft lb È 34 Nm 3 4 m kg 24 ft lb É LT 2 3 Ê ...

Page 23: ...0GT 2 Shock absorber 1 PZ50VT USA Canada 3 Shock absorber 1 PZ50VT Europe PZ50MP 4 Collar 2 5 Bushing 4 6 Tie rod 1 Disconnect 7 Steering knuckle 1 8 Upper arm ball joint 1 9 Upper arm 1 10 Bushing 2 11 Stabilizer holder 1 12 Bushing 1 5 5 4 4 10 10 16 16 16 15 14 13 13 17 7 6 8 1 34 Nm 3 4 m kg 24 ft lb Ê 45 Nm 4 5 m kg 32 ft lb Ë 90 Nm 9 0 m kg 65 ft lb Ì 65 Nm 6 5 m kg 47 ft lb Í Í Ë È Ë Ì É Í ...

Page 24: ...hing 4 17 Lower arm ball joint 1 For installation reverse the removal proce dure 5 5 4 4 10 10 16 16 16 15 14 13 13 17 7 6 8 1 34 Nm 3 4 m kg 24 ft lb Ê 45 Nm 4 5 m kg 32 ft lb Ë 90 Nm 9 0 m kg 65 ft lb Ì 65 Nm 6 5 m kg 47 ft lb Í Í Ë È Ë Ì É Í Ë New 11 12 9 Í Ê Ê 28 Nm 2 8 m kg 20 ft lb É 7 Nm 0 7 m kg 5 1 ft lb È LT 3 2 Ë ...

Page 25: ... PZ50MT The stabilizer force can be adjusted by changing the installation positions of the stabilizer bushing and stabilizer holder PZ50GT PZ50VT PZ50MP È PZ50 PZ50RT PZ50MT É PZ50GT PZ50VT PZ50MP a Forward b Very hard c Hard d Medium e Soft Stabilizer bushing and stabilizer holder stan dard installation positions d PZ50GT b PZ50VT PZ50MP a 1 2 3 È b c d e a a a a 1 2 3 É 2 Install Shock absorber ...

Page 26: ...bly Remove the parts in the order listed below 1 Stopper band 1 2 Front shock absorber 1 3 Bushing 2 4 Collar 1 5 Bushing 2 6 Collar 1 7 Front pivot arm 1 8 Bushing 2 9 Shaft 1 0 Collar 2 A Shaft 1 B Shaft 1 4 Nm 0 4 m kg 2 9 ft lb 49 Nm 4 9 m kg 35 ft lb 60 Nm 6 0 m kg 43 ft lb É Ê Ë È Ê 0 0 A 8 9 7 8 B 6 5 3 2 3 4 5 1 Ë É Ê Ê Ê É 110 Nm 11 0 m kg 80 ft lb È È ...

Page 27: ...g end guide F Spring end guide bracket 2 G Wheel bracket 2 H Suspension wheel 2 I Bushing 2 J Shaft 1 K Front suspension bracket 1 L Suspension wheel 2 M Collar 2 N Wheel bracket 2 O Connecting arm 1 P Collar 2 LT H G I J P O K H I G D C E F C D E F É Ê È É É È New New 60 Nm 6 0 m kg 43 ft lb 72 Nm 7 2 m kg 52 ft lb É Ê 6 Nm 0 6 m kg 4 3 ft lb È É É É Ê N N M PZ50MT M L L Ê LT ...

Page 28: ...T Torsion spring 2 U Rear pivot arm protector 2 V Circlip 2 W Adjuster 2 X Rear pivot arm 1 Y Shaft 1 Z Guide wheel 2 Rear pivot arm bracket 1 Shaft 1 Collar 4 _ Stopper 4 Q R U T S R X Y Z Z W V 72 Nm 7 2 m kg 52 ft lb 60 Nm 6 0 m kg 43 ft lb 35 Nm 3 5 m kg 25 ft lb 49 Nm 4 9 m kg 35 ft lb È É Ê Ë É È Ë Ê Ê Ë Ë LT LT LT LT New Ë É ...

Page 29: ... 2 c Guide wheel 1 d Collar 2 e Tension adjuster 2 f Collar 1 g Collar 1 h Suspension wheel 2 i Wheel bracket 2 j Shaft 1 k Sliding frame 2 For assembly reverse the disassembly pro cedure a b d e f g k k c d b É e PZ50MT PZ50MT PZ50MT h i j i h È È 75 Nm 7 5 m kg 54 ft lb 60 Nm 6 0 m kg 43 ft lb È É ...

Page 30: ... 1 3 Collar 2 4 Collar 1 5 Front pivot arm 1 6 Bushing 2 7 Shaft 1 8 Collar 2 9 Shaft 1 0 Collar 1 A Wheel bracket 2 B Suspension wheel 2 C Shaft 1 New New Ê D 3 6 7 9 4 3 H J J I I I I 1 Ê Ë Ë 5 N M 6 0 F Ë Ë Ë Ì É Ì K L M N A L K C A E D G 8 B B 2 È 8 Ë É 4 Nm 0 4 m kg 2 9 ft lb È 6 Nm 0 6 m kg 4 3 ft lb É 49 Nm 4 9 m kg 35 ft lb Ê 60 Nm 6 0 m kg 43 ft lb Ë 72 Nm 7 2 m kg 52 ft lb Ì ...

