Yamaha PZ500D Owner'S Manual Download Page 74

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9-1

816-022

3. Compression

Insufficient

•

Loose cylinder head nuts ... Tighten nuts
properly.

•

Damaged gasket ... Replace gasket.

•

Worn out piston and cylinder ... Consult
dealer.

B. Engine does not turn over with

manual starter

1. Seized engine ... Seizure is caused by

poor lubrication, inadequate fuel, or an
air leak –– Consult dealer.

2. “Hydrolock” (fuel has filled crankcase

when vehicle was transported) ... Re-
move spark plug(s), turn engine over
several times with ignition off to expel
excess fuel. Consult dealer.

C. Electric starter does not operate or

operates slowly (VT500XL)

1. Faulty wire connections ... Check con-

nections or consult dealer.

2. Battery discharged ... Check battery fluid

and charge battery.

3. Engine trouble ... Check B above.

D. Engine power is low

1. Faulty spark plug(s) ... Clean or replace

spark plug(s).

2. Jetting incorrect for altitude or tempera-

ture ... carburetor. Consult dealer.

3. Improper fuel flow ... See A.1. above.
4. Clutch settings not correct for altitude

and/or conditions ... Consult dealer.

E. Engine constantly backfires or mis-

fires

1. Faulty spark plug(s) ... Replace spark

plug(s).

2. Fuel system clogged ... See A.1. above.
3. T.O.R.S. malfunction ... See T.O.R.S. in

A.2. above.

ESS65300

TROUBLESHOOTING

A. Engine turns over but doesn’t start

1. Fuel System

No fuel supplied to combustion chamber

•

No fuel in tank ... Supply fuel.

•

Clogged fuel line ... Clean fuel line.

•

Clogged carburetor ... Clean carburetor.
Fuel supplied to combustion chamber.

•

Flooded engine (too much choke) ... Crank
engine with throttle open or wipe spark
plug dry.

2. Electrical System

Poor or no spark

•

Spark plug dirty with carbon/wet ... Re-
move carbon/wipe spark plug dry, or re-
place spark plug.

•

Faulty ignition system ... Consult dealer.

•

T.O.R.S. system malfunction ... Discon-
nect the carburetor switch connectors
and connect the wire harness connectors
together to bypass T.O.R.S.

WARNING

•

Before bypassing the T.O.R.S., be sure
the throttle returns properly to the
fully-closed position.

•

The T.O.R.S. is an important safety
device; in the case of a malfunction,
take the machine to a Yamaha dealer
immediately for repair.

Summary of Contents for PZ500D

Page 1: ...OWNER S MANUAL SNOWMOBILE PZ500D PZ500MLD VT500XLD 8DJ 28199 11 LIT 12628 02 08 ...

Page 2: ... ordering spare parts from your Yamaha dealer 1 The frame number is the nine digit number stamped on the frame of the machine See Fig Å 2 The model code number is the first three digits of the frame number See Fig Å 3 The engine number is stamped in the location as shown See Fig ı 4 Key number See Fig Ç Also record and keep these I D numbers in a separate place in case your machine is stolen B C A...

Page 3: ...quaint you with the operation of this snowmo bile and minor maintenance required for satisfactory ser vice Should major repairs ever be required you are advised to consult a nearby Yamaha dealer who has the techniques tools and parts to ensure your satisfaction We hope that the information within this booklet will help you enjoy many hours of pleasure with your Yamaha snowmobile PZ500D PZ500MLD VT...

Page 4: ...is manual should be considered a permanent part of thismachineandshouldremainwiththismachinewhen resold Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator a by stander or...

Page 5: ...PERATION CHECKS 6 1 FUEL 6 1 ENGINE OIL 6 2 THROTTLE LEVER 6 2 MANUAL STARTER 6 2 THROTTLE OVERRIDE SYSTEM T O R S CHECK 6 2 BRAKE 6 3 BRAKE FLUID LEAKAGE 6 4 V BELT 6 4 DRIVE V BELT GUARD 6 4 DRIVE TRACK 6 5 38 mm 1 5 in HIGH PROFILE PAT TERN DRIVE TRACK PZ500ML 6 5 SLIDE RUNNERS 6 6 STEERING SYSTEM 6 6 SKI SKI RUNNER 6 7 LIGHTS 6 7 BATTERY VT500XL 6 7 FITTINGS FASTENERS 6 8 SERVICE TOOLS AND SPA...

