Yamaha PZ50W Owner'S Manual Download Page 55

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8-7

Top cover
To remove the top cover

Pull up on the rear of the top cover.

Top cover

To install the top cover

Insert the projections on the front of the top cover into the
slots in the left and right upper covers, and then fit the
projections on the rear of the top cover into the grom-
mets.

Right upper cover
To remove the right upper cover

1. Remove the top cover. (See the above procedure.)
2. Remove the right upper cover by removing the bolts.

Right upper cover bolt

Right upper cover

To install the right upper cover

1. Place the right upper cover in the original position,

and then install and tighten the bolts to the specified
torque.

2. Install the top cover.

WARNING

●

Do not drive the snowmobile with the covers
unfastened or removed.

●

Keep your body and clothing away from rotating
parts when servicing the snowmobile with the
covers removed.

●

Do not touch the hot muffler and engine during or
immediately after operation.

Right upper cover bolt tightening torque:

8 Nm (0.8 m·kgf, 6 ft·lb)

E_8gc.book Page 7 Wednesday, May 17, 2006 4:52 PM

Summary of Contents for PZ50W

Page 1: ...OWNER S MANUAL SNOWMOBILE PZ50W ...

Page 2: ......

Page 3: ...y ID and key number in the spaces provided for assistance when ordering spare parts from a Yamaha dealer 1 The frame number is the seventeen digit number stamped on the frame of the snowmobile See fig È 2 The engine number is stamped in the location as shown See fig É 3 Key number See fig Ê Also record and keep the ID numbers in a separate place in case the snowmobile is stolen A B C ...

Page 4: ...bile If you have any questions concerning the operation or maintenance of your snowmobile please consult a Yamaha dealer To maintain the high quality and performance of this snowmobile it is important that you and your Yamaha dealer pay close attention to the recommended mainte nance schedules and operating instructions contained within this manual PZ50W OWNER S MANUAL 2006 by Yamaha Motor Corpora...

Page 5: ...nual should be considered a permanent part of this snowmobile and should remain with the snow mobile when 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 snowmobile operator a b...

Page 6: ...rake lever 5 9 Headlight beam switch 5 10 Grip thumb warmer adjustment switch 5 10 Covers 5 11 Drive guard 5 11 Storage compartment 5 12 PRE OPERATION CHECKS 6 1 Fuel 6 1 Engine oil 6 2 Engine oil level 6 3 Coolant 6 4 Throttle lever 6 5 Throttle override system T O R S 6 5 Brake 6 6 Brake fluid leakage 6 7 V belt 6 7 Drive guard 6 7 Drive track 6 8 Slide runners 6 8 Skis and ski runners 6 9 Steer...

Page 7: ...ance 8 11 Changing the engine oil 8 12 Cooling system 8 14 Replacing the V belt 8 16 Checking the drive chain housing oil level and the drive chain tension 8 17 Checking the brake pads 8 18 Checking the parking brake pads 8 19 Checking the brake fluid level 8 19 Changing the brake fluid 8 20 Suspension 8 20 Adjusting the drive track 8 22 Aligning the skis 8 24 Lubrication 8 25 Replacing a headligh...

Page 8: ...e parts replaced due 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 an...

Page 9: ...amages as well as oil spark plugs clutch drive belts and slide runners Q What are some examples of abnormal strain ne glect or abuse A These terms are general and overlap each other in areas Specific examples include Running the ma chine out of oil hitting an object submerged under snow operation on surfaces other than snow or ice operating the machine with a broken or damaged part which causes an...

Page 10: ...e dealer ship Since all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assistance please write YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corpora tion U S A be sure to include the model serial number names dates...

Page 11: ...1 4 ESU04280 YAMAHA EXTENDED SERVICE Y E S CW 06E ...

Page 12: ...ESU00070 2 LOCATION OF THE IMPORTANT LABELS Please read the following labels carefully before operat ing this snowmobile NOTE Maintain or replace safety and instruction labels as nec essary 1 2 8EK 77761 E0 ...

Page 13: ...s snowmobile is designed to carry the OPERA TOR ONLY Passengers are prohibited Carrying a passenger can cause loss of control 4 Do not operate the snowmobile after drinking alcohol or taking drugs Your ability to operate the snowmo bile is reduced by the influence of alcohol or drugs 5 For safety and proper care of the snowmobile always perform the pre operation checks on pages 6 1 6 10 before sta...