Page 31: ... 2 K Suspension wheel 2 L Circlip 2 M Spring end guide 2 NOTE Apply grease to the inner surface of each spring end guide N Spring end guide bracket 2 New New Ê D 3 6 7 9 4 3 H J J I I I I 1 Ê Ë Ë 5 N M 6 0 F Ë Ë Ë Ì É Ì K L M N A L K C A E D G 8 B B 2 È 8 Ë É 4 Nm 0 4 m kg 2 9 ft lb È 6 Nm 0 6 m kg 4 3 ft lb É 49 Nm 4 9 m kg 35 ft lb Ê 60 Nm 6 0 m kg 43 ft lb Ë 72 Nm 7 2 m kg 52 ft lb Ì ...

Page 32: ...ck lever guide plate 2 Z Lock lever 2 Collar 2 2 up adjusting block 2 2 up adjusting block plate 2 _ Collar 2 a Guide wheel 2 b Torsion spring 2 New k New n W X a b f d c e l g X j m g o p r r s s q i i p q o i Ì Í Í Ê Ì Ì Ë É È Ë Ë Z Y i h U V U V T T V U R R Q P S O U V O È P 49 Nm 4 9 m kg 35 ft lb 9 Nm 0 9 m kg 6 5 ft lb 25 Nm 2 5 m kg 18 ft lb 60 Nm 6 0 m kg 43 ft lb 6 Nm 0 6 m kg 4 3 ft lb È...

Page 33: ...trol rod stopper 1 n Circlip 2 o Control rod 2 p Locknut 2 q Adjuster nut 2 r Suspension wheel 4 s Suspension wheel bracket 4 New k New n W X a b f d c e l g X j m g o p r r s s q i i p q o i Ì Í Í Ê Ì Ì Ë É È Ë Ë Z Y i h U V U V T T V U R R Q P S O U V O È P 49 Nm 4 9 m kg 35 ft lb 9 Nm 0 9 m kg 6 5 ft lb 25 Nm 2 5 m kg 18 ft lb 60 Nm 6 0 m kg 43 ft lb 6 Nm 0 6 m kg 4 3 ft lb È É Ê Ë Ì 72 Nm 7 2 ...

Page 34: ... Remarks t Rear axle 1 u Guide wheel 2 v Collar 2 w Collar 1 x Guide wheel 1 y Collar 1 z Tension adjuster 2 Sliding frame 2 For assembly reverse the disassembly pro cedure 75 Nm 7 5 m kg 54 ft lb È t u v z w y x v u È z SLIDE RAIL SUSPENSION ...

Page 35: ... tank cover 1 5 Fuel tank side cover band 2 6 Fuel tank side cover left and right 2 7 Rear side cover left and right 2 8 Plastic band 4 9 Tail brake light coupler 1 Disconnect 10 Tail brake light assembly 1 11 Fuel pump coupler 1 Disconnect 12 Fuel hose connector holder 1 13 Fuel hose 1 Disconnect 1 4 17 8 8 5 É É Ê 6 6 9 18 11 2 14 12 19 3 10 16 15 13 6 8 È 4 7 14 Ê È 7 7 Nm 0 7 m kg 5 1 ft lb È ...

Page 36: ...pler 1 Disconnect 17 Fuel hose 2 Disconnect 18 Fuel pump 1 19 Fuel tank lower plate 1 For installation reverse the removal proce dure 1 4 17 8 8 5 É É Ê 6 6 9 18 11 2 14 12 19 3 10 16 15 13 6 8 È 4 7 14 Ê È 7 7 Nm 0 7 m kg 5 1 ft lb È 10 Nm 1 0 m kg 7 2 ft lb É 8 Nm 0 8 m kg 5 8 ft lb Ê SEAT AND FUEL TANK ...

Page 37: ...OTOR AND STARTER CLUTCH in CHAPTER 5 1 Primary sheave drive shaft cover 1 2 Gasket 1 3 Primary sheave drive shaft assembly 1 4 Lock washer 2 5 Balancer shaft driven gear 1 6 Balancer weight 1 7 Straight key 1 8 Balancer shaft 1 9 Lock washer 1 10 Balancer shaft drive gear 1 8 16 6 7 5 15 4 13 14 2 1 2 4 10 3 17 18 19 10 9 11 12 É É Ë È Ê New LT LT 12 Nm 1 2 m kg 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb ...

Page 38: ...Bearing retainer 1 16 Bearing 1 17 Bearing 1 18 Circlip 1 19 Bearing 1 For installation reverse the removal proce dure 8 16 6 7 5 15 4 13 14 2 1 2 4 10 3 17 18 19 10 9 11 12 É É Ë È Ê New LT LT 12 Nm 1 2 m kg 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb 75 Nm 7 5 m kg 54 ft lb 50 Nm 5 0 m kg 36 ft lb È É Ê Ë New New New ...

Page 39: ...cer shaft drive gear Lock washer Balancer shaft drive gear bolt NOTE Align the shallow groove a in the balancer shaft drive gear with the low spline b of the crankshaft b a 2 Install Straight key 1 Balancer weight 2 Balancer shaft driven gear 3 Lock washer 4 Balancer shaft driven gear nut 5 Balancer shaft drive gear bolt NOTE Align the punch mark a on the balancer shaft driven gear with the punch ...

Page 40: ...hten it NOTE Place an aluminum plate 1 or 2 between the teeth of the balancer shaft drive gear 3 and balancer shaft driven gear 4 1 2 3 4 4 Tighten Primary sheave drive shaft cover bolt NOTE Apply LOCTITE to the bolts black indicated by the marks on the primary sheave drive shaft cover T R Primary sheave drive shaft cover bolt 12 Nm 1 2 m kg 8 7 ft lb LOCTITE ...

