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Yamaha Phazer Venture Lite PZ50GTA 2011, Supplementary Service Manual

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Yamaha Phazer Venture Lite PZ50GTA 2011 Supplementary Service Manual Download Page 17

FI

8

FUEL INJECTION SYSTEM

FUEL INJECTION SYSTEM

Battery
ECU (engine control 
unit)
Fuel injection system 
relay
Cylinder-#2 ignition 
coil
Spark plug
Fuel pump

Cylinder identification 
sensor
Cylinder-#1 ignition 
coil
Cylinder-#1 intake air 
pressure sensor
Speed sensor
Throttle position sen-
sor

Injector #1
Oil pressure sensor
Knock sensor
Oil pressure switch
Coolant temperature 
sensor
Crankshaft position 
sensor
Injector #2

Cylinder-#2 intake air 
pressure sensor
Intake air temperature 
sensor
Grip/thumb warmer 
adjustment switch
Warning light

FUEL INJECTION SYSTEM

Summary of Contents for Phazer Venture Lite PZ50GTA 2011

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Page 3: ...GTW PZ50FXW PZ50MW PZ50VTW PZ50MPW SERVICE MANUAL 8GC 28197 10 LIT 12618 02 58 PZ50X PZ50GTX PZ50RTX PZ50MTX PZ50VTX PZ50MPX SUPPLEMENTARY SERVICE MANUAL 8GC 28197 11 LIT 12618 02 67 PZ50GTA PZ50RTA PZ50MTA PZ50VTA SUPPLEMENTARY SERVICE MANUAL 2010 by Yamaha Motor Corporation U S A 1st Edition April 2010 All rights reserved Any reprinting or unauthorized use without the written permission of Yamah...

Page 4: ...jection Track length 3 072 4 mm 121 in 3 648 5 mm 144 in Front suspension Independent double wishbone Front shock absorber 40 mm GYTR dual clicker HPG Fox FLOATTM air shock KYB gas cell KYB gas cell Rear suspension Dual Shock Dual Shock CK ProMountain 144 ProComfort 144 Rear shock absorber Front C36 KYB HPG C36 KYB aluminum HPG C36 KYB HPG KYB gas cell Rear C36 KYB HPG C40 aluminum HPG C36 KYB HPG...

Page 5: ... with the most satisfaction from his snowmobile and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable TIP This Service Manual co...

Page 6: ...which appear Filling fluid Lubricant Tightening torque Wear limit clearance Engine speed Special tool Electrical data Ω V A Illustrated symbols to in the exploded diagram indicate grade of lubricant and loca tion of lubrication point Apply locking agent LOCTITE Apply Yamabond No 5 Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply brake fluid Apply wheel bearing grease Apply low ...

Page 7: ...NERAL 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 ...

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Page 9: ...WIRING DIAGRAM PZ50VTA 11 ECU SELF DIAGNOSTIC FUNCTION 13 SELF DIAGNOSTIC FUNCTION TABLE 13 TROUBLESHOOTING CHART 15 DIAGNOSTIC MODE 16 OIL PRESSURE SENSING SYSTEM TROUBLESHOOTING 26 OIL PRESSURE SENSOR 27 CHAPTER 8 ELECTRICAL SWITCH INSPECTION 28 SWITCH INSPECTION 28 INSPECTING A SWITCH SHOWN IN THE MANUAL 29 CHAPTER 9 SPECIFICATIONS GENERAL SPECIFICATIONS 30 MAINTENANCE SPECIFICATIONS 30 FRONT S...

Page 10: ...celed as long as the throttle is not operated 4 Note that it may take a few seconds for the oil pressure to rise to the optimum level after the engine is started even in normal conditions If the meter display described in 1 is no longer dis played after a few seconds this indicates that everything is normal TIP When disassembling the engine replacing the engine oil or oil filter etc if the oil is ...

Page 11: ...OP LO remains on and the oil level pres sure warning indicator remains illuminated for more than a few seconds after starting the engine this indicates that oil pressure is incor rect In this case check the oil pressure sens ing system 1 Place the snowmobile on a level surface and apply the parking brake 2 Start the engine warm up for several min utes and then turn it off 3 Place a containers unde...

Page 12: ...from the oil pan and oil tank 12 If the oil filter cartridge is also to be replaced perform the following procedure Replacement steps Remove the air filter case Refer to COWLINGS in CHAPTER 3 Remove the oil cooler bolts Remove the oil cooler Remove the oil filter cartridge with an oil filter wrench Oil filter wrench 90890 01469 YM 01469 ENGINE OIL REPLACEMENT ...