Page 6: ...VE CHAIN HOUSING 8 13 BRAKE 8 14 BRAKE FLUID REPLACEMENT 8 15 PARKING BRAKE 8 15 SUSPENSION 8 16 FULL RATE ADJUSTER 8 18 TRACK ADJUSTMENT 8 19 SKI ALIGNMENT 8 21 HANDLEBAR ADJUSTMENT PZ500 VT500XL 8 21 HANDLEBAR ADJUSTMENT PZ500ML 8 22 LUBRICATION 8 23 HEADLIGHT 8 24 BATTERY VT500XL 8 25 FUSE REPLACEMENT VT500XL 8 26 TROUBLESHOOTING 9 1 STORAGE 10 1 RETURN TO SERVICE AFTER STORAGE 10 2 SPECIFICATI...

Page 7: ...e to normal wear or routine maintenance including oil spark plugs clutch drive belts slide runners and track THE CUSTOMER S RESPONSIBILITY under this warranty shall be to 1 Operate and maintain the snowmobile as specified in the appropriate Owner s Manual 2 Give notice to an authorized Yamaha snowmobile dealer of any and all apparent defects within ten 10 days after discovery and make the machine ...

Page 8: ...wear is however covered for one 1 year from the date of purchase Your Yamaha snowmobile dealer possesses criteria as to what constitutes abnormal wear Q Will the warranty be void or cancelled if I do not operate or maintain my new Yamaha exactly as specified in the Owner s Manual A No The warranty on a new Yamaha cannot be voided or cancelled However if a particular fail ureiscausedbyoperationorma...

Page 9: ...ha Motor Corporation U S A by the selling dealer at the time of your purchase If you should move after you have purchased your new snowmobile please advise us of your new address by sending a postcard listing your snowmobile model name engine serial number dealer number or dealer s name as it is shown on your warranty registration identification your name and new mailing address Mail to YAMAHA MOT...

Page 10: ... able expenses you incur because your Yamaha needs covered service replace ment vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb coverage goes into effect when you pur chase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period Y E S coverage is honored at any author ized Yamaha dealer na...

Page 11: ...étaire et toutes les étiquettes Ce véhicule est une machine à haute perfomance Elle doit être conduite par un conducteur expérimenté Avant de démarrer le moteur vérifier l opération du frein de l accélérateur et de la direction Le frein de sécurité doit être appliqué lors du démarrage Ne pas rouler avec le frein de sécurité actionné En cas d urgence utiliser l interrupteur d arrêt du moteur Ne pas...

Page 12: ... this vehicle This vehicle is a high performance machine It should be operated by an experienced operator Check throttle brake and steering for proper operation before starting engine Set parking brake before attempting to start engine Never run this vehicle with the parking brake applied To stop engine in an emergency push the engine stop switch down Do not operate engine without drive belt or dr...

Page 13: ... cause loss of control 4 Do not operate the machine after drinking alcohol or taking drugs Your ability to operate the machine is reduced by the influence of alcohol or drugs 5 For safety and proper care of the machine always perform the pre operation checks on pages 6 1 6 8 before starting the engine Check the throttle steering and brake operation every time before starting the engine Be sure the...

Page 14: ... skin or clothing immediately wash your skin with soap and water and change your clothes 10 Wear protective clothing Wear an approved helmet and a face shield or goggles Also wear a good quality snowmobile suit boots and a pair of snowmobile gloves or mittens that will permit use of your thumbs and fingers for operation of the controls Operation 1 Do not run the engine indoors except when starting...

Page 15: ...est braking method on most surfaces is to release the throttle and apply the brake gently not suddenly Maintenance and Storage 1 Do not leave the machine on its left side for an extended period of time Fuel may leak out from the fuel breather hose 2 Modifications made to the machine not approved by Yamaha or the removal of original equipment may render your machine unsafe for use and may cause sev...

Page 16: ... MEMO ...

Page 17: ...4 1 ESG05100 DESCRIPTION 1 Windshield 2 Steering handlebar 3 Seat 4 Passenger grip warmer switch VT500XL 5 Frame 6 Slide rail suspension 7 Drive track 8 Steering ski PZ500 VT500XL PZ500ML ...

Page 18: ...ever H Strap PZ500ML I Engine stop switch J Throttle lever K Drive select lever VT500XL L Starter handle M Shroud latch N Main switch O Starter lever P Grip warmer control knob Q HIGH BEAM indicator light R Odometer S Speedometer T Tachometer U OIL LEVEL warning indicator light V Trip odometer reset knob W Trip odometer VT500XL PZ500ML ...