Page 41: ...gative pressure hose 1 2 Idle adjusting screw 1 3 Throttle position sensor 1 4 Pressure regulator hose 1 5 Pressure regulator 1 6 Fuel strainer seat 1 7 Fuel strainer 1 8 Fuel rail 1 9 Injector 4 10 Throttle body heater hose 1 11 Air screw 2 12 Throttle body assembly 1 For installation reverse the removal proce dure New New New 2 12 10 9 1 4 5 8 3 New E E E 7 6 11 11 ...

Page 42: ...36 FI ...

Page 43: ...T USA Canada 1 165 mm 45 9 in PZ50MT 1 265 mm 49 8 in PZ50VT Europe PZ50MP Overall height 1 190 mm 46 9 in PZ50 PZ50RT PZ50MT 1 340 mm 52 8 in PZ50GT 1 380 mm 54 3 in PZ50VT PZ50MP Weight Dry weight 216 kg 476 2 lb PZ50 222 kg 489 4 lb PZ50GT USA Canada PZ50RT USA Canada 223 kg 491 6 lb PZ50GT Europe PZ50RT Europe 234 kg 515 9 lb PZ50MT USA Canada 235 kg 518 1 lb PZ50MT Europe 269 kg 593 0 lb PZ50...

Page 44: ... 59 US qt With oil filter replacement 2 63 L 2 31 Imp qt 2 78 US qt Total amount 3 00 L 2 64 Imp qt 3 17 US qt Oil tank capacity 2 00 L 1 76 Imp qt 2 11 US qt Oil filter Oil filter type Cartridge paper Drive chain oil Type SAE 75W or 80W API GL 4 Gear oil Capacity 0 25 L 0 22 Imp qt 0 26 US qt Coolant Filler cap opening pressure 93 3 122 7 kPa 0 93 1 23 kg cm2 13 2 17 5 psi Capacity 3 60 L 3 17 Im...

Page 45: ...T Europe PZ50MP Chassis Frame type Monocoque Caster 18 0 Ski stance center to center 1 080 mm 42 5 in PZ50 PZ50GT PZ50RT PZ50VT PZ50MP 980 mm 38 6 in PZ50MT Suspension Front suspension type Double wishbone Rear suspension type Slide rail suspension Track Track type Internal drive type Track width 355 6 mm 14 00 in PZ50 PZ50GT PZ50RT PZ50MT 381 0 mm 15 00 in PZ50VT 406 4 mm 16 00 in PZ50MP Length o...

Page 46: ...eter light LED Warning light LED High beam indicator light LED Low coolant temperature indicator light LED Knock control system indicator light LED Drive position indicator light LED PZ50GT PZ50RT PZ50MT PZ50VT PZ50MP Reverse position indicator light LED PZ50GT PZ50RT PZ50MT PZ50VT PZ50MP Model PZ50 PZ50GT PZ50RT PZ50MT PZ50VT PZ50MP ...

Page 47: ...ft Drive system Chain drive left Camshaft cap inside diameter 22 000 22 021 mm 0 8661 0 8670 in Camshaft journal diameter 21 959 21 972 mm 0 8645 0 8650 in Camshaft journal to camshaft cap clear ance 0 028 0 062 mm 0 0011 0 0024 in Camshaft dimensions Intake A 30 450 30 550 mm 1 1988 1 2028 in Limit 30 350 mm 1 1949 in B 22 610 22 710 mm 0 8902 0 8941 in Limit 22 510 mm 0 8862 in Exhaust A 30 700 ...

Page 48: ...t 0 5 0 9 mm 0 0197 0 0354 in Valve stem diameter Intake 3 975 3 990 mm 0 1565 0 1571 in Limit 3 945 mm 0 1553 in Exhaust 3 960 3 975 mm 0 1559 0 1565 in Limit 3 930 mm 0 1547 in Valve guide inside diameter Intake 4 000 4 012 mm 0 1575 0 1580 in Limit 4 050 mm 0 1594 in Exhaust 4 000 4 012 mm 0 1575 0 1580 in Limit 4 050 mm 0 1594 in Valve stem to valve guide clearance Intake 0 010 0 037 mm 0 0004...

Page 49: ... 8854 in Limit 22 457 mm 0 8841 in Valve lifter hole inside diameter Intake 20 000 20 018 mm 0 7874 0 7881 in Limit 20 048 mm 0 7893 in Exhaust 22 500 22 518 mm 0 8858 0 8865 in Limit 22 548 mm 0 8877 in Piston Piston size D 76 955 76 970 mm 3 0297 3 0303 in Measuring point H 11 0 mm 0 43 in Piston to cylinder clearance 0 030 0 055 mm 0 0012 0 0022 in Limit 0 120 mm 0 0047 in Piston pin bore off s...

Page 50: ...ng 2nd ring Ferox coating Connecting rod Small end diameter 17 005 17 018 mm 0 6695 0 6700 in Big end diameter 37 000 37 016 mm 1 4567 1 4573 in Crankshaft pin to big end bearing clearance 0 034 0 058 mm 0 0013 0 0023 in Bearing color code 0 White 1 Blue 2 Black 3 Brown Crank pin Crank pin outside diameter 33 976 34 000 1 3376 1 3386 in Crankshaft Measuring point 1 57 5 mm 2 26 in Measuring point ...