Page 14: ... inhale a lot of gasoline vapor or get some gasoline into your eyes see your doctor immediately If any gasoline spills on your 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 qual ity snowmobile suit boots and a pair of gloves or mit tens that will permit use of...

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

Page 16: ...ON 1 Top cover 2 Left side cover 3 Steering handlebar 4 Seat 5 Frame 6 Storage compartment 7 Slide rail suspension 8 Drive track 9 Skis 0 Right side cover A Right upper cover B Headlights C Air filter case cover D Front cover ...

Page 17: ... Q Fuel level warning indicator R Oil level warning indicator S Coolant temperature warning indicator T Self diagnosis warning indicator U Speedometer V Odometer tripmeter engine speed meter W Fuel meter and grip thumb warmer level indicator X Fuel meter indicator Y Knock control system KCS indicator light Z High beam indicator light Low coolant temperature indicator light Warning light Grip warme...

Page 18: ...r the engine starts NOTE The headlights and taillight come on after the engine starts ESU00022 Throttle lever Once the engine is running cleanly squeezing a the throt tle lever 1 will increase the engine speed and cause engagement of the drive system Regulate the speed of the snowmobile by varying the throttle position Because the throttle is spring loaded the snowmobile will deceler ate and the e...

Page 19: ... S If the throttle bodies or throttle cable malfunctions during operation the T O R S will operate when the throttle lever is released The T O R S is designed to interrupt the fuel injection and keep the engine speed between 2 800 and 3 000 r min if the throttle valves fail to return to the idle position when the throttle lever is released WARNING If the T O R S is activated make sure that the cau...

Page 20: ... warning indicator 5 will flash and the two digit code 84 6 will flash in the clock dis play The T O R S monitors the condition of the throttle position sensor speedometer assembly and speed sensor and will operate if any of the monitored items is disconnected or malfunctioning A B C Mode Item Idling starting Running Trouble Throttle switch Off On Off Throttle position sensor Closed Open Open Engi...

Page 21: ... on the warning light 1 the low coolant temperature indicator light 2 the knock control system KCS indicator light 3 and all segments of the meter display 4 turn on and off once The grip warmer level is initially displayed for 5 seconds then the display switches to the fuel meter Odometer tripmeter and engine speed meter modes Pushing the SELECT button 1 switches the display between the odometer m...

Page 22: ...ning light come on fill the fuel tank at the first opportunity NOTE The snowmobile must be stopped on a level surface to obtain an accurate fuel meter reading since the reading changes according to the movement and inclination of the snowmobile Grip thumb warmer level indicator The grip warmer indicator 1 comes on and the display switches to the grip warmer level when the grip warmer side of the g...

Page 23: ...level surface and allow it to idle for one minute If the oil level warning indicator and the warning light go off the engine oil level is sufficient however it is getting low Add engine oil as soon as possible If the oil level warning indicator and the warning light do not go off check the engine oil level in the oil tank see page 6 3 and add engine oil if necessary ESU04840 Low coolant temperatur...

Page 24: ...speed to 6 000 r min or less As soon as possible stop the engine let it cool sufficiently and then drain the fuel and refuel with the recommended fuel If the knock control system KCS indicator light is flashing have a Yamaha dealer inspect the snowmobile as soon as possible NOTE To help prevent knocking use premium unleaded gaso line only See pages 6 1 6 2 for more details ESU04180 Coolant tempera...

Page 25: ...lead couplers etc Stop the engine and allow it to cool off Then check that the wire harness couplers in the engine compartment are connected properly If the self diagnosis warning indicator warning light and an error code flash after the engine has been restarted note the error code and then have a Yamaha dealer inspect the snowmobile as soon as possible ESU00031 Engine stop switch The engine stop...

Page 26: ...This will help prevent brake lever damage when the snowmobile is placed on its side for service ESU00035 Parking brake lever When parking the snowmobile or starting the engine apply the parking brake by moving the brake lever 1 to the left To release the parking brake move the parking brake lever 1 to the right È To apply the parking brake É To release the parking brake WARNING Always set the park...

Page 27: ...humb warmer adjustment switch 1 controls the electrically heated handlebar grips and throttle lever To raise the temperature To raise the grip warmer temperature press the side of the switch To raise the thumb warmer tempera ture press the side of the switch To lower the temperature Continue to press the switch until the temperature level returns to the minimum level and then raise the tem peratur...