Page 13: ...cified amount of the recom mended engine oil Add 1 5 L 1 3 Imp qt 1 6 US qt of the rec ommended engine oil to the oil tank and then install and tighten the oil level gauge dipstick and the cylinder head cap Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Oil cooler bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Oil tank engine oil drain bolt 16 Nm 1 6 m kgf 12 ft lbf Oil pan engine oil drain bolt 30 Nm 3 ...

Page 14: ...ve the exhaust pipe joint upper cover Refer to EXHAUST PIPE AND MUFFLER in CHAPTER 5 Slightly loosen the oil gallery bolt Install the fuel tank Refer to SEAT AND FUEL TANK in CHAPTER 5 Refer to RIDER SEAT AND FUEL TANK in CHAPTER 5 Start the engine and keep it idling until engine oil starts to seep from the oil check bolt If no engine oil comes out after one minute turn the engine off so that it w...

Page 15: ...arter clutch gear Refer to A C MAGNETO ROTOR AND STARTER CLUTCH 1 Oil tank inlet hose 1 2 Oil tank outlet hose 1 3 Oil pressure switch 1 4 Oil pressure sensor 1 5 Oil filter cartridge 1 6 Oil pan 1 7 Gasket 1 8 Dowel pin 2 9 Oil pump drive chain guide 1 10 Oil pump driven sprocket shaft 1 11 Oil pump driven sprocket 1 12 Oil pump drive chain 1 13 Oil pump 1 OIL PAN AND OIL PUMP ...

Page 16: ...ENG 7 Order Job name Part name Q ty Remarks 14 Dowel pin 2 15 Collar 2 16 O ring 2 17 Gasket 1 OIL PAN AND OIL PUMP ...

Page 17: ...n sensor Cylinder 1 ignition coil Cylinder 1 intake air pressure sensor Speed sensor Throttle position sen sor Injector 1 Oil pressure sensor Knock sensor Oil pressure switch Coolant temperature sensor Crankshaft position sensor Injector 2 Cylinder 2 intake air pressure sensor Intake air temperature sensor Grip thumb warmer adjustment switch Warning light FUEL INJECTION SYSTEM ...

Page 18: ...FI 9 WIRING DIAGRAM PZ50GTA PZ50RTA PZ50MTA FUEL INJECTION SYSTEM ...

Page 19: ... coil Injector 1 Injector 2 Fuel injection system relay Fuel pump Throttle position sensor Speed sensor Cylinder identification sensor Cylinder 1 intake air pressure sensor Cylinder 2 intake air pressure sensor Knock sensor Coolant temperature sensor Intake air temperature sensor Grip thumb warmer adjustment switch Speedometer unit Multi function meter Warning light Headlight Headlight relay Headl...

Page 20: ...FI 11 WIRING DIAGRAM PZ50VTA FUEL INJECTION SYSTEM ...

Page 21: ...stem relay Fuel pump Throttle position sensor Speed sensor Cylinder identification sensor Cylinder 1 intake air pressure sensor Cylinder 2 intake air pressure sensor Knock sensor Coolant temperature sensor Intake air temperature sensor Grip thumb warmer adjustment switch Passenger grip warmer relay Passenger grip warmer switch Passenger grip warmer Speedometer unit Multi function meter Warning lig...

Page 22: ...an abnormal signal is received from a sensor the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue to operate or stop operating depending on the conditions Self Diagnostic Function table Fault code No Item Symptom Able unable to start Able unable to drive 11 Cylinder identif...

Page 23: ... while reading or writ ing on EEPROM CO adjustment value Under certain conditions Under certain conditions 46 Vehicle system power supply monitoring voltage The rectifier regulator does not func tion properly Able Able 50 ECU internal malfunction mem ory check error Faulty ECU memory When this mal function is detected in the ECU the fault code number might not appear on the meter Unable Unable 65 ...

Page 24: ...and repair the probable cause of the malfunction Engine malfunction Defective sensor or actuator NG Check and repair the inner parts of the engine Refer to CHAPTER 5 Check the engine condition Check and repair the correspondingsensor or actuator Fault code No No fault code No Check and repair Refer to TROUBLESHOOTING DETAILS Monitor the operation of the sensors and actuators in the diagnostic mode...

Page 25: ...the odometer tripmeter displays dIAG appears on the odometer tripmeter LCD 4 Check that dIAG appears and then simul taneously press the SELECT and RESET buttons for 2 seconds or more to activate the diagnostic mode The diagnos tic code number 01 appears on the speedometer LCD 5 Select the diagnostic code number corre sponding to the fault code number by pressing the SELECT and RESET but tons TIP T...