Page 51: ...9 0 15 mm 0 004 0 006 in Relief valve operating pressure 430 550 kPa 4 3 5 5 kg cm2 61 1 78 2 psi Oil pressure hot 50 kPa 0 5 kg cm2 7 11 psi at 1 500 r min Cooling system Filler cap opening pressure 93 3 122 7 kPa 0 93 1 23 kg cm2 13 2 17 5 psi Thermostat opening temperature 80 0 84 0 C 176 0 183 2 F Valve lift 7 0 mm 95 0 C 0 28 in 203 0 F Water pump type Single suction centrifugal pump Impeller...

Page 52: ...t B 32 5 mm 1 28 in Primary sheave spring Part number 90501 606G9 PZ50 PZ50GT PZ50RT 90501 605G7 PZ50MT 90501 556G7 PZ50VT USA Canada 90501 526G4 PZ50VT Europe PZ50MP Color code Pink Blue Pink PZ50 PZ50GT PZ50RT Green Yellow Green PZ50MT Yellow Blue Yellow PZ50VT USA Canada Blue Gold Blue PZ50VT Europe PZ50MP Outside diameter 60 0 mm 2 36 in Wire diameter 6 0 mm 0 236 in PZ50 PZ50GT PZ50RT PZ50MT ...

Page 53: ...VT PZ50MP Material Steel Size 13 3 mm 0 524 in PZ50 PZ50GT PZ50RT 10 3 mm 0 406 in PZ50MT USA Canada 13 9 mm 0 547 in PZ50MT Europe 17 2 mm 0 677 in PZ50VT PZ50MP Quantity 3 pcs Hole quantity 3 pcs Center None PZ50MT Part number 90261 06015 PZ50 PZ50GT PZ50RT 90261 06033 PZ50VT PZ50MP Material Steel Size 10 3 mm 0 406 in PZ50 PZ50GT PZ50RT 17 2 mm 0 677 in PZ50VT PZ50MP Quantity 3 pcs Hole quantit...

Page 54: ...d 931 kg mm rad 52 137 lb in rad PZ50 PZ50GT PZ50RT PZ50MT 10 098 N mm rad 1 030 kg mm rad 57 659 lb in rad PZ50VT PZ50MP Number of coils 5 33 PZ50 PZ50GT PZ50RT PZ50MT 5 99 PZ50VT PZ50MP Free length 85 mm 3 35 in Torque cam angle 39 PZ50 PZ50GT PZ50RT 37 PZ50MT PZ50VT PZ50MP Drive chain Type Borg Warner Morse TEC 23RH302 5 80ASM PZ50 PZ50GT PZ50RT PZ50MT Borg Warner Morse TEC 23RH302 5 82ASM PZ50...

Page 55: ...r suspension Front travel 221 0 mm 8 70 in PZ50 PZ50GT PZ50RT 205 0 mm 8 07 in PZ50MT 184 0 mm 7 24 in PZ50VT 216 0 mm 8 50 in PZ50MP Rear travel 412 0 mm 16 22 in PZ50 PZ50GT PZ50RT 364 0 mm 14 33 in PZ50MT 292 0 mm 11 50 in PZ50VT 313 0 mm 12 32 in PZ50MP Suspension spring rate Front 40 00 N mm 4 08 kg mm 228 40 lb in PZ50 PZ50GT PZ50RT Europe 33 00 N mm 3 36 kg mm 188 43 lb in PZ50RT USA Canada...

Page 56: ... PZ50RT USA Canada 1 690 0 N 0 3 m s 172 3 kg 0 3 m s 379 9 lb 0 3 m s PZ50RT Europe 610 0 N 0 3 m s 62 2 kg 0 3 m s 137 1 lb 0 3 m s PZ50MT USA Canada 1 600 0 N 0 3 m s 163 1 kg 0 3 m s 359 7 lb 0 3 m s PZ50MT Europe 770 0 N 0 3 m s 78 5 kg 0 3 m s 173 1 lb 0 3 m s PZ50VT USA Canada Compression 690 0 N 0 3 m s 70 4 kg 0 3 m s 155 1 lb 0 3 m s PZ50 640 0 N 0 3 m s 65 3 kg 0 3 m s 143 9 lb 0 3 m s ...

Page 57: ... 0 N 0 3 m s 117 3 kg 0 3 m s 258 5 lb 0 3 m s PZ50RT Europe 710 0 N 0 3 m s 72 4 kg 0 3 m s 159 6 lb 0 3 m s PZ50MT 610 0 N 0 3 m s 62 2 kg 0 3 m s 137 1 lb 0 3 m s PZ50VT USA Canada 1 870 0 N 0 3 m s 190 7 kg 0 3 m s 420 4 lb 0 3 m s PZ50VT Europe PZ50MP Slide runner Thickness 18 3 mm 0 72 in Wear limit 10 5 mm 0 41 in Track sprocket wheel Material Quadruple polyethylene Number of teeth 9 T PZ50...

Page 58: ...GT PZ50RT PZ50VT USA Canada 182 0 mm 7 17 in PZ50MT 180 0 mm 7 09 in PZ50VT Europe PZ50MP Ski runner material Steel Ski cover No Ski runner wear limit 6 mm 0 24 in Plastic ski wear limit 13 mm 0 51 in PZ50 PZ50GT PZ50RT PZ50VT USA Canada 24 mm 0 95 in PZ50MT PZ50VT Europe PZ50MP Ski suspension front suspension Type Independent wishbone Travel 219 0 mm 8 62 in PZ50 PZ50RT 198 0 mm 7 80 in PZ50GT 22...

