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2-6

INSP

ADJ

COOLING SYSTEM

7. Connect:

• Radiator outlet hose 1

8. Fill:

• Cooling system

CAUTION:

• Hard water or salt water is harmful to engine

parts. If soft water is not available, use boiled
or distilled water.

• Do not use water containing impurities or oil.

9. Bleed the air from the cooling system.

Recommended coolant:

High quality silicate-free ethylene
glycol antifreeze containing corro-
sion inhibitors

Coolant mixing ratio (coolant:water):

3:2 (60%:40%)

Total amount:

PZ50/PZ50GT/PZ50FX/PZ50M

3.6 L (3.17 Imp qt, 3.81 US qt)

PZ50VT/PZ50MP

3.7 L (3.26 Imp qt, 3.91 US qt)

10. Inspect:

• Cooling system

Decrease of pressure (leaks)

→

Repair as

required.

Inspection steps:

• Attach the cooling system tester

and adapter

to the coolant filler

• Apply 100 kPa (1.0 kg/cm

, 14 psi).

• Measure the pressure with the gauge.

Cooling system tester:

90890-01325, YU-24460-01

Adapter:

90890-01352, YU-33984

Содержание PZ50W

Страница 1: ...Manuals have been CycleHippied Over 30 Years of Powersports Industy Experience goes into the arrangement of the official Yamaha Factory Service Data If you obtained this manual from a source other than CycleHippie It may not have been properly CycleHippied Go to CycleHippie eBay Store ...

Страница 2: ...E MANUAL PZ50W PZ50GTW PZ50FXW PZ50MW PZ50VTW PZ50MPW LIT 12618 02 58 8GC 28197 10 PRINTED ON RECYCLED PAPER PRINTED IN U S A 2006 07 CR E YAMAHA MOTOR CO LTD Cover_SMB fm Page 1 Thursday July 27 2006 9 56 AM ...

Страница 3: ...jury or death to the snowmobile opera tor a bystander or a person inspecting or repairing the snowmobile A CAUTION indicates special precautions that must be taken to avoid damage to the snowmobile A NOTE provides key information that can make procedures easier or clearer MANUAL FORMAT All of the procedures in this manual are organized in a sequential step by step format The informa tion has been ...

Страница 4: ...Filling fluid A Lubricant B Tightening C Wear limit clearance D Engine speed E Special tool F Ω V A Illustrated symbols G to O in the exploded diagram indicate grade of lubricant and location of lubrica tion point G Apply locking agent LOCTITE H Apply Yamabond No 5 I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply wheel bearing grease M Apply low temperature lithium soap...

Страница 5: ...RAL INFORMATION GEN INFO 1 PERIODIC INSPECTION AND ADJUSTMENT INSP ADJ 2 CHASSIS CHAS 3 POWER TRAIN POWR TR 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 FUEL INJECTION SYSTEM FI 7 ELECTRICAL ELEC 8 SPECIFICATIONS SPEC 9 ...

Страница 6: ...16 COMPRESSION PRESSURE MEASUREMENT 2 17 ENGINE OIL LEVEL INSPECTION 2 19 ENGINE OIL REPLACEMENT 2 20 CYLINDER HEAD BREATHER HOSE INSPECTION 2 23 THROTTLE BODY JOINTS INSPECTION 2 23 CHECKING THE AIR FILTER ELEMENT 2 24 EXHAUST SYSTEM INSPECTION 2 25 POWER TRAIN 2 26 SHEAVE OFFSET ADJUSTMENT 2 26 DRIVE V BELT 2 28 ENGAGEMENT SPEED CHECK 2 29 PARKING BRAKE ADJUSTMENT 2 29 BRAKE FLUID LEVEL INSPECTI...

Страница 7: ...CHAIN INSTALLATION 4 30 BRAKE 4 31 BRAKE PAD REPLACEMENT 4 33 BRAKE CALIPER DISASSEMBLY 4 36 BRAKE CALIPER INSPECTION AND REPAIR 4 36 BRAKE CALIPER ASSEMBLY 4 37 BRAKE CALIPER INSTALLATION 4 37 INSPECTION 4 39 BRAKE MASTER CYLINDER ASSEMBLY 4 39 INSTALLATION 4 39 SLIDE RAIL SUSPENSION 4 40 PZ50 PZ50GT PZ50FX PZ50M 4 40 PZ50VT PZ50MP 4 45 REMOVAL 4 51 INSPECTION 4 51 ASSEMBLY 4 51 INSTALLATION 4 55...

Страница 8: ...TER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 7 1 WIRING DIAGRAM 7 2 ECU SELF DIAGNOSTIC FUNCTION 7 4 SELF DIAGNOSTIC FUNCTION TABLE 7 4 TROUBLESHOOTING CHART 7 6 DIAGNOSTIC MODE 7 7 TROUBLESHOOTING DETAILS 7 14 OIL PRESSURE SWITCH 7 28 INTAKE AIR TEMPERATURE SENSOR 7 28 THROTTLE BODY 7 29 INJECTORS 7 30 INSPECTION 7 31 PRESSURE REGULATOR OPERATION 7 31 INSPECTION AND ADJUSTMENT 7 32 CHAPTER 8...

Страница 9: ...P THUMB WARMER ADJUSTMENT SWITCH 8 46 PASSENGER GRIP WARMER PZ50VT 8 47 PASSENGER GRIP WARMER SWITCH PZ50VT 8 47 PASSENGER GRIP WARMER RELAY PZ50VT PZ50MP 8 48 COOLING SYSTEM PZ50M PZ50VT PZ50MP 8 50 CIRCUIT DIAGRAM 8 50 TROUBLESHOOTING 8 52 RADIATOR FAN MOTOR 8 53 RADIATOR FAN MOTOR RELAY 8 53 DRIVE REVERSE SELECTING SYSTEM PZ50GT PZ50FX PZ50M PZ50VT PZ50MP 8 54 CIRCUIT DIAGRAM 8 54 TROUBLESHOOTI...

Страница 10: ... serial number 1 is located on the right hand side of the frame just below the front of the seat ENGINE SERIAL NUMBER The engine serial number 1 is located on the left hand side of the crank case NOTE Designs and specifications are subject to change without notice MACHINE IDENTIFICATION ...

Страница 11: ...ts that have been mated through normal wear Mated parts must be reused or replaced as an assembly 4 During disassembly of the machine clean all parts and place them in trays in the order of disassembly This will speed up assembly time and help ensure that all parts are reinstalled correctly 5 Keep all parts away from any source of fire 6 Be sure to keep to the tightening torque specifications When...

Страница 12: ...turer s marks or numbers facing outwards In other words the stamped letters must be on the side exposed to view When installing oil seals apply a light coating of lightweight lithium base grease to the seal lips Oil the bearings liberally when installing CAUTION Do not use compressed air to spin the bearings dry This causes damage to the surface of the bearings CIRCLIPS All circlips should be insp...

Страница 13: ... others use part number starting with 90890 FOR TUNE UP Dial gauge P N YU 03097 90890 03097 This gauge is used for run out measurement Angle gauge Use goods on the market This tool is used to tightening the torque Steering linkage alignment plate P N YS 01515 90890 01515 Locks steering relay arm and pivot arm shaft in place while adjusting the steering linkage for front end alignment FOR ENGINE SE...

Страница 14: ... to loosen or tighten the oil filter cartridge Vacuum gauge P N YU 44456 90890 03094 This guide is used to synchronize the carburetors Compression gauge P N YU 33223 compression gage 90890 03081 These tools are used to measure engine compression Valve spring compressor P N YM 04019 90890 04019 Valve spring compressor attachment P N YM 04108 90890 04108 P N YM 04114 90890 04114 These tools are used...

Страница 15: ... N YM 04111 90890 04111 This tool is used to remove or install the valve guides Valve guide installer ø4 P N YM 04112 90890 04112 This tool is used to install the valve guides Valve guide reamer ø4 P N YM 04113 90890 04113 This tool is used to rebore the new valve guides Valve lapper P N 90890 04101 This tool is needed to remove and install the valve lifters Piston ring compressor P N YM 08037 908...

Страница 16: ... TRAIN SERVICE Sheave holder P N YS 01880 A 90890 01701 This tool is used to hold the primary sheave and A C magneto rotor Primary sheave puller 18 mm P N YS 01881 A 1 YS 01881 1 2 90890 01898 This tool is used for removing the primary sheave Clutch spider separator P N YS 28890 C 90890 01711 This tool is used when disassembling and assembling the primary sheave Clutch separator adapter P N YS 344...

Страница 17: ...0 06756 This tool is used to measure the vacuum pressure Fuel pressure adapter P N YM 03176 90890 03176 This tool is needed to measure fuel pressure Pressure gauge P N YU 03153 90890 03153 This tool is used to measure fuel pressure Vacuum gauge P N YU 08030 90890 03094 This guide is used to synchronize the throttle bodies FOR ELECTRICAL SERVICE Pocket tester P N YU 03112 C 90890 03112 This instrum...

Страница 18: ...1 9 GEN INFO SPECIAL TOOLS Digital circuit tester P N YU A1927 90890 03174 This instrument is necessary for checking the electrical componenets ...

Страница 19: ...EM Item Remarks Pre opera tion check Daily Initial 1 month or 800 km 500 mi 40 hr Every Seasonally or 4 000 km 2 500 mi 200 hr Spark plugs Check condition Adjust gap and clean Replace if necessary Valve clearance Check clearance Adjust clearance when engine is cold Every 40 000 km 25 000 mi Crankcase breather system Check breather hose for cracks or damage Replace if necessary Fuel filter Check co...

Страница 20: ...akage Adjust free play and or replace pads if necessary Replace brake fluid See NOTE on page 2 3 Disc brake installation Check for slight free play Lubricate shaft with specified grease as required Every 1 600 km 1 000 mi Drive chain oil Check oil level Replace Drive chain Check deflection Adjust if necessary Initial at 500 km 300 mi and every 800 km 500 mi thereafter Skis and ski runners Check fo...

Страница 21: ...ed Suspension component Lubricate with specified grease Parking brake cable end and lever end throttle cable end Lubricate with specified grease Check cable damage Replace if necessary Shroud and covers Make sure that the shroud and covers are securely fas tened Fittings and fasteners Check tightness Repair if necessary Tool kit and recommended equipment Check for proper placement Item Remarks Pre...

Страница 22: ...Measure Spark plug gap a Out of specification Regap Use a wire thickness gauge If necessary clean the spark plugs with a spark plug cleaner Standard spark plug NGK R CR9EKB NGK Before installing a spark plug clean the gasket sur face and spark plug surface 5 Install Spark plugs NOTE Finger tighten a the spark plug before torquing b it to specification Spark plug gap 0 6 0 7 mm 0 024 0 028 in T R S...

Страница 23: ...ap Slowly turn the cap counter clockwise until it stop This allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turn ing it counterclockwise to remove it 1 4 Place an open container under the radiator out let hose 1 5 Disconnect Radiator outlet hose 1 1 6 Drain the coolant NOTE Lift up the tail of the machine to drain the coolant WARNING Coolant is...

Страница 24: ...e free ethylene glycol antifreeze containing corro sion inhibitors Coolant mixing ratio coolant water 3 2 60 40 Total amount PZ50 PZ50GT PZ50FX PZ50M 3 6 L 3 17 Imp qt 3 81 US qt PZ50VT PZ50MP 3 7 L 3 26 Imp qt 3 91 US qt 10 Inspect Cooling system Decrease of pressure leaks Repair as required Inspection steps Attach the cooling system tester 1 and adapter 2 to the coolant filler 3 Apply 100 kPa 1 ...

Страница 25: ...essive V belt wear could occur or the machine could unexpectedly move forward if the clutch engages Operate the engine only in a well ventilated area Remove the coolant filler cap and bleed the cooling system again as described above No air bubbles OK Pour coolant into the coolant reservoir 2 until the coolant level reaches the COLD LEVEL mark b 1 b 2 VALVE CLEARANCE ADJUSTMENT NOTE Valve clearanc...

Страница 26: ... the mark b on the A C magneto cover NOTE TDC on the compression stroke can be found when the camshaft lobes are turned away from each other Measure the valve clearance with a thickness gauge 1 NOTE If the valve clearance is incorrect record the measured reading Measure the valve clearance in the following sequence Turn the crankshaft 180 counterclockwise and check the valve clearance of piston 2 ...

Страница 27: ...he position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place Select the proper valve pad from the following table NOTE The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter Since valve pads of various sizes are originally installed the valve pad number must be rounded in order to reach the closest...