Page 28: ...Keep your body and clothing away from rotating parts when servicing the snowmobile with the covers removed Do not touch the hot muffler and engine during or immediately after operation CAUTION Make sure that all cables leads etc are in place when installing the covers ESU00521 Drive guard The drive guard is designed to cover the V belt clutch and V belt in case parts break or come loose WARNING Ma...

Page 29: ...5 12 ESU00680 Storage compartment Open the storage compartment to store the service tools spare parts or other small items ...

Page 30: ...er R M 2 of 91 or higher or a research octane num ber of 95 or higher If the recommended fuel is not used the engine may not perform as it should WARNING Fuel is HIGHLY FLAMMABLE and poisonous Check the SAFETY INFORMATION section carefully before refueling See page 3 2 Do not fill the fuel tank above the bottom of the filler tube 1 Fuel could overflow if the snowmo bile is tilted or if the ambient...

Page 31: ...at snow or ice does not enter the fuel tank when refueling Do not use alcohol deicers or water absorbing additives with oxygenated fuel The fuel tank should be filled with straight gaso line as specified ESU04031 Engine oil Use a combination of the recommended SAE and API oil classifications shown in the chart below CB 02E CAUTION Use only 4 stroke engine oil SAE API SE SF SG or higher 40 20 0 20 ...

Page 32: ... engine to idle for at least 10 seconds before turning it off 3 Remove the right side cover See pages 8 5 8 8 for removal procedures 4 Disconnect the oil level gauge coupler 1 CAUTION Disconnect the oil level gauge coupler before remov ing the oil level gauge dipstick Otherwise the cable can twist and break 5 Remove the oil level gauge dipstick 2 wipe it clean insert it back into the oil filler ho...

Page 33: ...ight upper cover See pages 8 5 8 8 for removal procedures 2 Check the coolant level in the coolant reservoir when the engine is cold If the coolant level is below the COLD LEVEL mark add soft water until it reaches the COLD LEVEL mark See pages 8 14 8 15 for more details 1 COLD LEVEL mark WARNING Do not remove the coolant reservoir cap when the engine is hot 2 Coolant reservoir cap CAUTION Hard wa...

Page 34: ...ile could start moving forward unexpectedly which could cause an accident 1 Start the engine NOTE Refer to the Starting the engine section 2 Hold the pivot point of the throttle lever away from the throttle switch by putting your thumb above and forefinger below between the throttle lever pivot 1 and the engine stop switch housing 2 While holding the pivot point as described above press the thrott...

Page 35: ...cates a failure in the brake system Do not operate the snowmobile if you find any problems in the brake system You could lose braking ability which could lead to an accident Ask a Yamaha dealer to inspect and repair the brake system 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 snowmobile is placed on its side ...

Page 36: ...clean it up immediately ESU05240 V belt Check the V belt 1 Remove the left side cover See pages 8 5 8 8 for removal procedure 2 Remove the drive guard 3 Check the V belt for wear and damage Replace if necessary 4 Install the drive guard 5 Install the left side cover WARNING Make sure that the drive guard is installed securely before operating the snowmobile Never run the engine with the V belt or ...

Page 37: ...aladjusted Drive track damage or failure could result in loss of brak ing ability and snowmobile control which could cause an accident ESU00982 Slide runners Check the slide runners for wear and damage If the slide runners reach the wear limit they should be replaced 1 Slide runners a Wear limit CAUTION Ride on fresh snow frequently Operating on ice or hard packed snow will rapidly wear the slide ...

Page 38: ...c This will wear or damage the skis ESU00103 Steering system Check the handlebar for excessive free play 1 Push the handlebar up and down and back and forth 2 Turn the handlebar slightly to the right and left If excessive free play is noticed consult a Yamaha dealer ESU01050 Lights Check the lights Replace any burned out bulbs CAUTION Avoid using a scraper or hot water for cleaning the plastics le...

Page 39: ...ame 5 Install the air filter case cover and the front cover NOTE After riding the snowmobile make sure that there is no snow under the air filter element ESU00110 Fittings and fasteners Check the tightness of the fittings and fasteners Tighten in proper sequence and torque if necessary ESU00345 Tool kit and recommended equipment It is good practice to carry the tool kit spare parts and other neces...