Page 59: ...9 kg 0 3 m s 107 9 lb 0 3 m s PZ50MT Europe 660 N 0 3 m s 67 3 kg 0 3 m s 148 4 lb 0 3 m s PZ50VT USA Canada 2 690 N 0 3 m s 274 3 kg 0 3 m s 604 7 lb 0 3 m s PZ50VT Europe PZ50MP Compression 890 N 0 3 m s 90 8 kg 0 3 m s 200 0 lb 0 3 m s PZ50 630 N 0 3 m s 64 2 kg 0 3 m s 141 6 lb 0 3 m s PZ50GT 850 N 0 3 m s 86 7 kg 0 3 m s 191 1 lb 0 3 m s PZ50MT USA Canada 540 N 0 3 m s 55 1 kg 0 3 m s 121 4 l...

Page 60: ...73 MITSUBISHI PZ50 PZ50GT PZ50RT PZ50VT PZ50MP F8T83574 MITSUBISHI PZ50MT Rectifier regulator Type Short circuit type Model Manufacturer FH012 SHINDENGEN No load regulated voltage DC 14 2 14 8 V Capacity DC 50 A Withstand voltage 40 V Battery Manufacturer YUASA Type YTX14 BS 12V 12Ah Ten hour rate amperage 1 2 A Electric starter system Type Constant mesh type Starter motor Model Manufacturer 8GC Y...

Page 61: ... at 20 C 68 F White Black Passenger grip warmer Heater resistance high 8 82 10 78 Ω Green Black PZ50VT Heater resistance low 14 67 17 93 Ω Yellow Black PZ50VT Circuit breaker Type Fuse Amperage for individual circuit Main fuse 40 A 1 Fuel injection system fuse 10 A 1 Headlight fuse 20 A 1 Signal fuse 7 5 A 1 Ignition fuse 20 A 1 Auxiliary DC jack fuse 3 A 1 PZ50GT PZ50RT PZ50MT PZ50VT PZ50MP Radia...

Page 62: ...on sensor Model Manufacture 8GC MITSUBISHI Resistance 189 231 Ω at 20 C 68 F Gray Black Intake air pressure sensor Model Manufacture 5PS DENSO Intake air temperature sensor Model Manufacture 8FP MITSUBISHI Resistance 290 390 kΩ at 80 C 176 F Knock sensor Model Manufacture 8GC MITSUBISHI Resistance 504 616 kΩ at 20 C 68 F Model PZ50 PZ50GT PZ50RT PZ50MT PZ50VT PZ50MP ...

Page 63: ... Apply LOCTITE Rear engine mounting bolt spacer 7 0 7 5 1 Front engine mounting nut left and right 65 6 5 47 Rear engine mounting nut 40 4 0 29 Engine mounting bracket 23 2 3 17 Oil pan 10 1 0 7 2 Oil pan engine oil drain bolt 30 3 0 22 Oil filter cartridge 17 1 7 12 Oil filter bolt 30 3 0 22 Oil pressure switch 15 1 5 11 Oil pump 12 1 2 8 7 OIl pump drive chain guide 10 1 0 7 2 Apply LOCTITE Oil ...

Page 64: ...b and then tighten the connecting rod nuts further to reach the specified angle 120 150 Balancer shaft driven gear 50 5 0 36 Bearing retainer 10 1 0 7 2 Apply LOCTITE Connecting rod and cap See NOTE 3 A C magneto rotor 130 13 0 94 Apply the engine oil A C magneto rotor cover bolt M6 1 0 7 12 1 2 8 7 A C magneto rotor cover bolt M6 1 0 6 12 1 2 8 7 Apply LOCTITE Starter clutch 12 1 2 8 7 Apply LOCT...

Page 65: ...witch 17 1 7 12 PZ50GT PZ50RT PZ50MT PZ50VT PZ50MP Reverse position switch 17 1 7 12 PZ50GT PZ50RT PZ50MT PZ50VT PZ50MP Battery bracket 23 2 3 17 Brake caliper bracket and drive chain cover 48 4 8 35 Brake caliper bleed screw 6 0 6 4 3 Brake caliper retaining pin 18 1 8 13 Brake hose union bolt 30 3 0 22 Parking brake assembly and drive chain cover 10 1 0 7 2 Lever and parking brake assembly 16 1 ...

Page 66: ...PZ50MP Shock absorber and rear pivot arm 49 4 9 35 2 up adjusting block 60 6 0 43 PZ50VT PZ50MP Set bolt collar 9 0 9 6 5 PZ50VT PZ50MP Rear pivot arm joint 35 3 5 25 PZ50 PZ50GT PZ50RT PZ50MT Rear pivot arm and rear pivot arm bracket 72 7 2 52 Apply LOCTITE PZ50 PZ50GT PZ50RT PZ50MT Rear pivot arm bracket and sliding frame 72 7 2 52 Apply LOCTITE PZ50 PZ50GT PZ50RT PZ50MT Rear pivot arm bracket s...

Page 67: ...er seat 7 0 7 5 1 PZ50VT PZ50MP Rear cover 8 0 8 5 8 PZ50VT PZ50MP Sub frame panel 7 0 7 5 1 PZ50VT PZ50MP Rear carrier 23 2 3 17 PZ50VT PZ50MP Tail brake light assembly 10 1 0 7 2 PZ50VT PZ50MP Handlebar holder 15 1 5 11 Wind deflector bracket and wind deflector bolt 7 0 7 5 1 Apply LOCTITE PZ50RT Multi function meter bracket 20 2 0 14 Steering joint and steering joint bracket 21 2 1 15 PZ50VT PZ...