Страница 28: ...mber of the original valve pad and the measured valve clearance in the valve pad selection table The point where the column and row intersect is the new valve pad number NOTE The new valve pad number is only an approxima tion The valve clearance must be measured again and the above steps should be repeated if the mea surement is still incorrect ...

Страница 29: ... 1 30 230 235 240 1 31 1 35 235 240 1 36 1 40 240 Measured clearance INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 0 03 0 07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0 08 0 12 120 125 130 135 ...

Страница 30: ...obes camshaft journals and camshaft cap bolts Align the camshaft marks with the camshaft cap marks Rotate the crankshaft counterclockwise several turns to seat the parts Measure the valve clearance again If the valve clearance is still out of specification repeat all of the valve clearance adjustment steps until the specified clearance is obtained 7 Install Crankshaft end accessing screw Timing ma...

Страница 31: ...PZ50FX PZ50M Air filter case assembly Refer to COWLINGS in CHAPTER 3 2 Remove Vacuum cap 1 1 3 Install Vacuum gauge 1 4 Install Air filter case Refer to COWLINGS in CHAPTER 3 5 Start the engine and let it warm up for several minutes 6 Inspect Engine idle speed Out of specification Adjust Refer to ENGINE IDLE SPEED ADJUST MENT 7 Adjust Throttle body synchronization Vacuum gauge 90890 03094 YU 44456...

Страница 32: ...dle speed Out of specification Adjust Make sure that the vacuum pressure is within specification 9 Stop the engine and remove the measuring equipment 10 Adjust Throttle cable free play Refer to THROTTLE CABLE FREE PLAY ADJUSTMENT Vacuum pressure at engine idling speed 20 27 22 93 kPa 0 20 0 23 kg cm2 2 88 3 26 psi 1 ENGINE IDLE SPEED ADJUSTMENT NOTE Prior to adjusting the engine idling speed the t...

Страница 33: ...TLE CABLE FREE PLAY ADJUSTMENT NOTE Before adjusting the throttle cable free play the engine idle speed should be adjusted Adjust the throttle cable free play while the cable is in the cable guide 1 Measure Throttle cable free play a Out of specification Adjust 2 Adjust Throttle cable free play Throttle cable free play 2 0 3 0 mm 0 08 0 12 in a Throttle body side adjustment steps Remove the air fi...

Страница 34: ...ng does not run faster 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 the engine up to the clutch engagement speed Otherwise the machine could start moving forward unexpectedly which could cause an accident 1 Start the engine 2 Hold the pivot point of the throttle lever away from the thr...

Страница 35: ...easure Valve clearance Out of specification Adjust Refer to VALVE CLEARANCE ADJUST MENT 2 Start the engine warm it up for several minutes and then turn it off 3 Remove Fuel tank Refer to SEAT AND FUEL TANK in CHAP TER 5 PZ50 PZ50GT PZ50FX PZ50M Refer to RIDER SEAT AND FUEL TANK in CHAPTER 5 PZ50VT PZ50MP 4 Remove Spark plug CAUTION Before removing the spark plugs use com pressed air to blow away a...

Страница 36: ... sparking ground all ignition coil leads before cranking the engine NOTE The difference in compression pressure between cylinders should not exceed 100 kPa 1 kg cm2 14 2 psi 7 Install Spark plug Compression pressure with oil applied into cylinder Reading Diagnosis Higher than without oil Piston ring s wear or damage Repair Same as without oil Piston valves cylinder head gasket or piston possibly d...

Страница 37: ...t and become severed Remove the oil level gauge dipstick 2 wipe it clean insert it back into the filler hole without screwing it in and then remove it again to check the oil level The engine oil level should be between the maximum level mark H a and minimum level mark L b Below the minimum level mark Add the rec ommended engine oil to the proper level CAUTION When adding the engine oil be careful ...

Страница 38: ...ives with the oil or use oils of a higher grade than CD In addition do not use oils labeled ENERGY CONSERVING II or higher ENGINE OIL REPLACEMENT 1 Place the snowmobile on a level surface and apply the parking brake 2 Start the engine warm up for several minutes and then turn it off 3 Place a containers under the engine oil pan and oil tank 4 Remove Bottom panel 1 5 Remove Left side panel Right si...

Страница 39: ...rain Engine oil completely from the oil pan and oil tank 12 If the oil filter cartridge is also to be replaced perform the following procedure 1 Replacement steps Remove the air filter case Refer to COWLINGS in CHAPTER 3 Remove the oil filter bolts 1 Remove the oil filter cartridge 2 with an oil filter wrench 3 Oil filter wrench 90890 01469 YM 01469 1 1 3 2 ...

Страница 40: ...engine oil Add 1 5 L 1 3 Imp qt 1 6 US qt of the recom mended engine oil to the oil tank and then install and tighten the oil level gauge dipstick and the cylinder head cap 15 Inspect Engine and oil tank for engine oil leaks 16 Inspect Engine oil level Refer to ENGINE OIL LEVEL INSPECTION T R Oil filter cartridge 17 Nm 1 7 m kg 12 ft lb T R Oil cooler bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE T R Oil ...

Страница 41: ...ngine oil comes out after one minute turn the engine off so that it will not seize Check the engine oil passages the oil filter and the oil pump for damage or leakage Start the engine after solving the problem s and check the engine oil pressure again Tighten the oil check bolt to specification T R Oil check bolt 10 Nm 1 0 m kg 7 2 ft lb 1 CYLINDER HEAD BREATHER HOSE INSPECTION 1 Inspect Cylinder ...

Страница 42: ...er to COWLINGS in CHAPTER 3 2 Lift up the air filter element frame and remove the air filter element 3 Clean Air filter element NOTE Remove the snow 4 Inspect Air filter element Damage clogs Replace 5 Install Air filter element Air filter case cover CHECKING THE AIR FILTER ELEMENT ...

Страница 43: ... 5 Muffler damper 6 Cracks damage Replace Gasket 7 Gaskets 8 Exhaust gas leaks Replace 3 Inspect Tightening torque 4 Install Fuel tank Refer to SEAT AND FUEL TANK in CHAP TER 5 PZ50 PZ50GT PZ50FX PZ50M Refer to RIDER SEAT AND FUEL TANK in CHAPTER 5 PZ50VT PZ50MP T R Exhaust pipe joint bolt 9 25 Nm 2 5 m kg 18 ft lb Exhaust pipe muffler bolt 0 33 Nm 3 3 m kg 24 ft lb Muffler damper holder bolt A 10...

Страница 44: ...ation Adjust NOTE Push the secondary sheave inward towards the frame and then measure the sheave offset Sheave offset 14 5 17 5 mm 0 57 0 69 in 4 Adjust Sheave offset Adjustment steps Apply the brake to lock the secondary sheave Remove the secondary sheave bolt 1 washer 2 shim s left and secondary sheave 3 Install the appropriate shim s right 4 from the following table so that the sheave offset is...

Страница 45: ...asure Secondary sheave free play clearance a Use a feeler gauge Out of specification Adjust Secondary sheave free play clear ance 1 0 2 0 mm 0 04 0 08 in a 6 Adjust Secondary sheave free play clearance Adjustment steps Apply the brake to lock the secondary sheave Remove the secondary sheave bolt 1 and washer 2 Install the appropriate shim s left 3 from the following table so that the secondary she...

Страница 46: ...engine is started New belt width 34 1 mm 1 34 in Belt wear limit width 32 5 mm 1 28 in a a 1 Inspect Drive V belt Cracks damage wear Replace Oil or grease on the V belt Check the pri mary and secondary sheaves 2 Inspect Primary sheave Secondary sheave Oil or grease on the primary and secondary sheaves Use a rag soaked in lacquer thin ner or solvent to remove the oil or grease Check the primary and...

Страница 47: ...he machine starts moving forward Out of specification Adjust the primary sheave Engagement speed PZ50 PZ50GT PZ50FX 3 700 4 100 r min PZ50M USA Canada 4 100 4 500 r min PZ50M Europe 3 900 4 300 r min PZ50VT USA Canada 3 300 3 700 r min PZ50VT Europe PZ50MP 2 900 3 300 r min PARKING BRAKE ADJUSTMENT 1 Remove Right side cover Refer to COWLINGS in CHAPTER 3 2 Measure Parking brake cable distance Out ...

Страница 48: ...2 4 Measure Brake pad clearance a b Out of specification Adjust 5 Adjust Brake pad clearance Adjustment steps Loosen the locknut 1 Turn the adjuster 2 in or out until the specified clearance between the brake pad 3 and brake disc 4 is obtained Tighten the locknut Brake pad clearance a b 1 5 2 0 mm 0 059 0 079 in 1 2 BRAKE FLUID LEVEL INSPECTION 1 Place the machine on a level surface 2 Check Fluid ...

Страница 49: ...e the rubber seals causing leakage and poor brake performance Refill with the same type of fluid Mixing fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reservoir Water will significantly lower the boiling point of the fluid and may cause vapor lock BRAKE PAD INSPECTION 1 Remove Right si...

Страница 50: ...Right side cover Refer to COWLINGS in CHAPTER 3 2 Bleed Brake system Air bleeding steps a Fill the brake master cylinder reservoir with the proper brake fluid b Install the diaphragm Be careful not to spill any fluid or allow the brake master cylinder reservoir to overflow c Connect clear plastic hose 1 tightly to the brake caliper bleed screw 2 d Place the other end of the hose in a container e S...

Страница 51: ... engine and muffler while they are still hot with any part of your body or clothing during inspection or repair 1 Remove Right side cover Refer to COWLINGS in CHAPTER 3 2 Place the machine on a level surface 3 Check Oil level Checking steps Remove the dipstick 1 and wipe it off with a clean rag The put the dipstick in the hole CAUTION There is a magnet attached to the end of the dipstick It is use...

Страница 52: ...ick 1 NOTE Align the notch a of the dipstick handle with the projection b of the drive chain housing a b 1 Oil replacement Oil replacement steps Place the oil pan under the drain hole Remove the right lower cover Refer to COWLINGS in CHAPTER 3 Remove the oil drain bolt along with the gas ket 1 and drain the oil CAUTION Be sure to remove any oil from the heat protec tor Install the new gasket and o...

Страница 53: ... not allow anyone to stand behind the machine when the engine is running When the rear of the machine is raised to allow the track to spin a suitable stand must be used to support the rear of the machine Never allow anyone to hold the rear of the machine off the ground to allow the track to spin Never allow anyone near a rotating track Inspect the condition of the track frequently Replace the trac...

Страница 54: ...unner 6 Track 7 Track metal a Gap Ê Forward e Adjust the track deflection until the specified amount is obtained CAUTION The adjusters should be turned an equal amount f Recheck the alignment and deflection If neces sary repeat steps c to e until the specified amount is obtained g Tighten the rear axle nut Track alignment È Shifted to right É Shifted to left 3 Left adjuster Turn out Turn in 4 Righ...

Страница 55: ...s A loose track can slip ratchet derail or catch on suspension parts causing severe damage Do not overtighten the drive track otherwise it may increase the friction between the track and the slide runners resulting in the rapid wear of both compo nents Also this may put an excessive load on the suspension components resulting in component failure Marginal snow The drive track and the slide runners...

Страница 56: ...impact damage to the drive track Studded track In general track life will be shortened when studs are installed Drilling stud holes into the drive track will cut the internal fibers which weakens the track Avoid spinning the drive track Studs may catch on an object and pull out of the track leaving tears and damage around the already weakened area To minimize possible damage consult your stud man ...

Страница 57: ...Ski runner wear limit 6 mm 0 24 in Plastic ski wear limit PZ50 PZ50GT PZ50FX PZ50VT USA Canada 13 mm 0 51 in PZ50M PZ50VT Europe PZ50MP 24 mm 0 95 in STEERING SYSTEM Free play check 1 Check Steering system free play Move the handlebar up and down and back and forth Turn the handlebar slightly to the right and left Excessive free play Check that the handle bar tie rod ends and relay rod ends are in...

Страница 58: ...the air filter case assembly Refer to COWLINGS in CHAPTER 3 Loosen the locknuts tie rods 1 Turn the tie rods 2 in or out until the specified toe out is obtained Tighten the locknuts tie rods 1 CAUTION After tightening the inside and outside ball joint locknuts 1 make sure the tie rods 2 can be rotated freely through the ball joint travel If not loosen the locknuts 1 and reposition the ball joint s...

Страница 59: ...of the cables Do not grease the throttle cables They could freeze and cause a loss of control Rear suspension 1 Use a grease gun to inject grease into the nip ples 2 Apply grease to the pivoting parts È PZ50 PZ50GT PZ50FX PZ50M É PZ50VT PZ50MP 1 Nipple 2 Nipple both sides Recommended lubricant ESSO Beacon 325 Grease or Aeroshell Grease 7A Recommended lubricant ESSO Beacon 325 Grease or Aeroshell G...