Page 26: ... grip thumb warmer adjustment switch to oper ate the actuator If the grip warmer side of the switch is pushed again while the actuator is operat ing the actuator operation will stop and restart from the beginning 7 Turn the main switch off to cancel the diag nostic mode TIP To perform a reliable diagnosis make sure to turn off the power supply before every check and then start right from the begin...

Page 27: ...ction in ECU 01 21 Coolant temperature sensor open or short circuit detected Open or short circuit in sub wire harness 2 Open or short circuit in wire harness Defective coolant temperature sensor Malfunction in ECU 06 22 Intake air temperature sensor open or short circuit detected Open or short circuit in wire harness Defective intake air temperature sensor Malfunction in ECU 05 25 Cylinder 2 inta...

Page 28: ...Improperly installed knock sensor 67 Oil pressure sensor malfunc tion open or short circuit detected Open or short circuit in wire harness Defective oil pressure sensor Malfunction in ECU Improperly installed oil pressure sensor 84 Conditions requiring T O R S operation are detected Open or short circuit in wire harness Defective throttle position sensor Defective throttle switch Defective speed s...

Page 29: ...ases to less than the atmospheric pressure 04 Pressure difference atmospheric pressure and cylinder 2 intake air pressure Displays the pressure difference atmospheric pressure and cylinder 2 intake air pressure Generate the pressure difference by cranking the engine with the starter without actually starting the engine Not cranking atmospheric pressure Cranking intake air pres sure decreases to le...

Page 30: ...e the operation is being performed the operation will stop immediately and restart from the beginning 30 Cylinder 1 ignition coil Actuates the cylinder 1 ignition coil five times at 1 second intervals and displays the self diagno sis warning indicator 1 second after the grip warmer side of the grip thumb warmer adjust ment switch is pushed Connect an ignition checker This operation is performed ea...

Page 31: ...mes 50 Fuel injection system relay Actuates the fuel injection system relay five times at 1 second intervals and displays the self diagnosis warning indicator 1 second after the grip warmer side of the grip thumb warmer adjustment switch is pushed The indicator is off when the relay is on and it is on when the relay is off This operation is performed each time the grip warmer side of the switch is...

Page 32: ...armer side of the switch is pushed again while the operation is being performed the operation will stop immediately and restart from the beginning After pushing the switch check the operating sound of the passenger grip warmer relay five times 60 EEPROM fault code display Displays the cylinder number if an error is detected in the EEPROM CO adjustment value for the cylinder as fault code No 44 If ...

Page 33: ...re switch is not within the specified range Replace the oil pressure switch 4 ECU malfunction Replace the ECU Fault code No 67 Symptom Oil pressure sensor open or short circuit detected Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Oil pressure sensor coupler Check the couplers for any pins that may have pulled out Check the...

Page 34: ... checking procedure With the engine stopped carry out the steps below 1 Connect the temperature probe tester Ω 100 to the oil pressure switch coupler Positive tester probe connector terminal Negative tester probe identification sensor body Metal part 2 Check that the oil pressure switch has continu ity If it has continuity it is normal 3 If it does not have continuity the switch is defective Repla...

Page 35: ... If OP LO display limiter control is not canceled or the meter displays fault code No 30 Ensure that the engine oil level is correct start the engine and then check the level again OK NG 1 Check the engine oil level in the oil tank Refer to ENGINE OIL LEVEL INSPEC TION in CHAPTER2 2 Air may have entered the oil hoses and or oil pump The step below may resolve the issue b Set the snowmobile back do...

Page 36: ...ping into the coupler If water or oil comes into contact with the coupler this may result in a sensor mal function The same also applies to other FI related sensors Never subject the oil pressure sensor to strong shocks If the oil pressure sensor is dropped replace it 1 Disconnect Oil pressure sensor coupler 2 Remove Oil pressure sensor 3 Install Oil pressure sensor Oil pressure sensor bolt 15 Nm ...

Page 37: ...ster probes directly into the coupler When performing any checks using a waterproof coupler use the specified test harness or a suitable commercially avail able test harness Precautions when removing installing the sensor coupler When removing installing the coupler carefully wipe peripheral components with a soft cloth Be careful to prevent liq uid such as water or oil from dropping into the coup...