Page 68: ...Apply LOCTITE Upper arm and frame 45 4 5 32 Upper arm ball joint and steering knuckle 45 4 5 32 Lower arm and frame 65 6 5 47 Lower arm and steering knuckle 65 6 5 47 Stabilizer and stabilizer joint 45 4 5 32 PZ50 PZ50RT PZ50MT Stabilizer joint and lower arm 34 3 4 25 PZ50 PZ50RT PZ50MT Stabilizer bracket 7 0 7 5 1 PZ50GT PZ50VT PZ50MP Stabilizer holder 34 3 4 25 Parts to be tightened Tightening t...

Page 69: ...ry threads Components should be at room temperature A Distance across flats B Outside thread diameter DEFINITION OF UNITS A nut B bolt General torque specifications Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 0 94 Unit Read Definition Measurement mm cm Millimeter Centimeter 10 3 meter 10 2 meter Length...

Page 70: ...64 SPEC CABLE ROUTING F G H I J K L 7 9 8 A B C 0 D E 1 2 3 4 6 M N O P Q R S T U V W X Z Y 5 ...

Page 71: ...ss and fuel tank breather hose to the frame rear cross member with the plas tic band 0 To the oil level switch A Fasten the wire harness parking brake cable and brake hose to the frame rear cross member with the plastic band B Main switch C Fuel tank breather hose D Throttle cable E To the brake caliper F To the tail brake light G Fuel pump lead H Fuel hose I Fasten the fuel pump lead at the white...

Page 72: ...66 SPEC CABLE ROUTING F G H I J K L 7 9 8 A B C 0 D E 1 2 3 4 6 M N O P Q R S T U V W X Z Y 5 ...

Page 73: ...rame ground lead ter minal and the Rectifier regulator using the same nut T Sub wire harness coupler U Left handlebar switch lead cou plers V Rectifier regulator W Connect the wire harness cou pler to the Rectifier regulator coupler shown in the illustration X Crankshaft position sensor cou pler Y Fuel sender lead coupler Z Intake air pressure sensor cou pler Headlight coupler Intake air temperatu...

Page 74: ...68 SPEC CABLE ROUTING 1 2 3 4 5 6 2 ...

Page 75: ...he wire harness grip warmer sub wire harness and fuel tank breather hose to the frame rear cross member with the plastic band 4 Route the grip warmer sub wire harness along the wire harness 5 Grip warmer sub wire harness 6 Connect the grip warmer sub wire harness coupler to the wire harness coupler making sure to connect the end of the sub wire harness that is marked with tape ...

Page 76: ...70 SPEC CABLE ROUTING E F G H I J K 8 9 0 A B C D 1 2 3 4 5 6 7 L M N P R S T U V W X Z Y a Q O ...

Page 77: ...9 Route the fuel hose and sub wire harness over the wire harness and fuel tank breather hose 0 Fasten the wire harness parking brake cable and brake hose to the frame rear cross member with the plastic band A Fasten the wire harness and fuel tank breather hose to the frame rear cross member with the plas tic band B To parking brake C Fuel tank breather hose D Main switch E Tail brake light harness...

Page 78: ...72 SPEC CABLE ROUTING E F G H I J K 8 9 0 A B C D 1 2 3 4 5 6 7 L M N P R S T U V W X Z Y a Q O ...

Page 79: ...or coupler U Left handlebar switch lead cou plers V Install the frame ground lead ter minal and the Rectifier regulator using the same nut W Sub wire harness coupler X Rectifier regulator Y Connect the wire harness cou pler to the Rectifier regulator coupler shown in the illustration Z Crankshaft position sensor cou pler Fuel sender coupler Intake air pressure sensor cou pler Intake air temperatur...

Page 80: ...74 SPEC CABLE ROUTING F I J K L M N 87 0 9 A C B D E 1 2 3 4 5 6 O H G A B V W Q R S P T 6 7 X U A B ...

Page 81: ...PZ50RT PZ50MT PZ50VT PZ50MP 6 Sub wire harness 7 Gear motor Except for PZ50 8 Gear motor coupler PZ50GT PZ50RT PZ50MT PZ50VT PZ50MP 9 Fuel tank breather hose 0 Wire harness A Fasten the wire harness and fuel tank breather hose to the frame rear cross member with the plas tic band making sure to fasten the hose before and after the bend in the hose B Cylinder 1 ignition coil lead C Route the wire h...

Page 82: ...76 SPEC F I J K L M N 87 0 9 A C B D E 1 2 3 4 5 6 O H G A B V W Q R S P T 6 7 X U A B CABLE ROUTING ...

Page 83: ...bar switch M Speed sensor lead coupler N Throttle position sensor coupler O Oil pressure switch coupler P To the auxiliary DC jack lead PZ50VT PZ50MP Q To the Rectifier regulator R Wire harness S To the sub wire harness T To the throttle position sensor U To the frame ground lead V To the speed sensor W To oil pressure switch coupler X Fasten the sub wire harness at the white tape with the plastic...

Page 84: ...78 SPEC CABLE ROUTING A B D D E F G H I J 7 7 8 8 8 9 9 9 0 0 0 A A B B C 1 1 2 2 3 3 3 4 5 5 6 K L M N O P Q R S A B A ...