Страница 60: ... m 25 ft S 26 mm 1 0 in 66 mm 2 6 in 6 Adjust Headlight beam Adjustment steps Turn the headlight beam adjuster 1 in or out to adjust the headlight beams Headlight beam movement a Down and to the left b Up and to the right c Down and to the right d Up and to the left BATTERY INSPECTION WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly ca...

Страница 61: ...attery are different from those of conventional batteries The MF bat tery should be charged as explained in the charging method illustrations If the battery is overcharged the electrolyte level will drop considerably Therefore take special care when charging the battery NOTE Since MF batteries are sealed it is not possible to check the charge state of the battery by measuring the specific gravity ...

Страница 62: ...ltage i e the voltage when the positive terminal is discon nected No charging is necessary when the open circuit voltage equals or exceeds 12 8 V Check the charge of the battery as shown in the charts and the following example Example Open circuit voltage 12 0 V Charging time 6 5 hours Charge of the battery 20 30 Positive tester probe positive battery terminal Negative tester probe negative batter...

Страница 63: ...rminal To reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure that the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded bat tery charger le...

Страница 64: ...n circuit voltage Refer to BATTERY INSPEC TION If the current does not exceed the standard charging current after 5 minutes replace the battery If charging requires more than 5 hours it is advisable to check the charg ing current after a lapse of 5 hours If there is any change in the amper age readjust the voltage to obtain the standard charging current Measure the battery open circuit voltage aft...

Страница 65: ...g current writ ten on the battery Charge the battery until the battery s charging voltage is 15 V This type of battery charger cannot charge the MF battery A variable voltage charger is recommended Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes 12 8 V or more Charging is complete 12 7 V or less Recharging is required Under 12 0 V Replace the batt...

Страница 66: ... terminals Recommended lubricant Dielectric grease 2 1 FUSE INSPECTION The following procedure applies to all of the fuses CAUTION To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove Right side cover Refer to COWLINGS in CHAPTER 3 2 Inspect Continuity Inspection steps Connect the pocket tester to the fuse and check the continuity NOTE Set the pocke...

Страница 67: ...at specified Improvising or using a fuse with the wrong amperage rating may cause exten sive damage to the electrical system cause the lighting ignition grip warmer signal and meter systems to malfunction and could possibly cause a fire Item Amperage Q ty 1 Main fuse 40 A 1 2 Fuel injection system fuse 10 A 1 3 Headlight fuse 20 A 1 4 Signal fuse 7 5 A 1 5 Auxiliary DC jack fuse 1 3 A 1 6 Ignition...

Страница 68: ...g rate 29 4 N mm 3 0 kg mm 168 lb in Ò Wire diameter 6 0 mm 0 236 in Ó Outside diameter 60 0 mm 2 36 in Ô Weight ID 8GC 17605 00 8GC00 Õ Weight rivet Steel 13 3 OUT Steel 10 3 CENTER Steel 10 3 IN Steel 10 3 OUT Steel 10 3 CENTER Steel 10 3 IN Steel 10 3 OUT Steel 10 3 CENTER Aluminum 10 3 IN Steel 10 3 OUT Aluminum 10 3 CENTER Aluminum 10 3 IN Aluminum 10 3 OUT Aluminum 10 3 CENTER None IN Ö Weig...

Страница 69: ... N mm 3 0 kg mm 168 lb in Ò Wire diameter 6 0 mm 0 236 in Ó Outside diameter 60 0 mm 2 36 in Ô Weight ID 8GC 17605 00 8GC00 Õ Weight rivet Steel 13 3 OUT Steel 10 3 CENTER Steel 10 3 IN Steel 10 3 OUT Steel 10 3 CENTER Steel 10 3 IN Steel 10 3 OUT Steel 10 3 CENTER Aluminum 10 3 IN Steel 10 3 OUT Aluminum 10 3 CENTER Aluminum 10 3 IN Aluminum 10 3 OUT Aluminum 10 3 CENTER None IN Ö Weight bushing ...

Страница 70: ... 92 in Ð Preload 245 N 25 kg 55 lb Ñ Spring rate 27 0 N mm 2 75 kg mm 154 lb in Ò Wire diameter 6 0 mm 0 236 in Ó Outside diameter 60 0 mm 2 36 in Ô Weight ID 8DN 17605 30 8DN10 Õ Weight rivet Steel 13 9 OUT Steel 13 9 IN Steel 13 3 OUT Steel 13 9 IN Steel 13 3 OUT Steel 13 3 IN Steel 10 3 OUT Steel 10 3 IN Steel 10 3 OUT None IN Ö Weight bushing VESPEL TP 8549 Roller outer dia 15 0 mm 0 591 in Ø ...

Страница 71: ... 24 5 N mm 2 5 kg mm 140 lb in Ò Wire diameter 5 5 mm 0 217 in Ó Outside diameter 60 0 mm 2 36 in Ô Weight ID 8GC 17605 00 8GC00 Õ Weight rivet Steel 17 2 OUT Steel 17 2 CENTER Steel 13 9 IN Steel 17 2 OUT Steel 13 9 CENTER Steel 13 9 IN Steel 13 9 OUT Steel 13 9 CENTER Steel 13 3 IN Steel 13 3 OUT Steel 13 3 CENTER Steel 10 3 IN Steel 10 3 OUT Steel 10 3 CENTER Aluminum 10 3 IN Ö Weight bushing V...

Страница 72: ...6 N mm 2 0 kg mm 112 lb in Ò Wire diameter 5 2 mm 0 205 in Ó Outside diameter 60 0 mm 2 36 in Ô Weight ID 8GC 17605 00 8GC00 Õ Weight rivet Steel 17 2 OUT Steel 17 2 CENTER Steel 17 2 IN Steel 17 2 OUT Steel 13 9 CENTER Steel 13 9 IN Steel 13 9 OUT Steel 13 9 CENTER Steel 13 3 IN Steel 13 3 OUT Steel 13 3 CENTER Steel 10 3 IN Steel 10 3 OUT Steel 10 3 CENTER Aluminum 10 3 IN Ö Weight bushing VESPE...

Страница 73: ...le condi tions wet snow icy snow hills or rough terrain however engine speed may decrease after the shifting speed has been reached È Engine speed É Good condition Ê Clutch shifting speed Ë Clutch engagement speed Ì Starting position Í Distance travelled 800 m 2 500 ft GEAR SELECTION The reduction ratio of the driven gear to the drive gear must be set according to the snow conditions If there are ...

Страница 74: ... links 2 00 80 links 41 teeth 2 41 80 links 2 28 80 links 2 16 80 links 2 05 80 links 45 teeth 2 65 82 links 2 50 82 links 2 37 82 links 2 25 82 links 46 teeth 2 71 82 links 2 56 82 links 2 42 82 links È Part No É Spring rate N mm rad kg mm rad Ê Preload N mm kg mm lb in Ë Color Ì Wire gauge mm in Í No of coils Î Free length mm in Ï Outside diameter mm in Ð Standard 90508 50571 7071 721 8 7 0 89 4...

Страница 75: ...5 65 95 5 A 45 75 105 15 B 55 85 115 25 È Seat 1 2 3 4 É Sheave C 40 70 100 10 A 50 80 110 20 B 60 90 120 30 É Effects Ê Part no Ë Cam angle Ì Identification mark Í Standard Î Quicker upshifting dur ing acceleration Ï Quicker backshifting under load 89N 17684 01 42 89N 01 88R 17684 03 39 88R 03 PZ50 PZ50GT PZ50FX 8AT 17684 01 37 8AT 01 PZ50M PZ50VT PZ50MP 1 2 3 4 89N01 È Identification mark ...

Страница 76: ...22 1 2 25 343 35 White Silver White 5 5 0 217 59 0 2 323 4 66 81 0 3 189 90501 556G5 22 1 2 25 196 20 White Blue White 5 5 0 217 60 2 362 4 62 74 3 2 925 90501 556G6 19 6 2 0 196 20 Blue 5 5 0 217 60 2 362 4 95 75 4 2 969 90501 556G7 24 5 2 5 196 20 Yellow Blue Yellow 5 5 0 217 60 2 362 4 36 73 4 2 890 PZ50VT USA Can ada 90501 557G5 24 5 2 5 147 15 Yellow Gold Yellow 5 5 0 217 60 2 362 4 36 71 4 2...

Страница 77: ... Ë Standard 8BU 17605 20 45 41 1 603 8DN 17605 30 39 76 1 404 PZ50M 8ES 17605 00 54 63 1 928 8FA 17605 10 63 81 2 251 8FN 17605 00 75 28 2 657 8FP 17605 00 67 81 2 394 8FS 17605 00 65 52 2 313 8GC 17605 00 47 28 1 669 PZ50 PZ50GT PZ50FX PZ50VT PZ50MP 8BU 10 8DN 10 8ES 00 8FA 00 8FN 00 8 FP 0 0 8 FS 0 0 8G C 00 ...

Страница 78: ...FX OUT PZ50M USA Canada 90261 06028 Aluminum 10 3 0 406 0 85 0 030 None IN PZ50M USA Canada I D 9 mm 0 354 in È Roller with bush ing part number É Outside diameter mm in Ê Bushing type P N Ë Identification mark Width Ì Standard Í Effects 8FG 17624 00 14 5 0 57 VESPEL TP 8549 90386 09001 Î Grooved Machined 14 6 mm PZ50VT PZ50MP Ó Increased force Ô Decreased force 8FG 17624 10 15 0 0 59 VESPEL TP 85...

Страница 79: ...0FX Ê PZ50 PZ50M PZ50VT USA Canada Spring seat distance Standard Shorter Longer Preload Harder Softer Length a Min 205 mm 8 07 in 215 mm 8 46 in Max 215 mm 8 46 in Spring seat distance Standard Shorter Longer Preload Harder Softer Length a Min 190 mm 7 48 in 200 mm 7 87 in Max 200 mm 7 87 in Spring seat distance Standard Shorter Longer Preload Harder Softer Length a Min 231 6 mm 9 12 in 241 6 mm 9...

Страница 80: ...turning the adjuster 1 With the adjuster fully turned lightly in direction a CAUTION Do not continue to turn the adjuster in direc tion a after it stops The shock absorber can be damaged and rebound damping force adjustments cannot be made Do not turn the adjuster in direction b more than 20 clicks Even if the adjuster is continu ally turned after 20 clicks there will be no change in the rebound d...

Страница 81: ...uster in direction b more than 12 clicks Even if the adjuster is continu ally turned after 12 clicks there will be no change in the compression damping force Be sure to stop the adjuster at a position where there is a click Adjuster position 12 clicks out 7 clicks out 2 clicks out Minimum Standard Maximum Turns out b Turns in a Compres sion damp ing force Soft Hard 1 a b REAR SUSPENSION Stopper ba...

Страница 82: ...2 È È 1 1 2 No 4 No 3 No 2 No 1 É Choosing other settings CAUTION The standard settings work well under most general riding conditions The suspension can be adjusted to work better in one condition but only at the expense of another Keep this in mind when you adjust the suspension È PZ50 PZ50GT PZ50FX PZ50M É PZ50VT PZ50MP È No 5 hole É No 4 hole shortest No 1 hole longest More weight on skis Heav...

Страница 83: ...nger Preload Harder Softer Length a Min 175 mm 6 89 in 185 mm 7 28 in Max 185 mm 7 28 in Spring seat distance Standard Shorter Longer Preload Harder Softer Length a Min 180 mm 7 09 in 190 mm 7 48 in Max 190 mm 7 48 in Spring seat distance Standard Shorter Longer Preload Harder Softer Length a Min 182 mm 7 17 in 192 mm 7 56 in Max 192 mm 7 56 in Spring seat distance Standard Shorter Longer Preload ...

Страница 84: ...to flames or high heat which could cause it to explode É PZ50 PZ50GT USA Canada PZ50M Ê PZ50VT USA Canada Spring adjuster position 1 2 3 4 5 Preload Softer Harder Standard 1 Spring adjuster position 1 2 3 4 5 Preload Softer Harder Standard 3 É Ê Rear side Turn the adjuster 1 to proper position WARNING Always adjust both spring preload left and right to the same setting Uneven adjustment can cause ...

Страница 85: ...after it stops The shock absorber can be damaged and damping force adjustments cannot be made Do not turn the adjuster in direction b more than 20 clicks Even if the adjuster is continu ally turned after 20 clicks there will be no change in the damping force Be sure to stop the adjuster at a position where there is a click Adjuster position 20 clicks out 11 clicks out 1 click out Minimum Standard ...