Page 19: ...rted 3 WARMER The grip and thumb warmer circuit is switched on Also the ignition circuit is switched on and the engine can be started NOTE The handlebar grips and throttle lever will heat electrically after the engine starts 4 START VT500XL The starting circuit is switched on The starter motor starts NOTE The lights will come on after the engine starts CAUTION Releasetheswitchimmediatelyaftertheen...

Page 20: ...peration ESS21600 THROTTLE LEVER Oncetheengineisrunningcleanly squeezing2thethrottle lever 1 will increase the engine speed and cause engage mentofthedrivesystem Regulatethespeedofthemachine by varying the throttle position Because the throttle is spring loaded the machine will decelerate and the engine will return to an idle when the thumb is released 3 WARNING Check the throttle brake and steeri...

Page 21: ...or fails to return to idle when the lever is released WARNING If T O R S stops the engine make sure that the cause of the malfunction has been corrected and that the engine can be operated without a problem before restarting the engine Å Idle or starting ı Run Ç Trouble 1 Carburetor switch 2 Throttle switch 3 Throttle cable 4 Throttle valve a ON b OFF B C A 816 003 816 004 816 005 833 010 ESS21900...

Page 22: ...tch while driving so that you can react quickly in an emergency 831 008 ESS28100 BRAKE LEVER The machine is stopped by braking the entire drive system Squeeze the brake lever towards the handlebar to stop the machine 1 Brake lever 2 Brake lever end 3 Handlebar end NOTE When the brake is operated the brake light will illuminate CAUTION Be sure the brake lever end does not project out over the handl...

Page 23: ...chine with the parking brake ap plied This may overheat the brake disc and reduce brak ing ability B A 818 036 818 037 845 062 ESS28700 V BELT GUARD The V belt guard is designed to cover the clutch and V belt in case parts break or come loose WARNING Be sure the V belt guard is tightened securely before operating the machine Never run the engine without the V belt or with the V belt guard removed ...

Page 24: ... place when closing the shroud WARNING Do not drive the machine with the shroud open or unlatched or with the shroud removed Keep your body and clothing away from rotating parts when servicing with the shroud open Do not touch the hot muffler and engine during or immediately after operation 845 023 831 045 ESS28300 HEADLIGHT BEAM SWITCH Push the switch to change the head light beam alternately to ...

Page 25: ...ion 1 Grip warmer control knob Knob position Warmer temperature 2 Turn clockwise Higher 3 Turn counterclockwise Lower ESS08900 PASSENGER GRIP WARMER SWITCH VT500XL This switch controls the electrically heated passenger grips 1 Passenger grip warmer switch 2 ON 3 OFF ESS29900 TRIP ODOMETER RESET KNOB Use the knob to reset the trip odometer 1 Reset knob 2 Push 833 019 ...

Page 26: ... 3 Move to forward 4 Move to reverse Machine movement FWD Forward REV Reverse CAUTION Donotshiftfrom Forward to Reverse or Reverse to Forward while the machine is moving Otherwise the drive system could be damaged ESS28401 SPARK PLUG HOLDER Keep spare spark plugs for emergency use by placing them into the holder provided ESS24200 LUGGAGE BOX Open the box to store the service tools spare parts or o...

Page 27: ... mount bolts 1 and adjust the backrest posi tion WARNING Make sure that the mount bolts are tightened securely after adjusting Backrest position 2 Front position 1 3 Front position 2 4 Rear position 1 5 Rear position 2 6 Rear position 3 7 Rear position 4 849 002 849 003 ...

Page 28: ... L 9 7 Imp gal 11 7 US gal WARNING Fuel is highly flammable and poisonous Check SAFETY INFORMATION see page 3 2 carefully before refueling Do not fill the fuel tank above the bottom of the filler tube 1 The fuel could overflow if the machine is tilted or if the ambient temperature rises causing the fuel to warm up and expand Make sure that the fuel tank cap is closed securely after refueling Leaki...

Page 29: ... 815 005 ESS31200 MANUAL STARTER Check for proper operation Check the rope for damage ESS31500 THROTTLE LEVER Check the throttle lever operation before starting the en gine It must open smoothly and spring back to idle when released ESS31301 THROTTLE OVERRIDE SYSTEM T O R S CHECK WARNING When checking T O R S Be sure the parking brake is applied Be sure the throttle lever moves smoothly Do not run...