Page 40: ...starter motor cannot be operated when the engine stop switch is in the off position 1 Turn the main switch to the START position Warm up the engine until it does not run roughly 1 START CAUTION Release the switch immediately after the engine starts If the engine fails to start release the switch wait a few seconds then try again Each attempt should be as short as possible to preserve the battery D...

Page 41: ...ll throttle operation or any condition that might result in engine overheating must be avoided Operating your snowmobile for the first time Start the engine and let it idle for 15 minutes 0 160 km 0 100 mi Avoid prolonged operation above 8 000 r min 160 500 km 100 300 mi Avoid prolonged operation above 10 000 r min 500 km 300 mi and beyond The snowmobile can now be operated normally CAUTION After ...

Page 42: ...arded with added safety and a more reliable snowmobile Always wear the proper cloth ing for both warmth and to help protect you from injury if an accident occurs Become familiar with operating your snow mobile at low speeds even if you are an experienced rider Do not attempt to oper ate at maximum performance until you are totally familiar with the snowmobile s han dling and performance characteri...

Page 43: ... thor oughly familiar with the operation of your snowmobile Riding uphill You should practice first on gentle slopes Try more difficult climbs only after you have developed your skill As you approach a hill accelerate before you start the climb and then reduce the throttle to prevent track slippage It is also important to keep your weight on the uphill side at all times On climbs straight up the h...

Page 44: ...our downhill leg on the seat and the foot of your 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 possibility that your snowmobile could begin to slip sideways on the slope If this happens steer in the direction of the slide if there are no obstacles in your path As you regain proper bala...

Page 45: ...es 2 Snow mixed with a lot of dirt and sand All of the above surfaces have one thing in common in regard to drive track and slide runners little or no lubricating ability Drive track and all slide rail systems require lubrication snow or water between the slide runners and the slide metal In the absence of lubrication the slide runners will rapidly wear and in severe cases liter ally melt away and...

Page 46: ...erheating avoid sustained high speed usage in areas such as icy trails frozen lakes and rivers that have minimal snow coverage An overheated track will be weakened internally which may cause fail ure or damage Off trail riding Avoid off trail riding until there is sufficient snow cover age It generally takes several feet of snow to provide a good overall base to properly cover debris such as rocks...

Page 47: ...e lever slowly to move the snowmo bile 3 Turn the handlebar in the desired direction 4 Squeeze the brake lever to stop the snowmobile 5 Apply the parking brake by moving the parking brake lever to the left ESU00136 Stopping the engine Turn the main switch to the OFF position to stop the engine 1 OFF WARNING Push down the engine stop switch to stop the engine in an emergency Make sure that the key ...

Page 48: ...ally designed for your snowmobile is best This will help keep foreign objects out of the cooling vents and also help protect the snowmobile against damage from debris on the road If transporting the snowmobile in an open trailer or truck in areas where road salt is used coat metal suspension surfaces lightly with oil or another pro tectant This will help protect against corrosion Be sure to clean ...

Page 49: ...CONTROL THESE SER VICES NOT ONLY ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING PERI ODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES ESU04970 Periodic maintena...

Page 50: ... Fuel Check fuel level 6 1 6 2 Engine coolant Check coolant level 8 14 8 15 Air bleed the cooling system if necessary 8 14 Throttle lever handlebar side Check operation Repair if necessary 5 1 6 5 Throttle override system T O R S Check operation Repair if necessary 5 2 6 5 Engine stop switch Check operation Repair if necessary 5 8 Drive guard Check for cracks bends or damage Replace if necessary 5...

Page 51: ...ki runners Check for wear and damage 6 9 Replace if necessary Steering system Check operation 6 9 Adjust toe out if necessary Lights Check operation Replace bulbs if necessary 6 9 8 26 8 27 Battery Check condition Charge if necessary 8 27 Primary and second ary clutches Check engagement and shift speed Adjust if necessary Whenever operating elevation is changed Inspect sheaves for wear damage Insp...

Page 52: ...fied grease 8 25 Parking brake cable end and lever end throttle cable end Lubricate with specified grease 8 25 Check cable damage Replace if necessary Shroud and covers Make sure that the shroud and covers are securely fastened 5 11 8 5 8 8 Fittings and fasteners Check tightness Repair if necessary 6 10 Tool kit and recom mended equipment Check for proper placement 6 10 Item Remarks Pre operation ...