Страница 86: ...n the locknut 1 Turn the adjusting nut 2 in or out to adjust the control rod stroke WARNING Never adjust the control rods beyond the maxi mum range indicated on the rods with red paint 3 While holding the adjusting bolt securely tighten the locknut 1 Adjusting position 1 2 3 Effect Increase weight transfer Decrease weight transfer Standard 2 T R Locknut 25 Nm 2 5 m kg 18 ft lb a 3 1 2 3 1 2 ...

Страница 87: ...nd turn the 2 up adjusting block until it is in the desired position Release the lock lever NOTE Make sure that the lock lever has returned to its original position and that the 2 up adjusting block is locked in place Do not ride the snowmobile with the lock lever pulled out CAUTION Make sure that the 2 up adjusting blocks are in the same position on both sides of the machine Solo rider only 2 up ...

Страница 88: ...l 1 3 Air filter case cover 1 4 Headlight cover 1 5 Left side panel 1 6 Right side panel 1 7 Left side cover 1 8 Right side cover 1 9 Left lower cover 1 10 Right lower cover 1 11 Headlight coupler 2 12 Headlight assembly 1 13 Cylinder 2 intake air pressure sensor cou pler 1 Disconnect 7 5 4 12 6 18 3 10 2 8 17 16 11 15 13 14 8 Nm 0 8 m kg 5 8 ft lb È È È È È 9 1 PZ50FX 19 COWLINGS ...

Страница 89: ...ir temperature sensor coupler 1 Disconnect 16 Cylinder head breather hose 1 Disconnect 17 Oil tank breather hose 1 Disconnect 18 Air filter case assembly 1 19 Intake air pressure sensor hose 2 For installation reverse the removal proce dure 7 5 4 12 6 18 3 10 2 8 17 16 11 15 13 14 8 Nm 0 8 m kg 5 8 ft lb È È È È È 9 1 PZ50FX 19 3 ...

Страница 90: ...t lower cover 1 8 Cylinder 2 intake air pressure sensor cou pler 1 Disconnect 9 Cylinder 1 intake air pressure sensor cou pler 1 Disconnect 10 Intake air temperature sensor coupler 1 Disconnect 11 Cylinder head breather hose 1 Disconnect 12 Oil tank breather hose 1 Disconnect 13 Air filter case assembly 1 14 Intake air pressure sensor hose 2 Disconnect For installation reverse the removal proce du...

Страница 91: ...5 Steering pad 1 PZ50GT PZ50FX PZ50M 6 Plastic band 2 7 Thumb warmer lead coupler 1 Disconnect 8 Engine stop switch coupler 1 Disconnect 9 Throttle switch coupler 2 Disconnect 10 Grip warmer lead connector 2 Disconnect 11 Grip thumb warmer adjustment switch lead coupler 1 Disconnect 12 Brake light switch coupler 1 Disconnect 13 Headlight beam switch coupler 1 Disconnect 22 20 É 16 17 18 È Ë 15 14 ...

Страница 92: ...r cylinder assembly 1 NOTE After installing all parts refer to CABLE ROUTING in CHAPTER 9 to check the cable and lead routings 20 Handlebar holder 2 21 Handlebar 1 22 Steering joint 1 For installation reverse the removal proce dure 22 20 É 16 17 18 È Ë 15 14 19 9 2 8 10 7 11 10 12 13 21 6 6 5 3 4 1 Ê Ê 20 Nm 2 0 m kg 14 ft lb Ë 15 Nm 1 5 m kg 11 ft lb 16 Nm 1 6 m kg 11 ft lb 10 Nm 1 0 m kg 7 2 ft ...

Страница 93: ...mer lead coupler 1 Disconnect 7 Engine stop switch coupler 1 Disconnect 8 Throttle switch coupler 2 Disconnect 9 Grip warmer lead connector 2 Disconnect 10 Grip thumb warmer adjustment switch lead coupler 1 Disconnect 11 Brake light switch coupler 1 Disconnect 12 Headlight beam switch coupler 1 Disconnect 13 Right handlebar switch cover 1 21 19 É 15 16 17 È Ë 14 13 18 8 1 7 9 6 20 5 5 4 2 3 23 22 ...

Страница 94: ...BLE ROUTING in CHAPTER 9 to check the cable and lead routings 19 Handlebar holder 2 20 Handlebar 1 21 Steering joint 1 22 Steering joint bracket cover 1 23 Steering joint bracket 1 For installation reverse the removal proce dure 21 19 É 15 16 17 È Ë 14 13 18 8 1 7 9 6 20 5 5 4 2 3 23 22 Ì 10 9 12 11 Ê 4 4 Ì 15 Nm 1 5 m kg 11 ft lb 21 Nm 2 1 m kg 15 ft lb Ì 16 Nm 1 6 m kg 11 ft lb 10 Nm 1 0 m kg 7 ...

Страница 95: ...sher 1 7 Bearing holder 1 8 Bearing 1 9 Steering column 1 10 Bearing 1 11 Circlip 1 12 Steering arm 1 13 Steering control arm bracket 1 14 Spacer 1 PZ50VT PZ50MT New New New New New È È É É È Ê Ê Ê Ê Ì Ê Ê Ê Ë Í Í Í Í Ê Ê Î Î 17 New 2 3 É 4 10 9 10 5 8 6 15 1 14 13 16 11 12 23 23 21 22 22 20 25 20 26 27 19 7 18 21 24 LT LT LT LT LT Í Ï 1 ESSO beacon 325 grease or Aeroshell grease 7A Í 35 Nm 3 5 m ...

Страница 96: ... arm bracket 2 1 For installation reverse the removal proce dure New New New New New È È É É È Ê Ê Ê Ê Ì Ê Ê Ê Ë Í Í Í Í Ê Ê Î Î 17 New 2 3 É 4 10 9 10 5 8 6 15 1 14 13 16 11 12 23 23 21 22 22 20 25 20 26 27 19 7 18 21 24 LT LT LT LT LT Í Ï 1 ESSO beacon 325 grease or Aeroshell grease 7A Í 35 Nm 3 5 m kg 25 ft lb Î 38 Nm 3 8 m kg 27 ft lb Ï 90 Nm 9 0 m kg 65 ft lb 30 Nm 3 0 m kg 22 ft lb 21 Nm 2 1...

Страница 97: ...pivot arm brackets Wear damage Replace Steering column bearing contact surfaces Scratches wear damage Replace 3 Inspect Relay rod Tie rods Steering shaft Bends cracks damage Replace WARNING Do not attempt to straighten bent rods This may dangerously weaken the rods 4 Check Rod end movement Rod end free play exists Replace the rod end Rod end turns roughly Replace the rod end 5 Inspect Right relay ...

Страница 98: ...ocknut to specification È Left side É Right side È Tie rod part number É Set length a Ê Tie rod length b 8GC 23830 00 PZ50 PZ50GT PZ50FX PZ50VT PZ50MP 504 7 mm 19 87 in 433 2 mm 17 06 in 8GP 23830 00 PZ50M 464 9 mm 18 30 in 393 4 mm 15 49 in Tie rod angle 85 a b 2 1 2 3 3 c c È É 3 Install Tie rods 1 NOTE Make sure that the indentation a on the tie rod faces out CAUTION Always use new cotter pins ...

Страница 99: ...ft 1 Locknuts 2 Joints 3 CAUTION Always use new cotter pin 6 Bend the lock washer tab along a flat side of the bolt È Steering shaft part number É Set length a Ê Shaft length b 8GC 23820 00 311 3 mm 12 26 in 244 3 mm 9 62 in T R Steering shaft and steering control arm nut 21 Nm 2 1 m kg 15 ft lb Steering shaft and steering arm nut 35 Nm 3 5 m kg 25 ft lb 3 2 3 2 1 a b 1 ...

Страница 100: ...ighten the locknuts steering shaft 2 Steering linkage alignment plate 90890 01515 YS 01515 Turning the steering shaft in direction a Turning the handlebar in direction c Turning the steering shaft in direction b Turning the handlebar in direction d T R Steering shaft locknut 25 Nm 2 5 m kg 18 ft lb LOCTITE 1 8 Install Handlebar 1 Handlebar holders 2 CAUTION First tighten the bolts on the front sid...

Страница 101: ... Canada Order Job name Part name Q ty Remarks Ski removal Remove the parts in the order listed below 1 Cotter pin 1 2 Nut 1 3 Bolt 1 4 Collar 1 5 Collar 1 6 Washer 2 7 Collar 1 8 Ski stopper 1 9 Ski 1 For installation reverse the removal proce dure ...

Страница 102: ...e Part name Q ty Remarks Ski removal Remove the parts in the order listed below 1 Cotter pin 1 2 Nut 1 3 Bolt 1 4 Collar 1 5 Collar 1 6 Washer 2 7 Collar 1 8 Ski stopper 1 9 Ski stopper plate 1 10 Ski 1 For installation reverse the removal proce dure ...

Страница 103: ... name Part name Q ty Remarks Ski removal Remove the parts in the order listed below 1 Cotter pin 1 2 Nut 1 3 Bolt 1 4 Collar 2 5 Collar 1 6 Washer 2 7 Collar 1 8 Ski stopper 1 9 Ski 1 For installation reverse the removal proce dure ...

Страница 104: ...3 17 CHAS SKI INSPECTION 1 Inspect Ski Ski runner Ski stopper Ski stopper plate PZ50VT Europe PZ50MP Ski handle Wear cracks damage Replace Mounting bolt Collar Collars Wear damage Replace ...

Страница 105: ...I 1 Shock absorber 1 2 Collar 2 PZ50 PZ50M 3 Bushing 4 PZ50 PZ50M 4 Tie rod 1 Disconnect 5 Steering knuckle 1 6 Upper arm ball joint 1 7 Upper arm 1 8 Bushing 2 9 Stabilizer holder 1 10 Bushing 1 New 3 3 2 2 8 9 10 7 8 14 14 14 13 12 11 15 5 4 6 1 60 Nm 6 0 m kg 43 ft lb Ë 45 Nm 4 5 m kg 32 ft lb Ê 65 Nm 6 5 m kg 47 ft lb Ì PZ50FX Ì Ì É É É Ê Ì Ê Ê Ê È Ë Ê 1 ESSO beacon 325 grease or Aeroshell gre...

Страница 106: ... Lower arm ball joint 1 For installation reverse the removal proce dure New 3 3 2 2 8 9 10 7 8 14 14 14 13 12 11 15 5 4 6 1 60 Nm 6 0 m kg 43 ft lb Ë 45 Nm 4 5 m kg 32 ft lb Ê 65 Nm 6 5 m kg 47 ft lb Ì PZ50FX Ì Ì É É É Ê Ì Ê Ê Ê È Ë Ê 1 ESSO beacon 325 grease or Aeroshell grease 7A 28 Nm 2 8 m kg 20 ft lb È 34 Nm 3 4 m kg 24 ft lb É ...

Страница 107: ...ber 1 2 Collar 2 3 Bushing 4 4 Tie rod 1 Disconnect 5 Steering knuckle 1 6 Upper arm ball joint 1 7 Upper arm 1 8 Bushing 2 9 Stabilizer holder 1 10 Bushing 1 3 3 2 2 8 8 14 14 14 13 12 11 11 15 5 4 6 1 34 Nm 3 4 m kg 24 ft lb Ê 45 Nm 4 5 m kg 32 ft lb Ë 60 Nm 6 0 m kg 43 ft lb Ì 65 Nm 6 5 m kg 47 ft lb Í Í Ë È Ë Ì É Ë Í PZ50VT USA Canada Ë 1 ESSO beacon 325 grease or Aeroshell grease 7A New 9 10 ...

Страница 108: ...int 1 For installation reverse the removal proce dure 3 3 2 2 8 8 14 14 14 13 12 11 11 15 5 4 6 1 34 Nm 3 4 m kg 24 ft lb Ê 45 Nm 4 5 m kg 32 ft lb Ë 60 Nm 6 0 m kg 43 ft lb Ì 65 Nm 6 5 m kg 47 ft lb Í Í Ë È Ë Ì É Ë Í PZ50VT USA Canada Ë 1 ESSO beacon 325 grease or Aeroshell grease 7A New 9 10 7 Í Ê Ê 28 Nm 2 8 m kg 20 ft lb É 7 Nm 0 7 m kg 5 1 ft lb È ...