Page 85: ...lead 0 Wire harness A Speed sensor coupler B Fuel tank breather hose C Fasten the speed sensor lead and fuel tank breather hose to the frame rear cross member with the plastic band D To the auxiliary DC jack PZ50GT PZ50RT PZ50MT PZ50VT PZ50MP E Fasten the speed sensor lead and fuel tank breather hose with the holder F Drive guard G Fasten the speed sensor lead and fuel tank breather hose with a pl...

Page 86: ...80 SPEC CABLE ROUTING A B D D E F G H I J 7 7 8 8 8 9 9 9 0 0 0 A A B B C 1 1 2 2 3 3 3 4 5 5 6 K L M N O P Q R S A B A ...

Page 87: ...plastic band PZ50VT PZ50MP N Fasten the fuel tank breather hose auxiliary DC jack lead and speed sensor with the plastic band PZ50VT PZ50MP O Auxiliary DC jack lead PZ50VT PZ50MP P To the left handlebar switch Q Frame rear cross member R To the speed sensor S Align the paint mark on the fuel tank breather hose with the top of the grommet ...

Page 88: ...82 SPEC CABLE ROUTING F D G H I J K 8 9 0 A B C E 1 2 3 4 5 6 7 L M N N O O O P Q Q R S S T U V W X Y Z Z _ a b c d A A e e e f f f g g g h h h i i j j k k l PZ50 PZ50VT PZ50MP PZ50GT PZ50RT PZ50MT ...

Page 89: ...ank breather hose B Radiator outlet pipe C Radiator fan motor coupler D Knock sensor coupler E Radiator inlet hose F Fasten the wire harness radiator fan motor lead and knock sensor lead to the radiator outlet pipe with the plastic band making sure to align the radiator fan motor coupler with the wire har ness joint coupler Install the plastic band with its buckle posi tioned to the outside of the...

Page 90: ...84 SPEC CABLE ROUTING F D G H I J K 8 9 0 A B C E 1 2 3 4 5 6 7 L M N N O O O P Q Q R S S T U V W X Y Z Z _ a b c d A A e e e f f f g g g h h h i i j j k k l PZ50 PZ50VT PZ50MP PZ50GT PZ50RT PZ50MT ...

Page 91: ... lead O Negative battery lead P Fasten the starter motor lead negative battery lead and wire harness at the white tape to the oil tank with the plastic band Face the end of the plastic band upward Q Negative battery lead coupler R ECU lead S ECU T DC back buzzer lead PZ50GT PZ50RT PZ50MT PZ50VT PZ50MP U Positive battery lead V To the tail brake light W Tail brake light lead X Fasten the tail brake...

Page 92: ...86 SPEC CABLE ROUTING F D G H I J K 8 9 0 A B C E 1 2 3 4 5 6 7 L M N N O O O P Q Q R S S T U V W X Y Z Z _ a b c d A A e e e f f f g g g h h h i i j j k k l PZ50 PZ50VT PZ50MP PZ50GT PZ50RT PZ50MT ...

Page 93: ...coupler PZ50GT PZ50RT PZ50MT PZ50VT PZ50MP Fasten the wire harness brake hose and parking brake cable with the plastic band _ Battery a Fuse box b Main fuse c Starter relay d Starter relay lead e Load control relay f Fuel injection system relay g Headlight relay h Radiator fan motor relay i Gear motor relay 1 PZ50GT PZ50RT PZ50MT PZ50VT PZ50MP j Gear motor relay 2 PZ50GT PZ50RT PZ50MT PZ50VT PZ50M...

Page 94: ...88 SPEC CABLE ROUTING C F G H I I J K L 9 0 A B C C C D E 1 1 1 2 3 4 5 5 5 6 6 6 7 M N O P Q R S T U V W X Y Z a b b b c c c c d e f g h i A A B B C A A B B 8 C jk 1 2 3 5 6 b c ...

Page 95: ...itch leads behind the handlebar 0 Brake master cylinder A Left grip warmer lead B Brake light switch lead C Corrugated tube left grip warmer lead grip thumb warmer adjust ment switch lead brake light switch lead and headlight beam switch lead D Auxiliary DC jack PZ50GT PZ50RT PZ50MT optional E Rectifier regulator F Crankshaft position sensor cou pler G A C magneto coupler H Speed sensor lead I Pre...

Page 96: ...90 SPEC C F G H I I J K L 9 0 A B C C C D E 1 1 1 2 3 4 5 5 5 6 6 6 7 M N O P Q R S T U V W X Y Z a b b b c c c c d e f g h i A A B B C A A B B 8 C jk 1 2 3 5 6 b c CABLE ROUTING ...

Page 97: ...t hose W Throttle body heater outlet hose X Water pump inlet hose Y To the wire harness Z Route the water pump outlet hose and throttle body heater outlet hose behind the engine mounting bracket Coolant temperature sensor Throttle body heater inlet hose Thermostat cover _ To the parking brake a To the brake caliper b Brake hose c Throttle cable d Main switch e Pass the corrugated tube engine stop ...

Page 98: ...92 SPEC CABLE ROUTING C F G H I I J K L 9 0 A B C C C D E 1 1 1 2 3 4 5 5 5 6 6 6 7 M N O P Q R S T U V W X Y Z a b b b c c c c d e f g h i A A B B C A A B B 8 C jk 1 2 3 5 6 b c ...

Page 99: ...rugated tube engine stop switch lead throttle switch lead right grip warmer lead and thumb warmer lead and corrugated tube left grip warmer lead grip thumb warmer adjustment switch lead brake light switch lead and headlight beam switch lead towards the front and fasten the throttle cable at the throttle cable adjusting nut h Position the corrugated tube engine stop switch lead throttle switch lead...