Page 30: ...ould lead to an accident CAUTION Make sure that the brake lever end does not project out over the handlebar end This is to prevent brake lever damage when the machine is placed on its side 2 Brake fluid Check the brake fluid level Add fluid if necessary 1 Lower level See page 8 14 Recommended brake fluid DOT 4 2 Hold the pivot point of the throttle lever away from the throttle switch by putting yo...

Page 31: ...stic parts Never spill any fluid If any is spilled clean it up immediately ESS31800 V BELT Open the shroud and remove the V belt guard Check the V belt for wear and damage Replace if neces sary Wear limit 1 33 mm 1 30 in WARNING Be sure the V belt guard is tightened securely before operating the machine Never run the engine without the V belt or with the V belt guard removed ESS32700 DRIVE V BELT ...

Page 32: ... 38 mm 1 5 in HIGH PROFILE PATTERN DRIVE TRACK PZ500ML PZ500ML is originally equipped with a 38 mm 1 5 in high profile pattern drive track specifically for use in deep snow riding conditions Therefore avoid prolonged operation on hard surfaces such as ice hard packed snow dirt etc to extend the life of the track and slide runners CAUTION Only use in deep snow riding conditions Operation on areas w...

Page 33: ...0 mm 0 4 in CAUTION Ride on fresh snow frequently Operating on ice or hard packed snow will rapidly wear the slide runners 820 078 ESS34800 STEERING SYSTEM 1 Check the following for excessive free play 1 Pushthehandlebarupanddownandbackandforth 2 Turn the handlebar slightly to the right and left 2 If excessive free play is noticed consult a Yamaha dealer 819 003 ...

Page 34: ...er for cleaning to protect the plastics lens 1 832 032 830 004 B B 819 078 819 076 A ESS32301 SKI SKI RUNNER Check wear and damage Replace if necessary Ski runner wear limit 1 8 mm 0 31 in Å PZ500 VT500XL ı PZ500ML Plastic ski wear limit 2 8 mm 0 31 in CAUTION Avoid scratching the plastic skis when loading and unloading the snowmobile when riding in areas with little or no snow and on sharp edges ...

Page 35: ... luggage box Tool kit Flashlight Roll of plastic tape Steel wire Tow rope Emergency starter rope In addition to these it is advisable to have the following spare parts Drive belt Light bulbs Spark plugs When you start out for a long distance trip extra fuel and oil should be carried ESL34600 FITTINGS FASTENERS Check the tightness of the fittings fasteners Tighten in proper sequence and torque if n...

Page 36: ...ing Model PZ500 PZ500ML 2 Turn the main switch to the ON or WARMER posi tion 1 ON 2 WARMER 3 Pull slowly on the recoil starter until it is engaged then pull it briskly After the engine starts put the starter lever choke in the Half open position Warm up the engine until it does not run roughly or begin to stall when the starter lever is returned to the Close position Electric Starting Model VT500X...

Page 37: ...Starting Model PZ500 PZ500ML If the recoil starter system should fail take the emergency starter rope out of the tool kit box and proceed as follows NOTE The emergency starter rope is supplied in the tool kit box at the factory 1 Proceed with item 1 for the STARTING THE ENGINE and item 2 for the Manual Starting Model 2 Tighten the emergency starter rope on the screwdriver handle 1 Screwdriver hand...

Page 38: ...INE procedures for the Manual Starting Model ESS41501 BREAK IN There is never a more important period in the life of your machine than the Break In period For the first 10 hours approximately 200 km 125 mi do not put an excessive load on the engine Avoid prolonged full throttle operation Also avoid lugging the engine such as laborious operation in wet snow If any abnormal condition is noticed such...

Page 39: ... Pay particular attention to the safety information on page 3 1 3 3 Please read all warning and caution labels on your snow mobile Also read the Snowmobiler s Safety Handbook originally supplied with your machine LEARNING TO RIDE YOUR SNOWMOBILE Before you ride always perform the pre operation checks listed on page 8 1 8 3 The short time spent checking the condition of the machine will be rewarded...

Page 40: ...require much longer stopping distances Be alert plan ahead and begin decelerating early Improper use of the brake can cause the drive track to lose traction reducing control and increasing the possibility of an accident TURNING For most snow surfaces body English is the key to turning As you approach a curve slow down and begin to turn the handlebars in the desired direction As you do so put your ...