Страница 109: ...ock absorber to flames or any other source of high heat This may cause the unit to explode due to excessive gas pressure Do not deform or damage the gas chamber in any way Gas chamber damage will result in poor damping performance INSPECTION 1 Inspect Shock absorber Oil gas leaks bends damage Replace Bushings Wear scratches damage Replace 2 Inspect Steering knuckle Cracks bends damage Replace 3 In...

Страница 110: ...tion shown in the illustration PZ50 PZ50FX PZ50M The stabilizer force can be adjusted by changing the installation positions of the stabilizer bushing and stabilizer holder PZ50GT PZ50VT PZ50MP È PZ50 PZ50FX PZ50M É PZ50GT PZ50VT PZ50MP a Forward b Very hard c Hard d Medium e Soft Stabilizer bushing and stabilizer holder stan dard installation positions d PZ50GT b PZ50VT PZ50MP a 1 2 3 È b c d e a...

Страница 111: ...e spring preload setting before adjusting the ski toe out since this adjustments may affect the ski toe out setting Point the skis straight forward and measure the amount of ski toe out È Ski toe out 0 15 mm 0 0 59 in a b Toe out Refer to STEERING SYSTEM in CHAPTER 2 ...

Страница 112: ...rimary sheave removal Remove the parts in the order listed below Left side cover Refer to COWLINGS in CHAPTER 3 1 V belt 1 2 Primary sheave assembly 1 For installation reverse the removal proce dure 2 1 E 60 Nm 6 0 m kg 43 ft lb 120 Nm 12 0 m kg 85 ft lb È 1st 2nd È PRIMARY SHEAVE AND DRIVE V BELT ...

Страница 113: ... Remove the parts in the order listed below 1 Primary sheave cap 1 2 Primary sheave spring 1 3 Collar 3 4 Roller 3 5 Washer 6 6 Collar 3 7 Weight 3 8 Washer 6 9 Fixed sheave 1 0 Stopper 2 A Sliding sheave 1 B Bushing 1 C Spider 1 Left handed thread D Slider 6 For assembly reverse the disassembly pro cedure 4 ...

Страница 114: ...1 DISASSEMBLY 1 Remove Fixed sheave 1 Stopper 2 Sliding sheave 3 Bushing 4 Spider 5 Removal steps Immerse the primary sheave assembly in 80 100 C 176 212 F water for several min utes Attach the lower piece of the clutch spider sepa rator 6 onto a rigid table using suitable mount ing bolts Then install the clutch separator adapter 7 onto the separator Clutch spider separator 90890 01711 YS 28890 C ...

Страница 115: ... the spider CAUTION The spider has a left handed thread Since a high torque is required to loosen the spider make sure that the spider fixed sheave and special tool are well secured Loosen the spider carefully to prevent cracks and damage to the sheaves and spider Remove the fixed sheave fixed sheave stop per and sliding sheave from the spider Clutch spider separator 90890 01711 YS 28890 C INSPECT...

Страница 116: ... GEAR SELECTION in CHAPTER 2 4 Inspect Primary sheave cap bush 1 Sliding sheave bush 2 Cracks damage Replace Primary sheave spring standard free length PZ50 PZ50GT PZ50FX 72 1 mm 2 84 in PZ50M 74 1 mm 2 92 in PZ50VT USA Canada 73 4 mm 2 89 in PZ50VT Europe PZ50MP 72 9 mm 2 87 in Clutch bushing press YS 42424 5 Inspect Weight 1 Roller 2 Bushing 3 Slider 4 Rivet 5 Collar Wear scratches damage Replac...

Страница 117: ...nside diameter Out of specification Replace as a set NOTE When replacing the weight and roller bushings use the YXR clutch bushing jig kit Ê Removing Ë Installing Bushing inside diameter Roller È New 9 077 mm 0 357 in Wear limit 9 3 mm 0 366 in Weight É New 8 077 mm 0 318 in Wear limit 8 3 mm 0 327 in YXR clutch bushing jig kit YS 39752 È É Ê Ë ASSEMBLY 1 Install Sliding sheave onto the spider NOT...

Страница 118: ...s and other areas a 16 mm 0 63 in b 30 mm 1 18 in 3 Install Fixed sheave stoppers 1 NOTE Stopper tapered portion should face fixed sheave 4 Tighten Spider Tightening steps Finger tighten the spider until it is stopped by the fixed sheave stopper Hold the fixed sheave with the clutch spider separator 1 NOTE Securely fit the projections on the clutch separator adapter 2 into the fixed sheave holes C...

Страница 119: ... special tool are well secured Tighten the spider carefully to prevent cracks and dam age to the sheaves and spider T R Spider 200 Nm 20 0 m kg 145 ft lb 5 Install Weight Bolts 1 Nuts 2 NOTE To maintain the primary sheave balance the bolts 1 must be installed with their threaded portions pointing in a counterclockwise direction as illus trated 6 Install Primary sheave spring 1 Primary sheave cap 2...

Страница 120: ...2 using the primary sheave holder 3 and tighten the primary sheave bolt to specification Loosen the primary sheave bolt completely Retighten the primary sheave bolt to specifica tion 4 Adjust V belt position Refer to DRIVE V BELT in CHAPTER 2 Sheave offset Secondary sheave free play clearance Refer to SHEAVE OFFSET ADJUSTMENT in CHAPTER 2 Sheave holder 90890 01701 YS 01880 A T R Primary sheave bol...

Страница 121: ...order listed below NOTE Apply the brake to lock the secondary sheave V belt Refer to PRIMARY SHEAVE AND DRIVE V BELT 1 Washer 1 2 Shim left Refer to SHEAVE OFFSET ADJUSTMENT in CHAPTER 2 3 Secondary sheave assembly 1 4 Shim right Refer to SHEAVE OFFSET ADJUSTMENT in CHAPTER 2 5 Washer 1 For installation reverse the removal proce dure ...

Страница 122: ...the parts in the order listed below 1 Circlip 1 2 Washer 1 3 Spring seat 1 4 Secondary sheave spring 1 5 Sliding sheave 1 6 Washer 2 7 Fixed sheave 1 8 Bushing 1 For assembly reverse the disassembly pro cedure 1 2 3 4 8 7 5 6 7 Nm 0 7 m kg 5 1 ft lb È È 1 ESSO beacon 325 grease or Aeroshell grease 7A New ...

Страница 123: ...ou have the proper tools and understand the instructions thoroughly INSPECTION 1 Inspect Sliding sheave Fixed sheave Spring seat Cracks damage Replace 2 Inspect Bushing 1 Sliding sheave V belt contact surface 2 Scratches wear damage Replace Sliding bushing 3 Unsymmetrical wear damage Replace 3 Inspect Secondary sheave spring 1 Cracks damage Replace 4 Measure Secondary sheave spring standard free l...

Страница 124: ... seat Standard spring position A 1 PZ50 PZ50GT PZ50FX PZ50VT PZ50MP B 1 PZ50M Installation steps CAUTION Always use a new circlip Turn in the screw for the sheave compressor so that the spring seat splines engage with the fixed sheave splines Hold the spring seat 1 and turn the sliding sheave 2 counterclockwise to the specified twist angle a Push down on the spring seat until the bolts come throug...

Страница 125: ...ixed sheave 2 Tighten Secondary sheave bolt 3 Adjust Sheave offset Secondary sheave free play clearance Refer to SHEAVE OFFSET ADJUSTMENT in CHAPTER 2 Recommended grease ESSO beacon 325 grease or Aeroshell grease 7A T R Secondary sheave bolt 60 Nm 6 0 m kg 43 ft lb ...

Страница 126: ... 5 Chain tension adjusting bolt 1 Loosen 6 Drive chain cover 1 7 Rubber seal 1 8 Chain tensioner assembly 1 9 Spacer 1 10 Drive sprocket 1 11 Driven sprocket 1 12 Drive chain 1 13 Spacer 1 For installation reverse the removal proce dure LT É 2 1 4 3 12 9 10 13 8 11 7 7 5 È Ê Ë 16 Nm 1 6 m kg 11 ft lb È 24 Nm 2 4 m kg 17 ft lb É 25 Nm 2 5 m kg 18 ft lb Ê 48 Nm 4 8 m kg 35 ft lb Ë New New New New 1 ...

Страница 127: ...itting damage Replace Replacement steps Remove the circlip drive chain cover Remove the bearing using a general bearing puller Install the new bearing NOTE Use a socket 1 that is the same size as the outside diameter of the bearing race CAUTION Do not strike the inner race 2 or ball bearings 3 Contact only the outer race 4 Install a new circlip drive chain cover CAUTION Always use new circlips 2 I...

Страница 128: ...wo or three differ ent places If replacement is necessary always replace the chain and the sprockets as a set Maximum 14 link drive chain section length 133 35 mm 5 25 in Limit 137 35 mm 5 41 in 4 Inspect Drive chain Stiffness Clean and lubricate or replace 5 Measure Brake disc thickness a Measure the brake disc thickness 1 3 mm 0 04 0 12 in from the edge of the brake disc Out of specification Rep...

Страница 129: ...that there are no gaps Be sure to install the spacers in their original positions otherwise the brake disc and sec ondary shaft will stick a 0 2 0 7 mm 0 008 0 028 in ESSO beacon 325 grease or Aeroshell grease 7A For the secondary shaft and drive chain installation refer to SECONDARY SHAFT 2 Fill Drive chain housing oil Refer to DRIVE CHAIN in CHAPTER 2 3 Adjust Drive chain slack Refer to DRIVE CH...

Страница 130: ...ts in the order listed below Secondary sheave assembly Refer to SECONDARY SHEAVE Drive chain Refer to DRIVE CHAIN 1 Bearing holder 2 2 Secondary shaft 1 3 Circlip 1 4 Bearing 1 5 Bearing 1 For installation reverse the removal proce dure È 1 5 1 4 3 2 24 Nm 2 4 m kg 17 ft lb È New 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Страница 131: ...INSPECTION 1 Inspect Secondary shaft 1 Scratches excessive damage Replace Splines 2 Wear damage Replace the secondary shaft Bearing contact surface 3 Scratches wear damage Replace the sec ondary shaft 2 Inspect Bearing 1 Pitting damage Replace NOTE When reassembling the bearing press the bearing onto the secondary shaft as shown È 124 9 125 1 mm 4 92 4 93 in È 1 INSTALLATION 1 Install Secondary sh...

Страница 132: ...ighten Bearing holder bolts 1 4 Check Secondary shaft stiffness CAUTION When the secondary shaft is operated in peri odic motion and if its movement is heavy install it again correctly T R Bearing holder bolt 24 Nm 2 4 m kg 17 ft lb 1 ...

Страница 133: ...NOTE Tighten the drive chain cover bolts in proper tight ening sequence as shown Install the brake disc Adjust the brake disc clearance 2 Measure Brake disc clearance a Out of the specification Adjust 3 Adjust Brake disc clearance Adjustment steps Remove the circlip 4 Adjust the brake disc clearance by adding or removing shim s 5 Install the new circlip T R Driven sprocket bolt 48 Nm 4 8 m kg 35 f...

Страница 134: ...50GT PZ50FX PZ50M Refer to RIDER SEAT AND FUEL TANK in CHAPTER 5 PZ50VT PZ50MP Coolant reservoir radiator outlet pipe 2 Refer to RADIATOR AND HEAT EXCHANGER in CHAPTER 6 Exhaust pipe joint lower cover Refer to EXHAUST PIPE AND MUFFLER in CHAPTER 5 1 Bearing holder 2 2 Bearing 1 3 Circlip 1 4 Gear motor coupler 1 Disconnect 5 Reverse position switch connector 1 Disconnect 3 3 11 10 7 6 4 9 1 1 5 8 ...

Страница 135: ...aft assembly 1 10 Circlip 1 11 Bearing 1 For installation reverse the removal proce dure 3 3 11 10 7 6 4 9 1 1 5 8 2 Ê É É É È Ë New New New New LT LT 4 17 Nm 1 7 m kg 12 ft lb 10 Nm 1 0 m kg 7 2 ft lb 9 Nm 0 9 m kg 6 5 ft lb 24 Nm 2 4 m kg 17 ft lb È É Ê Ë 1 ESSO beacon 325 grease or Aeroshell grease 7A SECONDARY SHAFT AND REVERSE GEAR CASE ...

Страница 136: ...se position switch 1 3 Right reverse gear case 1 4 Gasket 1 5 Dowel pin 2 6 Middle shaft 1 7 Counter axle 1 8 Chain 1 9 Reverse driven gear 1 0 Shift fork 1 A Dog gear 1 B Shift fork guide bar 1 C Circlip 1 D Washer 2 E Reverse drive gear 1 I B 0 K D G F E D C A M 6 5 5 8 4 3 1 J 7 9 L H 2 É 6 Nm 0 6 m kg 4 3 ft lb È 17 Nm 1 7 m kg 12 ft lb É New New New New New È É 1 ESSO beacon 325 grease or Aer...