Page 38: ...is chart shows the switch positions in the column and the switch lead colors in the top row For each switch position indicates the terminals with continuity The example chart shows that There is continuity between the Brown and Red leads when the switch is set to ON There is continuity between the Brown and Red and between Brown White and Red White leads when the switch is set to START SWITCH INSP...

Page 39: ...re diameter 8 5 mm 0 33 in PZ50MTA Shock absorber Damping force Extension 1200 N 0 3 m s 122 4 kgf 0 3 m s 269 8 lbf 0 3 m s PZ50MTA Compression 860 N 0 3 m s 88 7 kgf 0 3 m s 193 4 lbf 0 3 m s PZ50MTA Item Description V belt Part number 8GK 17641 10 Circumference 1135 0 mm 44 68 in Width A 34 5 mm 1 36 in Primary sheave spring Number of coils 4 73 PZ50GTA PZ50RTA Slide rail suspension rear suspen...

Page 40: ... 3 kgf 0 3 m s 380 0 lbf 0 3 m s PZ50MTA Compression 920 N 0 3 m s 93 8 kgf 0 3 m s 206 9 lbf 0 3 m s PZ50RTA 1 000 N 0 3 m s 102 0 kgf 0 3 m s 224 9 lbf 0 3 m s PZ50MTA Item Description Item Description Grip warmer Grip warmer heater resistance left 6 75 8 25 Ω at 20 C 68 F Black Black PZ50GTA PZ50RTA PZ50MTA right 6 75 8 25 Ω at 20 C 68 F Black Black PZ50GTA PZ50RTA PZ50MTA Parts to be tightened...

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Page 42: ...SPEC 32 CABLE ROUTING CABLE ROUTING ...

Page 43: ...mp lead at the positioning tape to the fuel hose with the clamp Clamp To the meter Install the fuel tank breather hose to the fuel tank with the hose clamp Be sure to connect the hose end that does not have a paint mark to the fuel tank Parking brake cable Brake hose Route the fuel tank breather hose along the frame rear cross member Tighten the rectifier regulator securing flange nut together wit...

Page 44: ...SPEC 34 CABLE ROUTING ...

Page 45: ...ght lead coupler To the brake Throttle cable Install the throttle cable protec tor aligning it with the rivet nut of the throttle cable To the tail brake light Fuel hose Clamp the fuel pump lead at the white tape to the fuel hose with the clamp Clamp To the meter Parking brake cable Install the fuel tank breather hose to the fuel tank with the hose clamp Be sure to connect the hose end that does n...

Page 46: ...SPEC 36 CABLE ROUTING ...

Page 47: ...ess under the frame rear cross member Cylinder identification sensor Cylinder identification sensor coupler Clamp the cylinder identification sensor lead to the cylinder head cover boss with the clamp To the auxiliary DC jack Throttle position sensor lead coupler To the speed sensor Injector sub wire harness cou pler To the handlebar switch Speed sensor coupler To the oil pressure sensor Oil press...

Page 48: ...SPEC 38 CABLE ROUTING ...

Page 49: ...harness under the frame rear cross member Cylinder identification sensor Cylinder identification sensor coupler Clamp the cylinder identification sensor lead to the cylinder head cover boss with the clamp To the auxiliary DC outlet Throttle position sensor lead coupler To the speed sensor Injector sub wire harness cou pler To the handlebar switch Speed sensor coupler To the oil pressure sensor Oil...

Page 50: ...SPEC 40 CABLE ROUTING ...

Page 51: ...ather hose to the frame rear cross member with the clamp For routing order insignificant To the auxiliary DC jack Hose protector Drive guard Clamp the speed sensor lead and fuel tank breather hose with a clamp For routing order insignificant Clamp the speed sensor lead and fuel tank breather hose with the lead holder be sure to bend the holder so that the lead and hose will not come loose For rout...

Page 52: ...SPEC 42 CABLE ROUTING ...

Page 53: ...peed sensor lead and fuel tank breather hose to the frame rear cross member with the clamp For routing order insignificant Hose protector Drive guard Clamp the speed sensor lead and fuel tank breather hose with a clamp For routing order insignificant Clamp the speed sensor lead and fuel tank breather hose with the lead holder be sure to bend the holder so that the lead and hose will not come loose...

Page 54: ...SPEC 44 CABLE ROUTING ...

Page 55: ...ness starter motor lead and negative bat tery lead to the oil tank with the clamp Face the end of the clamp upward Clamp the starter motor lead negative battery lead and wire harness at the positioning tape to the oil tank with the clamp Face the end of the clamp upward Fuse box ECU engine control unit band ECU engine control unit ECU engine control unit rub ber pad Battery seat Battery band Back ...