Page 41: ...nt track slippage It is also important to keep your weight on the uphill side at all times On climbs straight up the hill this can be accom plished by leaning forward and on steeper inclines stand ing on the running boards and leaning forward over the handlebars Also see CROSSING A SLOPE Slow down as you reach the crest of the hill and be prepared to react to obstacles sharp drops or other people ...

Page 42: ...t to maintain proper balance As you travel across the slope lean your body to position your weight towards the uphill side A recommended riding position is to kneel with the knee of the downhill leg on the seat and the foot of the uphill leg on the running board This position will make it easier for you to shift your body weight as needed Snow and ice are slippery so be prepared for the possibil i...

Page 43: ...or result in rapid wear of the ski runners drive track slide runners and drive sprockets Operation of the machine under the following conditions should be avoided at all costs 1 Dirt 2 Sand 3 Rocks 4 Grass 5 Bare pavement Other conditions that should be avoided for the sake of drive track and slide runner life are 1 Glare ice surfaces 2 Snow mixed with a lot of dirt and sand All the above conditio...

Page 44: ...e hill riding WARNING Improper use of the strap on the handlebar can result in severe injury or death Use the strap only as an operator grip point when needed to shift weight uphill to maintain balance during traverse side hill riding Only experienced operators should traverse slopes steep enough to require strap use Keep the right hand on the right handlebar grip for steering andgripthestrapwitht...

Page 45: ...p the machine 5 Apply the parking brake move the parking brake lever to the left VT500XL 1 Select the desirable shifting position by moving the shift lever 1 Push down 2 FWD Forward 3 REV Reverse WARNING Be sure the throttle lever is fully released and the machine is at a full stop before shifting Be sure to move the shift lever to forward or reverse until it stops completely while the engine is i...

Page 46: ... machine 6 Apply the parking brake move the parking brake lever to the left 818 043 ESS48200 STOPPING THE ENGINE 1 Turn the main switch to the OFF position to stop the engine 1 OFF Å PZ500 PZ500ML ı VT500XL WARNING Push down the engine stop switch to stop the engine in an emergency Be sure the key is removed from the switch when ever the operator leaves the machine to prevent accidental starting A...

Page 47: ...from hydro static lock When possible the fuel tank should be empty during transportation especially if the trip will be 30 minutes or longer If transporting the machine in an open trailer or truck put a tight fitting cover on the machine A cover specifi cally designed for your snowmobile is best This will help keep foreign objects out of the cooling vents in the shroud and also help protect the ma...

Page 48: ...e if necessary Check throttle lever operation Adjust the jets Check wear and damage Replace if necessary Adjust fan belt if necessary Check operation and rope damage Replace if necessary Check operation Repair if necessary Check operation Repair if necessary Check operation Repair if necessary Spark plug Engine oil Fuel Fuel filter Fuel line Oil line Carburetor Fan belt Manual starter Engine stop ...

Page 49: ...ce if necessary Check operation and fluid leakage Adjust free play and or replace pads if necessary Replace brake fluid Check oil level Replace Check deflection Adjust if necessary Check wear and damage Replace if necessary Check operation Adjust toe out if necessary Check damage Replace if necessary Check operation Replace bulbs if necessary Exhaust system Decarbonization Drive V belt guard Drive...

Page 50: ...if cracked or damaged 8 23 5 6 6 8 6 8 Check fluid level Check specific gravity and breather pipe operation Charge Correct if neces sary Check engagement and shift speed Adjust if necessary Check wear and damage Replace if necessary Lubricate with specified grease Lubricate with specified grease Adjust if necessary Lubricate with specified grease Lubricate with specified grease Lubricate with spec...

Page 51: ...t The condition of the spark plug can indicate the condition of the engine Check the coloration on the white porcelain insulator around the center elec trode Theidealcolorationatthispointisamediumtoalight tan color for a machine that is being ridden normally If a spark plug shows a distinctly different color there could be something wrong with the engine For example a very white center electrode p...

Page 52: ...in Before installing any spark plug measure the electrode gapwithawirethicknessgaugeandadjusttospecification Spark plug gap 2 0 7 0 8 mm 0 028 0 031 in When installing the plug always clean the gasket surface Wipe off any grime from the threads and torque the spark plug properly Spark plug torque 20 Nm 2 0 m kg 14 ft lb 834 001 ESS52400 ENGINE IDLE SPEED ADJUSTMENT CAUTION Be sure this adjustment ...