Страница 137: ...Left reverse gear case 1 I Secondary shaft 1 J Bearing 1 K Bearing 1 L Bearing 1 M Bearing 1 For assembly reverse the disassembly pro cedure I B 0 K D G F E D C A M 6 5 5 8 4 3 1 J 7 9 L H 2 É 6 Nm 0 6 m kg 4 3 ft lb È 17 Nm 1 7 m kg 12 ft lb É New New New New New È É 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Страница 138: ...condary sheave assembly Refer to SECONDARY SHEAVE 3 Remove Exhaust pipe muffler assembly 1 Exhaust pipe joint upper cover Exhaust pipe joints 2 Exhaust pipe joint lower cover 3 NOTE Slide the exhaust pipe muffler assembly rearward as shown in the illustration 1 3 2 4 Remove Secondary shaft assembly 1 Removal steps Slide the secondary shaft assembly to the left until the right end of the assembly i...

Страница 139: ...gear case Shift fork Pitting wear damage Replace Oil seal Wear damage Replace Bearings Pitting damage Replace 3 Inspect Reverse driven gear Reverse drive gear Counter axle Middle shaft Dog gear Pitting wear damage Replace Chain Wear damage Replace Shift Clean or replace ASSEMBLY 1 Install Oil seal 1 NOTE Press the oil seal onto the left reverse gear case as shown È 0 5 1 5 mm 0 02 0 06 in È 1 2 In...

Страница 140: ...lb T R Set bolt secondary shaft 9 Nm 0 9 m kg 6 5 ft lb LOCTITE 1 1 2 3 2 Install Shift arm Gear motor Installation steps Check that the gear motor is in the drive posi tion Refer to GEAR MOTOR in CHAPTER 8 Install the shift arm 1 onto the gear motor making sure that the center of the projection a on the shift arm is within the range shown in the illustration Slide the shift fork 2 toward the midd...

Страница 141: ...r to DRIVE CHAIN 4 Check Secondary shaft stiffness CAUTION When the secondary shaft is operated in peri odic motion and if its movement is heavy install it again correctly SECONDARY SHAFT AND DRIVE CHAIN INSTALLATION 1 Install Secondary shaft Drive chain parts Refer to SECONDARY SHAFT ...

Страница 142: ... PZ50MP 6 Gear motor relay 1 1 PZ50GT PZ50FX PZ50M PZ50VT PZ50MP 7 Gear motor relay 2 1 PZ50GT PZ50FX PZ50M PZ50VT PZ50MP 8 Gear motor relay 3 1 PZ50GT PZ50FX PZ50M PZ50VT PZ50MP 9 Passenger grip warmer relay 1 PZ50VT PZ50MP 10 Headlight relay 1 11 Load control relay 1 12 Fuel injection system relay 1 13 Radiator fan motor relay 1 PZ50GT PZ50FX PZ50M PZ50VT PZ50MP 14 Battery bracket 1 For installa...

Страница 143: ...removal Remove the parts in the order listed below 1 Retaining pin 2 2 Brake pad 2 3 Pad spring 1 4 Brake caliper assembly 1 For installation reverse the removal proce dure 4 1 1 2 3 È É Ê Ê 18 Nm 1 8 m kg 13 ft lb 6 Nm 0 6 m kg 4 3 ft lb È É 48 Nm 4 8 m kg 35 ft lb Ê ...

Страница 144: ...e damage may occur Do not disconnect any hydraulic connection otherwise the entire system must be disas sembled drained cleaned and then properly filled and bled after reassembly BRAKE PAD REPLACEMENT NOTE It is not necessary to disassemble the brake caliper and brake hose in order to replace the brake pads 1 Remove Brake pads NOTE Do not depress the brake lever when the caliper or disc is off the...

Страница 145: ...aliper bleed screws and push the pistons into the caliper with your finger Tighten the caliper bleed screw 2 Install the brake pads and pad spring 3 Check Brake fluid level Refer to BRAKE FLUID LEVEL INSPEC TION in CHAPTER 2 4 Check Brake lever operation A soft or spongy feeling Bleed brake sys tem Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM in CHAPTER 2 T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb 2 ...

Страница 146: ...ring 1 5 Brake caliper bracket 1 6 Brake caliper 1 7 Brake caliper piston 2 8 Brake caliper piston seal 4 9 Parking brake cable 1 10 Spring 1 11 Parking brake assembly 1 For installation reverse the removal proce dure 9 11 10 3 2 4 8 8 7 7 5 1 6 New New É Ê Ë È Ì Ì 16 Nm 1 6 m kg 12 ft lb 10 Nm 1 0 m kg 7 2 ft lb 48 Nm 4 8 m kg 35 ft lb 30 Nm 3 0 m kg 22 ft lb É 6 Nm 0 6 m kg 4 3 ft lb È Ê Ë Ì 1 S...

Страница 147: ...d air into the hose joint opening a to force out the pistons from the caliper body WARNING Never try to pry out the pistons a BRAKE CALIPER INSPECTION AND REPAIR WARNING All internal brake components should be cleaned only with new brake fluid Do not use solvents as they will cause seals to swell and distort Recommended brake component replacement schedule Brake pads As required Piston seals Every...

Страница 148: ...er is disassembled BRAKE CALIPER ASSEMBLY WARNING All internal parts should be cleaned only with new brake fluid Internal parts should be lubricated with brake fluid when installed Replace the piston seals whenever a caliper is disassembled Recommended brake fluid DOT 4 BRAKE CALIPER INSTALLATION 1 Install Brake hose 1 CAUTION When installing the brake hose 1 onto the brake caliper 2 make sure tha...

Страница 149: ...ake light switch 1 2 Brake lever 1 3 Brake hose 1 4 Holder 1 5 Parking brake cable 1 Disconnect 6 Parking brake lever 1 7 Master cylinder assembly 1 For installation reverse the removal proce dure Brake master cylinder disassembly Remove the parts in the order listed below 1 Reservoir cap set 1 2 Diaphragm 1 3 Master cylinder kit 1 4 Master cylinder body 1 For assembly reverse the disassembly pro ...

Страница 150: ...t BRAKE MASTER CYLINDER ASSEMBLY WARNING All internal parts should be cleaned only with new brake fluid Internal parts should be lubricated with brake fluid when installed Replace the piston seals and dust seals whenever a caliper is disassembled INSTALLATION 1 Install Brake hose CAUTION When installing the brake hose onto the brake master cylinder make sure that the brake pipe touches the project...

Страница 151: ...Remarks Slide rail suspension removal Remove the parts in the order listed below Rear axle nut Loosen Tension adjuster Loosen 1 Slide rail suspension 1 For installation reverse the removal proce dure LT LT 1 È É 110 Nm 11 0 m kg 80 ft lb 72 Nm 7 2 m kg 52 ft lb È É 1 ESSO beacon 325 grease or Aeroshell grease 7A ...

Страница 152: ...nd 1 2 Front shock absorber 1 3 Bushing 2 4 Collar 1 5 Bushing 2 6 Collar 1 7 Front pivot arm 1 8 Bushing 2 9 Shaft 1 0 Collar 2 A Shaft 1 B Collar 1 C Shaft 1 4 Nm 0 4 m kg 2 9 ft lb 49 Nm 4 9 m kg 35 ft lb 60 Nm 6 0 m kg 43 ft lb É Ê Ë È Ê 0 0 A 8 9 7 8 C 6 5 3 2 3 4 5 1 Ë É È Ê Ê Ê É 110 Nm 11 0 m kg 80 ft lb 1 ESSO beacon 325 grease or Aeroshell grease 7A B ...

Страница 153: ...G Spring end guide bracket 2 H Wheel bracket 2 I Suspension wheel 2 J Bushing 2 K Shaft 1 L Front suspension bracket 1 M Collar 1 N Suspension wheel 2 O Collar 2 P Wheel bracket 2 LT I H J K L M I J H E D F G D E F G É Ê È É É È New New 60 Nm 6 0 m kg 43 ft lb 72 Nm 7 2 m kg 52 ft lb É Ê 6 Nm 0 6 m kg 4 3 ft lb È É É É Ê 1 ESSO beacon 325 grease or Aeroshell grease 7A P P O PZ50M O N N Ê LT ...

Страница 154: ...ng 2 V Rear pivot arm protector 2 W Circlip 2 X Adjuster 2 Y Rear pivot arm 1 Z Shaft 1 Guide wheel 2 Rear pivot arm bracket 1 Shaft 1 _ Collar 4 a Stopper 4 R S V U T Q S Y Z a X W 1 ESSO beacon 325 grease or Aeroshell grease 7A 72 Nm 7 2 m kg 52 ft lb 60 Nm 6 0 m kg 43 ft lb 35 Nm 3 5 m kg 25 ft lb 49 Nm 4 9 m kg 35 ft lb È É Ê Ë É È Ë Ê Ê Ë Ë LT LT LT LT New Ë É ...

Страница 155: ...el 2 d Guide wheel 1 e Collar 2 f Tension adjuster 2 g Collar 1 h Collar 1 i Suspension wheel 2 j Wheel bracket 2 k Shaft 1 l Sliding frame 2 For assembly reverse the disassembly pro cedure b c e f g h l l d e c É f PZ50M PZ50M PZ50M i j k j i È È 75 Nm 7 5 m kg 54 ft lb 60 Nm 6 0 m kg 43 ft lb È É ...

Страница 156: ...b name Part name Q ty Remarks Slide rail suspension removal Remove the parts in the order listed below Rear axle nut Loosen Tension adjuster Loosen 1 Slide rail suspension 1 For installation reverse the removal proce dure 72 Nm 7 2 m kg 52 ft lb È 1 È È LT LT ...

Страница 157: ...nt pivot arm 1 6 Bushing 2 7 Shaft 1 8 Collar 2 9 Shaft 1 0 Collar 1 A Wheel bracket 2 B Suspension wheel 2 C Shaft 1 3 New New 6 7 8 9 4 2 3 H J J I I I I 1 Ê Ë Ë È 5 8 N M 6 0 F Ë Ë Ë É Ë Ì Ê É Ì K L M N B A D L K C A B E D G 1 ESSO beacon 325 grease or Aeroshell grease 7A 4 Nm 0 4 m kg 2 9 ft lb 49 Nm 4 9 m kg 35 ft lb 60 Nm 6 0 m kg 43 ft lb 72 Nm 7 2 m kg 52 ft lb Ê Ë Ì È 6 Nm 0 6 m kg 4 3 ft...

Страница 158: ... L Circlip 2 M Spring end guide 2 NOTE Apply grease to the inner surface of each spring end guide N Spring end guide bracket 2 3 New New 6 7 8 9 4 2 3 H J J I I I I 1 Ê Ë Ë È 5 8 N M 6 0 F Ë Ë Ë É Ë Ì Ê É Ì K L M N B A D L K C A B E D G 1 ESSO beacon 325 grease or Aeroshell grease 7A 4 Nm 0 4 m kg 2 9 ft lb 49 Nm 4 9 m kg 35 ft lb 60 Nm 6 0 m kg 43 ft lb 72 Nm 7 2 m kg 52 ft lb Ê Ë Ì È 6 Nm 0 6 m ...

Страница 159: ...te 2 Z Lock lever 2 Collar 2 2 up adjusting block 2 2 up adjusting block plate 2 _ Collar 2 a Guide wheel 2 b Torsion spring 2 New k New n W X a b f d c e l g X j m g o p q i i p q o i Ì Í Í Ê Ì Ì Ë É È Ë Ë Z Y i h U V U V T T V U R R Q P S O U V 1 ESSO beacon 325 grease or Aeroshell grease 7A O È P 49 Nm 4 9 m kg 35 ft lb 9 Nm 0 9 m kg 6 5 ft lb 25 Nm 2 5 m kg 18 ft lb 60 Nm 6 0 m kg 43 ft lb 6 N...

Страница 160: ...2 m Control rod stopper 1 n Circlip 2 o Control rod 2 p Locknut 2 q Adjuster nut 2 New k New n W X a b f d c e l g X j m g o p q i i p q o i Ì Í Í Ê Ì Ì Ë É È Ë Ë Z Y i h U V U V T T V U R R Q P S O U V 1 ESSO beacon 325 grease or Aeroshell grease 7A O È P 49 Nm 4 9 m kg 35 ft lb 9 Nm 0 9 m kg 6 5 ft lb 25 Nm 2 5 m kg 18 ft lb 60 Nm 6 0 m kg 43 ft lb 6 Nm 0 6 m kg 4 3 ft lb È É Ê Ë Ì 72 Nm 7 2 m k...