Page 56: ...SPEC 46 CABLE ROUTING ...

Page 57: ...arter motor Knock sensor Clamp Pass the throttle body heater outlet hose behind the engine mounting bracket To the wire harness Coolant temperature sensor Thermostat housing cover To the parking brake To the brake Brake hose Main switch Pass the corrugated tube park ing brake cable throttle cable meter lead and brake hose with the holder Clamp the corrugated tube parking brake cable throttle cable...

Page 58: ...SPEC 48 CABLE ROUTING ...

Page 59: ...hrottle body heater outlet hose behind the engine mounting bracket To the wire harness Coolant temperature sensor Thermostat housing cover To the parking brake To the brake Brake hose Main switch Pass the corrugated tube park ing brake cable throttle cable meter lead and brake hose with the holder Clamp the corrugated tube parking brake cable throttle cable meter lead and brake hose with the clamp...

Page 60: ...SPEC 50 CABLE ROUTING ...

Page 61: ...r Shroud frame Headlight lead Clamp the headlight lead at the white tape to the shroud frame with the clamp making sure to position the clamp near the bracket Clamp the headlight lead to the shroud frame with the clamp making sure to route the lead along the bend in the frame CABLE ROUTING ...

Page 62: ...SPEC 52 CABLE ROUTING ...

Page 63: ...f the seat lower plate After installing the seat lower plate put the rubber cover on the seat rail Put out the clamp of the seat rail from the hole of the rubber cover Tail brake light Tail brake light lead positioning tape 0 20 mm 0 0 79 in from the end of the positioning tape Rubber cover Using the tail brake light lead positioning tape as a guide clamp the tail brake light lead as shown in the ...

Page 64: ...SPEC 54 CABLE ROUTING ...

Page 65: ...enger grip warmer switch Clamp the tail brake light lead to the rear carrier with the clamp Connect the tail brake light cou pler and then place it in the tail brake light cover Tail brake light Front of the snowmobile Install the passenger grip warmer switch with letter Hi on the switch faced toward the front of the snowmobile CABLE ROUTING ...

Page 66: ...SPEC 56 ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART ...

Page 67: ...Relief valve 7 Oil tank 8 Oil pressure switch 9 Oil cooler 10 Oil pressure sensor 11 Oil filter 12 Main gallery 13 Primary sheave drive shaft 14 Crankshaft 15 Oil nozzle 16 AC magneto rotor bolt 17 Timing chain tensioner 18 Intake camshaft 19 Exhaust camshaft ENGINE OIL LUBRICATION CHART ...

Page 68: ...ation sensor Cylinder 1 intake air pressure sensor Cylinder 2 intake air pressure sensor Knock sensor Coolant temperature sensor Intake air temperature sensor Grip thumb warmer adjustment switch Gear motor relay 1 Gear motor relay 2 Gear motor relay 3 Gear motor Engine ground Frame ground Brake light switch Tail brake light Fuel sender Oil level switch Speedometer unit Multi function meter Warning...

Page 69: ... Brown Red Br W Brown White G B Green Black G W Green White G Y Green Yellow Gy R Gray Red L B Blue Black L R Blue Red L W Blue White L Y Blue Yellow O B Orange Black O R Orange Red P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Sky blue White W B White Black W L White Blue W R White Red W Y White Yellow Y B Yellow Black Y G Yellow Green Y L Yellow Blue Y...

Page 70: ...sensor Cylinder 2 intake air pressure sensor Knock sensor Coolant temperature sensor Intake air temperature sensor Grip thumb warmer adjustment switch Gear motor relay 1 Gear motor relay 2 Gear motor relay 3 Gear motor Engine ground Passenger grip warmer relay Frame ground Passenger grip warmer switch Passenger grip warmer Brake light switch Tail brake light Fuel sender Oil level switch Speedomete...

Page 71: ...Red Br W Brown White G B Green Black G R Green Red G W Green White G Y Green Yellow Gy R Gray Red L B Blue Black L R Blue Red L W Blue White L Y Blue Yellow O B Orange Black O R Orange Red P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Sky blue White W B White Black W L White Blue W R White Red W Y White Yellow Y B Yellow Black Y G Yellow Green Y L Yellow...

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Page 75: ...WIRING DIAGRAM 2011 PZ50GTA PZ50RTA PZ50MTA ...

Page 76: ...WIRING DIAGRAM 2011 PZ50GTA PZ50RTA PZ50MTA ...

Page 77: ...WIRING DIAGRAM 2011 PZ50VTA ...

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