Page 53: ...e play 1 1 0 2 0 mm 0 04 0 08 in 2 Locknut 3 Adjuster 3 Tighten the locknut 816 017 ESS54600 OIL PUMP CABLE ADJUSTMENT CAUTION Be sure the throttle cable is adjusted first 1 Loosen the adjuster locknut 2 Pull the oil pump outer cable and adjust the free play between the adjuster and outer cable by turning the adjuster in or out Pump cable free play 1 19 1 mm 0 75 0 04 in 2 Locknut 3 Adjuster 3 Tig...

Page 54: ...changes use of alcohol oxygenated fuels etc and should be done by an authorized Yamaha dealer CAUTION The drive chain gears and V belt clutch should be adjusted when operating over 900 m 3000 ft high altitude Consult a Yamaha dealer Pilot Screw Adjustment Turn the pilot screw in or out to adjust low speed tuning Standard pilot screw position 1 0 turn out from the seated position 804 056 Warm weath...

Page 55: ... Standard main jet 1 Left side carburetor P T O side 143 8 2 Right side carburetor Magneto side 142 5 Warm weather High altitude Cold weather Low altitude Main jet Mixture Condition Smaller No Larger No Leaner Richer 803 013 804 027 804 057 804 035 804 022 1 Remove the air chamber 2 Loosen the carburetor clamps and remove the carbure tor 3 Pinch the fuel hose to prevent fuel flowing 4 Remove the d...

Page 56: ...authorized Yamaha dealer care fully Proper carburetion adjustments will correct the fuel air ratio Remember less air at higher altitude means there is less horsepower available even with proper carburetion Ex pect acceleration and top speed to be reduced at higher altitudes To overcome operating with less power at high altitudes your snowmobile may also require different clutch and driveline setti...

Page 57: ... 08 in below the secondary sheave edge 1 If not the clutch engagement speed will be changed The machine may move unexpectedly when the en gine is started Adjust the V belt position by removing or adding a spacer 2 on each adjusting bolt For this adjustment consult a Yamaha dealer CAUTION As the V belt wears adjustment may be necessary To ensure proper clutch performance the V belt position should ...

Page 58: ...k on the secondary sheave only Do not force the V belt between the sheaves the sliding and fixed sheave must touch each other Mea sure the V belt position Standard V belt position 4 Below the sheave edge 0 2 mm 0 0 08 in 6 If the position is incorrect adjust the V belt position by removing or adding a spacer 5 on each adjusting bolt 6 805 100 805 099 805 107 V belt position Above the edge Below th...

Page 59: ...ary sheave 9 Rotate the secondary sliding sheave clockwise 7 and push 8 it so that it separates from the fixed sheave 10 Install the belt 9 between the secondary sliding and fixed sheaves 11 Install the drive V belt guard WARNING Never run the engine without the drive V belt or with the drive V belt guard removed 805 108 805 109 ...

Page 60: ...ousing When removing the dipstick be sure to Pull it out slowly and gently so the metal particles do not fall off the magnet back into the drive chain housing Wipe off the magnet before reinserting the dipstick into the drive chain housing 3 Pull up the dipstick and check that the oil is between the upper and lower levels If not add oil to the upper level 1 Upper level 2 Lower level Drive chain oi...

Page 61: ...mm 0 06 in 818 045 ESS61100 Checking the brake fluid level Place the machine on a level surface Check that the brake fluid is above the lower level and replenish when neces sary 1 Lower level Recommended brake fluid DOT 4 WARNING Be careful that water does not enter the master cylin der when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock If the...

Page 62: ...or wear by measuring the thickness of the pads If the pads reach the wear limit consult a Yamaha dealer for replacement Wear limit 1 1 0 mm 0 04 in Adjustment As the pads wear adjustment may be necessary to ensure proper brake performance WARNING Be sure this adjustment is made by a Yamaha dealer 1 Loosen the locknut 1 2 Turn the pad adjuster 2 in or out to adjust the clearance between the pad 3 a...

Page 63: ...ypes of terrain or riding conditions WARNING Be sure this adjustment is made by a Yamaha dealer ESS67510 Ski Spring Preload The spring preload can be adjusted by turning the adjuster 1 PZ500 VT500XL 819 067 5 4 3 2 1 2 Harder Softer 3 2 Spring adjuster position Preload Standard CAUTION Be sure the left and right spring preload is the same 5 4 3 2 1 2 Harder Softer 3 1 Spring adjuster position Prel...