Page 53: ... torque wrench available during a service operation requiring one take your snowmobile to a Yamaha dealer to check the torque settings and adjust them if necessary ESU05300 Removing and installing the covers Air filter case cover and front cover To remove the air filter case cover and front cover 1 Unhook the latch and then slide the front cover upward 2 Loosen the quick fasteners lift up the air ...

Page 54: ...r case cover 2 Slot in the air filter case 3 Holder on the front cover 4 Projection on the air filter case cover Left side cover To remove the left side cover Loosen the quick fasteners and then remove the left side cover 1 Quick fastener 2 Left side cover To install the left side cover Place the left side cover in the original position and then tighten the quick fasteners Right side cover To remo...

Page 55: ...Remove the right upper cover by removing the bolts 1 Right upper cover bolt 2 Right upper cover To install the right upper cover 1 Place the right upper cover in the original position and then install and tighten the bolts to the specified torque 2 Install the top cover WARNING Do not drive the snowmobile with the covers unfastened or removed Keep your body and clothing away from rotating parts wh...

Page 56: ...di cate an intake track air leak or carburetion problem for that cylinder Do not attempt to diagnose such problems yourself Instead take the snowmobile to a Yamaha dealer for inspection and possible repairs You should periodically remove and inspect the spark plug because heat and deposits will cause a spark plug to slowly break down and erode Consult a Yamaha dealer before chang ing to a differen...

Page 57: ...asket surface Wipe off any grime from the threads and tighten the spark plug to the specified torque CAUTION Make sure that the spark plug caps are securely installed Otherwise the spark plug caps could be damaged due to engine vibration Spark plug reach a 19 0 mm 0 75 in Spark plug gap b 0 6 0 7 mm 0 024 0 028 in Spark plug tightening torque 12 5 Nm 1 25 m kgf 9 ft lb ...

Page 58: ...Insert a Phillips screwdriver into the hole and then turn the idle adjusting screw 2 in or out to adjust the engine idling speed 5 Install the rubber cap ESU05310 Adjusting the throttle cable 1 Loosen the locknut 2 Turn the adjuster in or out until the proper throttle lever free play is achieved 1 Locknut 2 Adjuster 3 Tighten the locknut Standard engine idling speed 1 800 100 r min Throttle lever ...

Page 59: ... higher altitudes To overcome operating with less power at high altitudes your snowmobile may also require different settings for the drive chain gears and V belt clutch to avoid poor per formance and rapid wear If you plan to operate your snowmobile at an altitude different from the area where you bought it be sure to consult a Yamaha dealer The dealer can tell you if there are any changes necess...

Page 60: ... should be replaced every 20 000 km 12 000 mi of operation Have a Yamaha dealer replace the oil filter cartridge To change the engine oil without oil filter cartridge replacement 1 Place the snowmobile on a level surface and apply the parking brake 2 Start the engine warm it up for several minutes and then turn it off 3 Remove the right side cover See pages 8 5 8 8 for removal procedure 4 Remove t...

Page 61: ... gauge dipstick Make sure that no foreign material enters the engine oil tank 12 Start the engine and then let it idle for several min utes while checking it for oil leakage If oil is leaking immediately turn the engine off and make sure that the engine oil drain bolts and oil level gauge dipstick are installed correctly 13 Turn the engine off and then connect the oil level gauge coupler Tightenin...

Page 62: ...team may be blown out under pressure which could cause serious injury When the engine has cooled place a thick rag or towel over the coolant reservoir cap and slowly rotate the cap counterclockwise to the detent This procedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning counter clockwise and remove it The cooling system must be bled...

Page 63: ... becomes empty if air can be seen in the cooling system or if there is a cooling system leak Consult a Yamaha dealer 1 Remove the top cover and the right upper cover See pages 8 5 8 8 for removal procedures 2 Remove the coolant reservoir cap add the recom mended coolant until it reaches the COLD LEVEL mark and then install the cap 1 COLD LEVEL mark 2 Coolant reservoir cap 3 Start the engine allow ...

Page 64: ...e by changing the positions of the spacers Have a Yamaha dealer make this adjustment CD 05E NOTE Apply the parking brake before replacing the V belt 1 Remove the left side cover See pages 8 5 8 8 for removal procedure 2 Remove the drive guard 3 Rotate the secondary sliding sheave clockwise 1 and push 2 it so that it separates from the secondary fixed sheave 4 Pull 3 the V belt up over the secondar...