Page 100: ...94 SPEC CABLE ROUTING 8 9 0 A B 1 2 3 4 5 6 7 E F G H I C D e e U V W X Y Z _ a b c d I B 1 5 6 T a b b g B 1 5 6 a b f J K L M N O P Q R S B hi 1 2 3 5 6 a b C A A B B C A A B B ...

Page 101: ...ght switch lead B Corrugated tube left grip warmer lead grip thumb warmer adjust ment switch lead brake light switch lead and headlight beam switch lead C Auxiliary DC jack D Rectifier regulator E Crankshaft position sensor cou pler F A C magneto coupler G Fuel tank breather hose H Speed sensor lead I Pressure regulator hose J Throttle position sensor coupler K Throttle body heater hose L Fasten t...

Page 102: ...96 SPEC CABLE ROUTING 8 9 0 A B 1 2 3 4 5 6 7 E F G H I C D e e U V W X Y Z _ a b c d I B 1 5 6 T a b b g B 1 5 6 a b f J K L M N O P Q R S B hi 1 2 3 5 6 a b C A A B B C A A B B ...

Page 103: ...e W Water pump inlet hose X To the wire harness Y Route the water pump outlet hose and throttle body heater outlet hose behind the engine mounting bracket Z Coolant temperature sensor Throttle body heater inlet hose Thermostat cover To the parking brake _ To the brake caliper a Brake hose b Throttle cable c Main switch d Pass the corrugated tube engine stop switch lead throttle switch lead right g...

Page 104: ...98 SPEC CABLE ROUTING 8 9 0 A B 1 2 3 4 5 6 7 E F G H I C D e e U V W X Y Z _ a b c d I B 1 5 6 T a b b g B 1 5 6 a b f J K L M N O P Q R S B hi 1 2 3 5 6 a b C A A B B C A A B B ...

Page 105: ... the corrugated tube engine stop switch lead throttle switch lead right grip warmer lead and thumb warmer lead and corrugated tube left grip warmer lead grip thumb warmer adjustment switch lead brake light switch lead and headlight beam switch lead towards the front and fasten the throttle cable at the throttle cable adjusting nut g Position the corrugated tube engine stop switch lead throttle swi...

Page 106: ...100 SPEC CABLE ROUTING 1 2 3 4 5 6 ...

Page 107: ...eadlight lead at the white tape to the shroud frame with the plastic band making sure to position the band near the bracket 5 Fasten the headlight lead to the shroud frame with the plastic band making sure to route the lead along the bend in the frame 6 Route the headlight lead to the inside of the shroud frame ...

Page 108: ...102 SPEC CABLE ROUTING 9 0 1 2 3 4 5 5 6 7 8 PZ50 PZ50GT PZ50RT PZ50MT PZ50VT PZ50MP ...

Page 109: ...ht lead and its end fac ing downward 4 Fasten the tail brake light lead at the white tape with the plastic band Face the end of the plastic band downward 5 Tail brake light 6 Passenger grip warmer switch coupler 7 Connect the passenger grip warmer coupler and then place it in the rear lower cover 8 Passenger grip warmer switch 9 Fasten the tail brake light lead to the rear carrier with the plastic...

Page 110: ...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 11 CR E YAMAHA MOTOR CO LTD 2008 ...

Page 111: ...djustment cou pler Y Engine ground Z Frame ground Brake light switch Tail brake light Fuel sender _ Oil level switch a Speedometer unit b Multi function meter c Warning light d Low coolant temper ature indicator light e Knock control sys tem indicator light f High beam indicator light g Headlight h Headlight relay i Headlight beam switch j Radiator fan motor k Radiator fan motor relay l Ignition f...

Page 112: ...BLACK B GRAY W W W Gy BLACK B L Gy B WIRE HARNESS SUB WIRE HARNESS 2 B LG W Ch B L G W Ch A WIRE HARNESS SUB WIRE HARNESS 1 B R L R L R L R L L L B B O R W G B R B G B R 10A W B L B L BLACK W L B BLACK B B CLOSE OPEN RUN STOP OFF ON HI LO 20A 15A 7 5A 20A 40A OFF ON START Gy L Y B Y L W R W R W Gy Br L L B L Gy Br R R W R W Gy R G B G B G B R B R B R B R L R L R L R L R GR W B R L L Y B L B L W Y ...

Page 113: ...Brake light switch i Tail brake light j Fuel sender k Oil level switch l Speedometer unit m Multi function meter n Warning light o Low coolant temper ature indicator light p Knock control sys tem indicator light q Drive position indi cator light r Reverse position indicator light s High beam indicator light t Headlight u Headlight relay v Headlight beam switch w Radiator fan motor x Radiator fan m...

Page 114: ...y R R W BLACK BLACK DARK GREEN L P B R L BLACK Br B Y R G Br R R G BLACK Sb R G G B Sb BLACK L B R B L Y L B L Y GRAY GRAY R W R D D D Sb W B Y R L Br Sb B W B BLACK BLACK Y L Br B B A A A A GRAY L R R L R W R G B L B W BLACK BLACK B L B L R B B B B Y R B Y R B R Y R Y R B B B B R OFF ON START 40A 10A 20A 20A 15A 3A 4A 7 5A HI LO OFF ON CLOSE OPEN RUN STOP LO OFF HI Y L O B L R L R L W W W WWW R B...

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