Page 64: ...ing the adjuster 1 WARNING Be sure this adjustment is made by a Yamaha dealer PZ500 1 2 3 4 5 Softer Harder 2 Spring adjuster position Preload Å Standard Front A 820 061 PZ500ML 1 2 3 4 5 Softer Harder 1 Spring adjuster position Preload ı Standard Front B 820 097 PZ500 PZ500ML VT500XL 1 2 3 4 5 Softer Harder 3 Spring adjuster position Preload Ç Standard Front C 820 071 VT500XL ...

Page 65: ...ng bolt ends are set at the same position on each side 3 While holding the adjusting bolt securely tighten the nut 1 Nut tightening torque 49 Nm 4 9 m kg 35 4 ft lb CAUTION Never allow the adjusting bolt to move while tighten ing the nut ESS68510 FULL RATE ADJUSTER The total suspension spring rate and damping character istics can be adjusted by changing the installed position of the shock absorber...

Page 66: ... if it is damaged to the depth where fabric reinforcement material is visible or support rods are broken Oth erwise track damage and or failure could result in loss of braking ability and machine control which could cause an accident Never install studs cleats closer than three inches from the edge of the track Track Deflection Measurement 1 Lay the machine on its side 2 Measure the track deflecti...

Page 67: ... 3 Start the engine and rotate the track one or two turns Stop the engine 4 Check the track alignment with the slide runner 3 If the alignment is incorrect turn the left and right adjusters to adjust 820 076 820 008 820 005 820 009 6 7 Turn out Turn in Turn in Turn out 4 Left adjuster 5 Right adjuster Track alignment 6 Shifted to right 7 Shifted to left 8 Slide runner 9 Track 0 Track metal A Gap B...

Page 68: ...the following for ski alignment 1 Ski is facing forward 2 Ski toe out 1 2 is within specification Ski toe out 1 2 0 15 mm 0 0 59 in 3 If the alignment is not correct consult a Yamaha dealer 819 001 845 024 819 072 ESS63000 HANDLEBAR ADJUSTMENT PZ500 VT500XL 1 Remove the handlebar cover 1 2 Loosen the handlebar bolts Move the handlebar as sembly up or down to adjust the handlebar height to the desi...

Page 69: ... 070 ESU00236 HANDLEBAR ADJUSTMENT PZ500ML 1 Remove the handlebar cover 1 2 Loosen the handlebar bolts 3 Move the handlebar up or down 7 to adjust the handlebar height to the desired position CAUTION Besuretheprojectiononthehandlebarisnotinstalled into the area a shown 819 082 819 083 819 086 ...

Page 70: ...e the brake throttle cables themselves becausetheycouldbecomefrozen whichcouldcause loss of control 2 Front suspension 3 Rear suspention 820 095 820 067 820 082 820 093 2 2 3 819 081 4 Tighten the handlebar bolts and install the handlebar cover Handlebar bolt tightening torque 23 Nm 2 3 m kg 17 ft lb CAUTION Be sure the small gap b side of the handlebar holders faces forward c ...

Page 71: ... bulb until it cools down 6 Install the new bulb Bulb type 12 V 60 55 W CAUTION Keepoiloryourhandsawayfromtheglasspartofbulb or its life and illumination will be affected If the glass is oil stained thoroughly clean it with a cloth moistened with alcohol or lacquer thinner Beam Adjustment 1 Turn the adjuster 1 in or out to adjust the headlight beam Beam moves 2 Down and to the left 3 Up and to the...

Page 72: ...sonous and dangerous If contains sulfuric sulphuric acid and can cause se vere burns Avoid contact with the skin eyes or cloth ing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medi cal attention Batteriesproduceexplosivegases...

Page 73: ...e electrical system damage and can be A FIRE HAZARD CAUTION Be sure the main switch is turned off to prevent accidental short circuiting 1 Lift up the shroud 2 Replace the blown fuse with a fuse of the proper amperage NOTE If the fuse immediately blows again consult a Yamaha dealer Fuse type 10 A 835 007 ...