Page 65: ...ed ESU05350 Checking the drive chain housing oil level and the drive chain tension Checking the oil level WARNING The engine oil tank brake disc and coolant hoses will be very hot after the engine has been run Avoid contact while they are still hot with any part of your body or clothing during inspection or repair 1 Place the snowmobile on a level surface 2 Remove the right side cover See pages 8 ...

Page 66: ...ng 6 Install the right side cover Adjusting the chain tension 1 Remove the right side cover See pages 8 5 8 8 for removal procedures 2 Loosen the locknut 3 Turn the adjusting bolt clockwise until it is finger tight and then loosen it 1 4 turn 4 Hold the adjusting bolt in place while tightening the locknut 1 Locknut 2 Adjusting bolt 5 Install the right side cover ESU00174 Checking the brake pads Ch...

Page 67: ... and the adjusting bolt 2 2 Loosen the cable locknut 3 3 Turn the cable adjuster 4 in or out to adjust the cable length 4 Tighten the cable locknut 5 Turn the adjusting bolt in or out to adjust the clear ance between the parking brake pads 5 and the brake disc 6 6 Tighten the locknut ESU00180 Checking the brake fluid level Place the snowmobile on a level surface Check that the brake fluid is above...

Page 68: ...eplacement is necessary when the following components are replaced during the periodic mainte nance or if they are damaged or leaking a All oil seals of the master cylinder and caliper cylinder b The brake hose WARNING Make sure that the brake fluid and the above parts are replaced by a Yamaha dealer ESU00183 Suspension The suspension can be adjusted to suit rider preference A softer setting for e...

Page 69: ...ng preload adjusters 1 one on the shock absorber in the front of the rear suspension assembly and one on the spring in the rear of the assembly The spring preload for the shock absorber and the spring can be adjusted separately by turning the respective spring preload adjuster WARNING Be sure to have a Yamaha dealer make this adjust ment CD 13E CD 23E Spring adjuster position 5 4 3 2 1 Preload 2 H...

Page 70: ...the drive track condition frequently Replace damaged slide metal Replace the drive track if it is damaged to the depth where fabric reinforcement material is visible or support rods are broken Otherwise track damage or failure could result in loss of braking ability and snow mobile control which could cause an accident Measuring the drive track deflection 1 Lay the snowmobile on its side 2 Measure...

Page 71: ... the drive track one or two turns Stop the engine 4 Check the drive track alignment with the slide runners 2 If the alignment is incorrect align the drive track by turning the left and right adjusters CD 08E 7 Slide runners 8 Drive track 9 Slide metal a Gap b Forward 5 Adjust the drive track deflection to specification CD 09E 5 6 Drive track alignment 5 Shifted to right 6 Shifted to left 3 Left ad...

Page 72: ... is achieved 7 Tighten the rear axle nut ESU02001 Aligning the skis 1 Turn the handlebar so the skis face straight ahead 2 Check the following for ski alignment a Skis are facing forward b Ski toe out 1 2 is within specification 3 If the alignment is not correct consult a Yamaha dealer Rear axle tightening torque 75 Nm 7 5 m kgf 54 2 ft lb Ski toe out 1 2 0 15 mm 0 0 59 in ...

Page 73: ...NING Apply a dab of grease onto the cable end only Do not grease the throttle cable because it could become frozen which could cause loss of control 2 Rear suspension WARNING Be sure to have a Yamaha dealer lubricate the front and rear suspensions Lubricant Low temperature grease 2 ...

Page 74: ...NING Keep flammable products and your hands away from the hot bulb until it has cooled down 6 Install the new bulb and then hook the bulb holder onto the headlight unit 7 Install the bulb holder cover and then connect the headlight coupler 8 Install the top cover CAUTION Keep oil and your hands away from the glass part of the bulb or its life and illumination will be affected If the glass is oil s...

Page 75: ...harged Keep in mind that the battery tends to discharge more quickly if the snowmobile is equipped with electrical accessories WARNING Battery electrolyte is poisonous and dangerous It contains sulfuric acid and can cause severe burns Avoid contact with skin eyes or clothing ANTIDOTE EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg ...