Страница 161: ... name Part name Q ty Remarks r Rear axle 1 s Guide wheel 2 t Collar 2 u Collar 1 v Guide wheel 1 w Collar 1 x Tension adjuster 2 y Sliding frame 2 For assembly reverse the disassembly pro cedure 75 Nm 7 5 m kg 54 ft lb È r s t x u w y v y t s È x ...

Страница 162: ...e Pull rod PZ50VT PZ50MP Bends damage Replace Shock absorber Oil leaks damage Replace Bushings Wear cracks damage Replace Front pivot arm Rear pivot arm Rear pivot arm bracket PZ50 PZ50GT PZ50FX PZ50M Suspension wheel bracket Front suspension bracket Rear suspension bracket Connecting arm Connecting arm Rear pivot arm joint Sliding frame Cracks damage Replace Slide runner Wear damage Replace ASSEM...

Страница 163: ...Z50FX PZ50M NOTE For PZ50GT PZ50M Install the rear shock absorber with the charging valve a facing upward If the shock absorber is not equipped with a charging valve install it with the label facing downward For PZ50FX Install the rear shock absorber with its gas cylin der b facing downward È PZ50GT PZ50M É PZ50FX 1 a È 1 b É 5 Install Front shock absorber 1 PZ50GT PZ50FX NOTE Install the front sh...

Страница 164: ...tall the lock lever guide plate 2 as shown in the illustration so that the projection on the plate con tacts the projection a on the 2 up adjusting block Make sure that the 2 up adjusting block is locked in place and the end b of the lock lever is sticking out from the sliding frame 1 2 a b ...

Страница 165: ...stall Stopper band 1 NOTE Install the stopper band with a toward the front pivot arm and b toward the shaft È PZ50 É PZ50GT PZ50M Ê PZ50FX Ë PZ50VT Ì PZ50MP T R Stopper band nut 4 Nm 0 4 m kg 2 9 ft lb a b 1 È a b 1 É a b 1 Ê a 1 b Ë a 1 b Ì ...

Страница 166: ...her s È Control rod 1 É Length a mm in Ê Length b mm in Ë Length c mm in PZ50VT PZ50MP 242 3 9 54 188 7 7 43 2 5P 2 5 0 098P 2 0 197 Ì Control rod 1 part numbers Í Control rod stopper part numbers Î Washer part numbers Ï Washer thickness mm in Ð Upper Ò Q ty Ñ Lower Ò Q ty 8ET 4745A 00 PZ50VT PZ50MP 8ES 4745D 00 90202 25001 2 0 0 079 1 90202 25002 4 0 0 157 1 90201 24015 2 0 0 079 1 c a b Ï Ï Ð Í ...

Страница 167: ...sheave Refer to SECONDARY SHEAVE 1 Speed sensor 1 2 Bearing holder 1 3 Gear unit 1 4 Set bolt 2 5 Bearing 1 6 Bearing holder 1 7 Front axle assembly 1 8 Track 1 9 Bearing housing 1 10 Spacer 1 11 Circlip 1 12 Bearing 1 For installation reverse the removal proce dure 1 2 3 5 6 10 7 4 4 9 12 11 8 Ê É É É É É 3 New New New LT LT È È LT LT 1 ESSO beacon 325 grease or Aeroshell grease 7A 9 Nm 0 9 m kg ...

Страница 168: ...amage Replace 1 2 2 Inspect Sprocket wheels 1 Wear break damage Replace Front axle 2 Bends scratches excessive damage Replace 3 Inspect Bearing Pitting damage Replace 1 2 INSTALLATION 1 Install Oil seal 1 NOTE Press the oil seal onto the bearing housing as shown È 2 5 3 5 mm 0 10 0 14 in 1 È ...

Страница 169: ...36 in 122 4 mm 4 82 in 2 7 m m 1 0 6 i n 155 2 mm 6 11 in 123 mm 4 84 in È 122 2 mm 4 81 in 4 mm 0 16 in 4 mm 0 16 in 63 mm 2 48 in 120 9 mm 4 76 in 2 7 m m 1 0 6 i n 155 2 mm 6 11 in 123 mm 4 84 in É 150 7 mm 5 93 in 60 mm 2 36 in 149 4 mm 5 88 in 2 7 m m 1 0 6 i n 182 2 mm 7 17 in 123 mm 4 84 in Ê 3 Place the track in the chassis NOTE For track with a direction of rotation mark a Install the tra...

Страница 170: ... 2 Rear cover 1 3 Plastic band 4 4 Tail brake light coupler 1 Disconnect 5 Tail brake light assembly 1 6 Main switch coupler 1 Disconnect 7 Fuel tank cover 1 8 Fuel pump coupler 1 Disconnect 9 Fuel hose connector holder 1 10 Fuel hose 1 Disconnect 1 4 14 3 3 4 15 8 2 11 9 16 6 5 13 12 10 6 3 È É 7 11 É È 10 Nm 1 0 m kg 7 2 ft lb 7 Nm 0 7 m kg 5 1 ft lb È É SEAT AND FUEL TANK ...

Страница 171: ... Fuel tank assembly 1 13 Fuel sender coupler 1 Disconnect 14 Fuel hose 2 Disconnect 15 Fuel pump 1 16 Fuel tank lower plate 1 For installation reverse the removal proce dure 1 4 14 3 3 4 15 8 2 11 9 16 6 5 13 12 10 6 3 È É 7 11 É È 10 Nm 1 0 m kg 7 2 ft lb 7 Nm 0 7 m kg 5 1 ft lb È É 5 ...

Страница 172: ...ssenger seat bracket 1 3 Backrest 1 4 Passenger seat 1 5 Left side rear cover 1 6 Right side rear cover 1 7 Left side rear lower cover 1 8 Right side rear lower cover 1 9 Passenger grip warmer switch coupler 1 Disconnect 10 Plastic band 3 13 9 10 12 1 13 8 14 7 11 15 15 4 3 6 5 2 7 Nm 0 7 m kg 5 1 ft lb 10 Nm 1 0 m kg 7 2 ft lb È Ê 23 Nm 2 3 m kg 17 ft lb Ë 8 Nm 0 8 m kg 5 8 ft lb É Ë Ë Ê Ë È É È ...

Страница 173: ...oupler 1 Disconnect 13 Passenger grip warmer coupler 2 Disconnect 14 Rear carrier 1 15 Passenger grip warmer 2 For installation reverse the removal proce dure 13 9 10 12 1 13 8 14 7 11 15 15 4 3 6 5 2 7 Nm 0 7 m kg 5 1 ft lb 10 Nm 1 0 m kg 7 2 ft lb È Ê 23 Nm 2 3 m kg 17 ft lb Ë 8 Nm 0 8 m kg 5 8 ft lb É Ë Ë Ê Ë È É È É É È Ë É Ë 4 4 ...

Страница 174: ...EAT 1 Sub wire harness 3 coupler 1 Disconnect 2 Rider seat 1 3 Side cover 2 4 Main switch coupler 1 Disconnect 5 Auxiliary DC jack coupler 1 Disconnect 6 Fuel tank cover 1 7 Fuel pump coupler 1 Disconnect 8 Fuel hose connector holder 1 9 Fuel hose 1 Disconnect 10 Plastic band 6 11 14 10 10 10 12 1 13 4 3 3 6 8 6 5 2 7 9 8 Nm 0 8 m kg 5 8 ft lb 11 Nm 1 1 m kg 8 0 ft lb Ë 7 Nm 0 7 m kg 5 1 ft lb È É...

Страница 175: ...y 1 12 Fuel sender coupler 1 Disconnect 13 Fuel return hose 2 Disconnect 14 Fuel pump 1 For installation reverse the removal proce dure 11 14 10 10 10 12 1 13 4 3 3 6 8 6 5 2 7 9 8 Nm 0 8 m kg 5 8 ft lb 11 Nm 1 1 m kg 8 0 ft lb Ë 7 Nm 0 7 m kg 5 1 ft lb È É 10 Nm 1 0 m kg 7 2 ft lb Ê É È Ë Ê ...

Страница 176: ...slot part a of the fuel hose connector cover 1 then slide the screwdriver in the direction of the arrow and remove the fuel hose To remove the fuel hose from the throttle body slide the fuel hose connector cover 2 on the end of the hose in direction of the arrow shown press the two buttons 3 on the sides of the connector and then remove the hose Before removing the hose place a few rags in the are...

Страница 177: ... specified torque in the proper tightening sequence as shown Install the fuel pump in the direction shown in the illustration T R Fuel pump nut 7 Nm 0 7 m kg 5 1 ft lb New 2 Install Fuel hose Fuel hose holder Fuel pump coupler CAUTION When installing the fuel hose make sure that it is securely connected and that the fuel hose holder is in the correct position otherwise the fuel hose will not be pr...

Страница 178: ... 2 Exhaust pipe band 2 3 Muffler damper holder 2 4 Seat rail assembly 1 5 Exhaust pipe muffler assembly 1 6 Muffler end cover 1 7 Muffler damper 1 8 Gasket 2 9 Exhaust pipe joint 2 10 Gasket 1 11 Exhaust pipe joint lower cover 1 For installation reverse the removal proce dure 6 Nm 0 6 m kg 4 3 ft lb 10 Nm 1 0 m kg 7 2 ft lb 18 Nm 1 8 m kg 13 ft lb 23 Nm 2 3 m kg 17 ft lb Ê Ë Ì È 25 Nm 2 5 m kg 18 ...

Страница 179: ...me panel 1 2 Exhaust pipe joint upper cover 1 3 Exhaust pipe band 2 4 Muffler damper holder 2 5 Exhaust pipe muffler assembly 1 6 Muffler damper 1 7 Gasket 2 8 Exhaust pipe joint 2 9 Gasket 1 10 Exhaust pipe joint lower cover 1 For installation reverse the removal proce dure 18 Nm 1 8 m kg 13 ft lb 10 Nm 1 0 m kg 7 2 ft lb 8 Nm 0 8 m kg 5 8 ft lb 33 Nm 3 3 m kg 24 ft lb Î 25 Nm 2 5 m kg 18 ft lb 6...

Страница 180: ... pipe bolt 1 at the rear of the hole a in the seat rail assembly and then finger tighten it È Forward a 1 È 3 Install Exhaust pipe band 1 4 Tighten Exhaust pipe bolt 5 Tighten Muffler damper holder bolts T R Exhaust pipe band bolt 18 Nm 1 8 m kg 13 ft lb T R Exhaust pipe bolt 33 Nm 3 3 m kg 24 ft lb T R Muffler damper holder bolt 10 Nm 1 0 m kg 7 2 ft lb 1 ...

Страница 181: ...R 3 Engine oil Drain Refer to ENGINE OIL REPLACEMENT in CHAPTER 2 1 Oil level switch coupler 1 Disconnect 2 Oil tank breather hose 1 Disconnect 3 Oil tank inlet hose 1 Disconnect 4 Oil tank outlet hose 1 Disconnect 5 Oil tank 1 6 Oil level gauge 1 For installation reverse the removal proce dure 1 6 5 2 3 4 È LS 16 Nm 1 6 m kg 11 ft lb É 10 Nm 1 0 m kg 7 2 ft lb È É New ...

Страница 182: ...le body Refer to THROTTLE BODY in CHAPTER 7 Primary sheave Refer to PRIMARY SHEAVE AND DRIVE V BELT in CHAPTER 4 Brake disc Refer to DRIVE CHAIN in CHAPTER 4 Radiator coolant reservoir thermostat Refer to RADIATOR AND HEAT EXCHANGER in CHAPTER 6 Handlebar steering shaft Refer to STEERING in CHAPTER 3 Oil tank inlet hose oil tank outlet hose Refer to OIL TANK Fuel tank Refer to SEAT AND FUEL TANK 4...

Страница 183: ...lead coupler 2 Disconnect 2 Rectifier regulator lead coupler 1 Disconnect 3 Frame ground lead 1 Disconnect 4 Starter motor lead 1 Disconnect 5 Knock sensor coupler 1 Disconnect 6 Sub wire harness 2 coupler 1 Disconnect 7 Cam position sensor coupler 1 Disconnect 8 Ignition coil coupler 3 Disconnect 9 Speed sensor lead coupler 1 Disconnect For installation reverse the removal proce dure 4 5 6 1 1 2 ...