Page 74: ...ttings not correct for altitude and or conditions Consult dealer E Engine constantly backfires or mis fires 1 Faulty spark plug s Replace spark plug s 2 Fuel system clogged See A 1 above 3 T O R S malfunction See T O R S in A 2 above ESS65300 TROUBLESHOOTING A Engine turns over but doesn t start 1 Fuel System No fuel supplied to combustion chamber No fuel in tank Supply fuel Clogged fuel line Clea...

Page 75: ...or burns 1 Belt or sheave surface oily or dirty clean 2 Problem with drive line See F above I Engine does not upshift or downshift properly engages harshly 1 Drive belt worn replace belt or consult dealer 2 Clutch settings incorrect for altitude con ditions Consult dealer 3 Primary clutch worn or sticking Consult dealer 4 Secondaryclutchwornorsticking Con sult dealer J Noise or excessive vibration...

Page 76: ...ol is used because the alcohol content in the fuel increases the chance for water to enter the engine Use Yamaha Stor Rite Fogging Oil or an equivalent to protect both combustion chamber and crank shaftfromcorrosion Analternatemethod is to remove the airbox and squirt oil into the carburetor throats while the engine is running CAUTION Do not attempt to store the machine by simply starting the engi...

Page 77: ...ldbetrappedunderneathwhich could increase the chance of rusting RETURN TO SERVICE AFTER STORAGE When returning your machine to service reinstall the drive belt and adjust the track Reinstall the battery and make sure that the battery vent tube is properly reinstalled and is not kinked Remove the spark plugs and clean them or replace them Perform all other pre opera tion and seasonal maintenance li...

Page 78: ...0 kg 485 lb PZ500ML 244 kg 538 lb VT500XL 1070 mm 42 1 in PZ500 VT500XL 980 mm 38 6 in PZ500ML ESS75100 ENGINE PZ500 PZ500ML VT500XL Type Cylinder arrangement Displacement Bore Stroke Idle speed Engine oil pype Carburetor pype Fuel Starting system Axial fan cooled 2 stroke 7 port Parallel 2 cylinder 485 cm3 72 0 59 6 mm 2 83 2 35 in 1300 100 r min YAMALUBE 2 cycle oil MIKUNI B38 32 2 Unleaded gaso...

Page 79: ...ox 20 mm 0 78 in VT500XL Approx 3800 r min PZ500 Approx 4100 r min PZ500ML Approx 3700 r min VT500XL Approx 7250 r min Silent chain enclosed in oil bath 39 21 1 86 PZ500 VT500XL 39 18 2 17 PZ500ML 44 3 L 9 7 lmp gal 11 7 US gal 3 3 L 2 9 lmp qt 3 5 US qt Hydraulic disc type Handle lever left hand operated Handle lever right hand operated Drive track and suspension Track Width Track deflection Leng...

Page 80: ...acity Maximum charge rate Headlight Bulb Quantity Tail brake light Bulb Quantity Meter light Bulb Quantity Indicator light Bulb Quantity CDI BR9ES NGK 0 7 0 8 mm 0 028 0 031 in YB16AL A2 12 V 16A h VT500XL 1 6 Amperes hr for 10 hrs VT500XL 12 V 60 55 W 1 12 V 8 23 W 1 12 V 1 7 W 2 12 V 3 4 W 2 ...

Page 81: ...R W Y R Br B R Y B B R B L Y G L Y G B R B R R W B W B R L B R B Y R Y W R B R B B Y R B W G Y L G Y L Y G L G Y L G R R G R R O B W W G Br B Y B BLACK BLUE L L R R Y B G Br P Br P L G Y B L G Y B OFF ON 1 4 3 5 6 7 8 9 0 F E G H H I J K L M N O P Q R S T U V W L A B C D 2 W G Br B L W R L B L Y G L L L W Y B R B B R Y R Y R W R R W R W R W W G Br B W B Y Y W B R B Y Y R Y W L L G Y G Y G G G Y Y ...

Page 82: ...enger warmer switch VT500XL L Passenger warmer VT500XL M DC back buzzer VT500XL N Gear position switch VT500XL O Headlight P Oil level switch Q Meter assembly R Oil level light S High beam light T Speedometer light U Tachometer light V Tachometer W Headlight beam switch COLOR CODE B Black Br Brown Ch Chocolate G Green Gy Gray L Blue O Orange P Pink R Red W White Y Yellow B R Black Red B W Black Wh...

Page 83: ...PRINTED IN JAPAN 99 4 1 8 4 CR PRINTED ON RECYCLED PAPER ...

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Yamaha PZ500D, Owner'S Manual

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