Page 76: ...e right side cover See pages 8 5 8 8 for removal procedures 2 Disconnect the negative battery lead 3 Replace the blown fuse with one of the proper amperage 6 Spare fuses 20 A 7 5 A 4 Connect the negative battery lead 5 Install the right side cover NOTE If the fuse immediately blows again ask a Yamaha dealer to inspect the snowmobile Specified fuses 1 Main fuse 40 A 2 Fuel injection system fuse 10 ...

Page 77: ...3 Compression Insufficient Loose cylinder head nuts Tighten nuts properly Worn or damaged gasket Replace gasket Worn or damaged piston and cylinder Ask a Yamaha dealer to inspect B Starting the engine with a dis charged battery If the snowmobile battery is discharged the engine can be started using a 12 volt battery and jumper cables WARNING Connect the jumper cables only to the battery terminals ...

Page 78: ...ull it out 2 Faulty wire connections Check con nections or ask a Yamaha dealer to inspect 3 Discharged battery Charge battery or see B above 4 Seized engine Seizure is caused by poor lubrication inadequate fuel or an air leak Ask a Yamaha dealer to inspect D Engine power is low 1 Low coolant temperature indicator light is flashing Warm the engine up 2 Faulty spark plugs Clean or replace the spark ...

Page 79: ...lean 2 Problem with the driveline See H above J Engine does not upshift or down shift properly or engages harshly 1 Worn or damaged V belt Replace the V belt or ask a Yamaha dealer to inspect 2 Incorrect V belt clutch settings for alti tude or conditions Ask a Yamaha dealer to inspect 3 Worn or sticking primary sheave assembly Ask a Yamaha dealer to inspect 4 Worn or sticking secondary sheave asse...

Page 80: ... the alcohol content in the fuel increases the chance for water to enter the engine Use Yamaha Stor Rite Engine Fogging Oil or an equiva lent fogging oil to protect both the com bustion chamber and crankshaft from corrosion An alternate method is to remove the intake silencer and squirt oil into the throttle bodies while the engine is running CAUTION Do not attempt to store the snowmobile by simpl...

Page 81: ...ti lated place out of direct sunlight Put a fab ric cover over the snowmobile preferably one that is designed for it Do not use a plastic or vinyl cover condensation could be trapped underneath which could increase the chances of rusting Returning to service after storage When returning your snowmobile to ser vice install the V belt and battery and adjust the drive track Remove the spark plugs and...

Page 82: ...linder Displacement 449 cm3 Bore Stroke 77 0 53 6 mm 3 03 2 11 in Idle speed 1 800 100 r min Engine oil type API SE SF SG or higher SAE 0W 30 Throttle body type KEIHIN TSK43 Fuel Premium unleaded gasoline Pump octane R M 2 91 or higher Starting system Electric starter PZ50 Drive track and suspension Track Molded rubber fiber glass rod reinforced Width 356 mm 14 0 in Track deflection 30 35 mm 1 18 ...

Page 83: ...thout oil filter cartridge replacement 2 45 L 2 16 lmp qt 2 59 US qt Total amount 3 00 L 2 64 lmp qt 3 17 US qt Brake Type Hydraulic disc type ventilated disc Operation Handle lever left hand operated Throttle Operation Handle lever right hand operated 1 Subject to change according to elevation settings 2 Usually achieved after approximately 800 m 0 5 mi traveled PZ50 Ignition system TCI Spark plu...

Page 84: ... L R L W Br B R R R B B BLACK L W R W R W L W B B B R B Y R B R B Lg Y R L Y B Y L W R W R W Y L Y W G W Br W B L G B W B W Y P W L R R L R B Gy R Gy Br L Y G Ch Lg Lg Y L W P B O B Ch R L R L G B G B G B R B B R L B R L R L B B B BLACK B L W B L B L W Y L Y B L L P W B L L A R L R L B L G W Br W B L L P W B L L R L R R W G Lg L W Y Y W O B G W Br B Gy B Y W Y Y W W L P W R L Y G Ch B L L Y Lg R W...

Page 85: ... switch W Frame ground X Brake light switch Y Tail brake light Z Fuel sender Oil level switch Speedometer unit Headlight relay _ Headlight a Headlight beam switch b HEAD Headlight fuse c SIG Signal fuse d IGN Ignition fuse e Load control relay COLOR CODE B Black Br Brown Ch Chocolate G Green Gy Gray L Blue Lg Light green O Orange P Pink R Red W White Y Yellow B L Black Blue B R Black Red B Y Black...

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