Страница 184: ...ng bolt washer 1 1 6 Engine mounting bracket 1 7 Front engine left mounting bolt 1 8 Rear engine mounting bolt 1 9 Rear engine mounting bolt spacer 1 10 Front engine mounting bolt spacer 2 11 Engine assembly 1 For installation reverse the removal proce dure Ë 1 Ê 3 2 Ì 9 È 10 Ì 2 7 10 11 8 2 É 6 5 Ì 4 30 Nm 3 0 m kg 22 ft lb 25 Nm 2 5 m kg 18 ft lb 7 Nm 0 7 m kg 5 1 ft lb 23 Nm 2 3 m kg 17 ft lb È...

Страница 185: ...re is a gap between each engine mounting bolt spacer 2 and engine damper 3 Remove the engine mounting bolts and engine mounting bracket Remove the rear engine mounting bolt spacer and then remove the engine assembly Engine mount spacer wrench 90890 01516 YS 01516 2 3 1 INSTALLATION NOTE After installing all parts refer to CABLE ROUT ING in CHAPTER 9 to check the cable lead and hose routing 1 Insta...

Страница 186: ...5 12 in long Install the engine mount spacer wrench 1 Tighten the rear engine mounting bolt spacer Tighten the rear engine mounting nut Tighten the front engine mounting bolt spacers 2 right and left until they come to contact with the engine damper 3 NOTE Do not apply torque to the front engine mounting bolt spacers Remove the rod from the engine mounting bracket and then install the front engine...

Страница 187: ...0GT PZ50FX PZ50M Refer to RIDER SEAT AND FUEL TANK PZ50VT PZ50MP 1 Cylinder identification sensor 1 2 Ignition coil 3 3 Spark plug 3 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Timing chain guide top side 1 For installation reverse the removal proce dure New 4 2 1 3 5 Ê Ë È É New 10 Nm 1 0 m kg 7 2 ft lb 8 Nm 0 8 m kg 5 8 ft lb 13 Nm 1 3 m kg 9 4 ft lb 12 Nm 1 2 m kg 8 7 ft lb È É Ê Ë...

Страница 188: ...r 1 4 Timing chain tensioner gasket 1 5 Intake camshaft cap 3 NOTE During removal the dowel pins may still be connected to the camshaft caps 6 Exhaust camshaft cap 3 7 Dowel pin 4 8 Intake camshaft 1 9 Exhaust camshaft assembly 1 10 Intake camshaft sprocket 1 For installation reverse the removal proce dure 9 Nm 0 9 m kg 6 5 ft lb 24 Nm 2 4 m kg 17 ft lb 12 Nm 1 2 m kg 8 7 ft lb È É Ê M 5 8 10 6 7 ...

Страница 189: ...pointer b on the A C magneto cover TDC on the compression stroke can be found when the camshaft lobes are turned away from each other a b 3 Remove Timing chain tensioner 1 Gasket 1 4 Remove Camshaft caps Dowel pins CAUTION To prevent damage to the cylinder head cam shafts or camshaft caps loosen the camshaft cap bolts in stages and in a crisscross pattern working from the outside in 5 Remove Intak...

Страница 190: ...discoloration pitting scratches Replace the camshaft 2 Measure Camshaft lobe dimensions a and b Out of specification Replace the camshaft Camshaft dimensions Intake Limit a 30 350 mm 1 1949 in b 22 510 mm 0 8862 in Exhaust Limit a 30 600 mm 1 2047 in b 22 493 mm 0 8856 in 3 Measure Camshaft runout Out of specification Replace Camshaft runout 0 03 mm 0 0012 in ...

Страница 191: ...t when measuring the camshaft journal to camshaft cap clearance with the Plastigauge Remove the camshaft caps and then measure the width of the Plastigauge 1 Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0024 in Camshaft cap bolt 9 Nm 0 9 m kg 6 5 ft lb 1 1 5 Measure Camshaft journal diameter a Out of specification Replace the camshaft Within specification Replace the cylinder...

Страница 192: ...sioner spring 3 Timing chain tensioner housing 5 NOTE Squeeze the timing chain tensioner clip 4 and then remove the timing chain tensioner springs and timing chain tensioner rod 10 Inspect Timing chain tensioner housing Timing chain tensioner rod Timing chain tensioner spring seat Timing chain tensioner spring Damage wear Replace the as a set 11 Assemble Timing chain tensioner spring Timing chain ...

Страница 193: ...sing NOTE Do not release the timing chain tensioner clip while pushing the rod into the housing otherwise the rod may be ejected Hook the clip 4 to the timing chain tensioner rod 3 NOTE Hook the timing chain tensioner rod pin 5 to the center of the clip 4 After the installation check that the clip 4 can come off by its own weight by pushing the timing chain tensioner rod 3 at the position of insta...

Страница 194: ...camshaft 2 with the camshaft sprocket Installation steps Turn the crankshaft counterclockwise When piston 1 is at TDC on the compression stroke align the TDC mark a on the A C mag neto rotor with the stationary pointer b on the A C magneto cover Install the timing chain onto both camshaft sprockets and then install the camshafts NOTE When installing the timing chain start with the exhaust camshaft...

Страница 195: ... damage to the cylinder head cam shaft caps and camshafts will result Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing T R Camshaft cap bolt 9 Nm 0 9 m kg 6 5 ft lb a a 5 Install Timing chain tensioner gasket 1 Timing chain tensioner 2 NOTE Be sure to install the timing chain tensioner gas ket so that its section with the L mark a is pro truding from...

Страница 196: ...rks c and d Make sure the marks c and d on the timing chain sprockets are parallel with the edge of the cylinder head Out of alignment Adjust Refer to the installation steps above 10 Measure Valve clearance Out of specification Adjust Refer to VALVE CLEARANCE ADJUST MENT in CHAPTER 2 a b d c c d 11 Install Cylinder head cover gasket Cylinder head cover NOTE Apply bond TB1541 1 onto the mating surf...

Страница 197: ... ENGINE ASSEMBLY Camshafts Refer to CAMSHAFTS 1 Timing chain guide exhaust side 1 2 Cylinder head 1 3 Cylinder head gasket 1 4 Dowel pin 2 For installation reverse the removal proce dure New New 4 4 3 2 1 6 È É E 10 Nm 1 0 m kg 7 2 ft lb È 12 Nm 1 2 m kg 8 7 ft lb É Ê Specified angle 175 185 Final 25 Nm 2 5 m kg 18 ft lb 25 Nm 2 5 m kg 18 ft lb 1st 2nd Ê ...

Страница 198: ...iming chain guide 3 Inspect Cylinder head Damage scratches Replace Cylinder head water jacket Mineral deposits rust Eliminate 4 Measure Cylinder head warpage Out of specification Resurface the cylinder head Measurement steps Place a straightedge 1 and a thickness gauge 2 across the cylinder head Measure the warpage If the limit is exceeded resurface the cylinder head as follows Place a 400 600 gri...

Страница 199: ...rolled therefore tighten the bolts using the following procedure Tightening steps Lubricate the cylinder head bolts and washers with engine oil Install the washers and cylinder head bolts Tighten the cylinder head bolts in the proper tightening sequence as shown Loosen and retighten the cylinder head bolts in the proper tightening sequence as shown T R Cylinder head bolt M10 1st 25 Nm 2 5 m kg 18 ...

Страница 200: ...en retighten it Replace the bolt with a new one and perform the procedure again CAUTION Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angle NOTE When using a hexagonal bolt note that the angle from one corner to another is 60 T R Cylinder head bolt M10 Final Specified angle 175 185 4 Tighten Cylinder head bolts M6 1 T R Cylinder...

Страница 201: ...the order listed below Cylinder head Refer to CYLINDER HEAD 1 Valve lifter 10 2 Valve pad 10 3 Valve cotter 20 4 Upper spring seat 10 5 Valve spring 10 6 Exhaust valve 4 7 Intake valve 6 8 Oil seal 10 9 Lower spring seat 10 10 Valve guide 10 For installation reverse the removal proce dure M M M M M M New 8 5 4 3 2 1 3 9 New 10 6 10 7 9 8 5 4 3 2 3 1 ...

Страница 202: ... in their original place 2 Inspect Valve for leakage Leakage at the valve seat Check the valve face valve seat and valve seat width Inspection steps Pour a clean solvent a into the intake and exhaust ports Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 3 Remove Valve cotters 1 NOTE Remove the valve cotters by compressing the valve spring with the valve spri...

Страница 203: ...valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clearance Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 08 mm 0 0031 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 10 mm 0 0039 in 2 Replace Valve guide NOTE To ease valve guide removal and installation and to maintain the correct fit heat the cylinder head to 100 C 212 F in an oven Replacemen...

Страница 204: ... Measure Valve margin thickness a Out of specification Replace the valve Valve guide remover ø4 90890 04111 YM 04111 Valve guide installer ø4 90890 04112 YM 04112 Valve guide reamer ø4 90890 04113 YM 04113 Valve margin thickness Intake 0 5 0 9 mm 0 0197 0 0354 in Exhaust 0 5 0 9 mm 0 0197 0 0354 in 6 Measure Valve stem runout Out of specification Replace the valve NOTE When installing a new valve ...

Страница 205: ...and valve face contacted one another the blueing will have been removed Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 1 2 1 4 mm 0 0472 0 0551 in Limit 1 9 mm 0 0748 in 10 Lap Valve face Valve seat NOTE After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped Lapping steps Apply a coarse lapping com...

Страница 206: ...g procedure be sure to clean off all of the lapping compound from the valve face and valve seat Apply Mechanic s blueing dye Dykem b onto the valve face Install the valve into the cylinder head Press the valve through the valve guide and onto the valve seat to make a clear impression Measure the valve seat width c again If the valve seat width is out of specification reface and lap the valve seat ...

Страница 207: ...4 2 kg at 30 13 mm 27 1 31 2 lb at 1 19 in Exhaust 150 6 173 2 N at 30 50 mm 15 4 17 7 kg at 30 50 mm 33 9 38 9 lb at 1 20 in 13 Measure Valve spring tilt a Out of specification Replace the valve spring Maximum valve spring tilt Intake 2 5 1 6 mm 0 06 in Exhaust 2 5 1 7 mm 0 07 in 14 Inspect Valve lifter Damage scratches Replace the valve lift ers and cylinder head INSTALLATION 1 Deburr Valve stem...

Страница 208: ... the cylinder head NOTE Make sure each valve is installed in its original place Install the valve spring with the larger pitch a fac ing up b Smaller pitch 4 Install Valve cotters 1 NOTE Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach ment Intake valve 90890 041...

Страница 209: ... the valve tip with excessive force could damage the valve 6 Lubricate Valve pad Valve lifter with the recommended lubricant 7 Install Valve pad Valve lifter NOTE The valve lifter must move smoothly when rotated with a finger Each valve lifter and valve pad must be rein stalled in its original position Recommended lubricant Molybdenum disulfide oil ...

Страница 210: ...A C magneto cover 1 2 Gasket 1 3 Dowel pin 2 4 Pickup coil 1 5 Stator coil 1 6 A C magneto rotor 1 7 Idle gear shaft 1 8 Starter clutch idle gear 1 9 Starter clutch 1 10 Woodruff key 1 11 Starter clutch gear 1 12 Washer 1 For installation reverse the removal proce dure LT E E E LT LT LT LT 7 8 11 12 9 5 6 1 2 3 3 4 É É Ê Ê Ë 130 Nm 13 0 m kg 94 ft lb 12 Nm 1 2 m kg 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft ...

Страница 211: ...r Sheave holder 90890 01701 YS 01880 A 1 2 2 Remove A C magneto rotor 1 with the rotor holding puller 2 and flywheel puller attachment Woodruff key CAUTION To protect the end of the crankshaft place an appropriate sized socket between the rotor holding puller set s center bolt and the crank shaft NOTE Make sure the rotor holding puller is centered over the A C magneto rotor Rotor holding puller 90...

Страница 212: ...n on the magneto rotor Sheave holder 90890 01701 YS 01880 A INSPECTION 1 Inspect Stator coil Pickup coil Damage Replace the pickup coil stator assembly 2 Inspect Starter clutch rollers 1 Damage wear Replace 3 Inspect Starter clutch idle gear Starter clutch gear 1 Burrs chips roughness wear Replace the defective part s Starter clutch gear s contacting surfaces a Damage pitting wear Replace the star...

Страница 213: ...he starter clutch is faulty and must be replaced É È INSTALLATION 1 Install Starter clutch NOTE While holding the magneto rotor with the sheave holder tighten the starter clutch bolt Do not allow the sheave holder to touch the pro jection on the magneto rotor 2 Tighten Starter clutch bolts 1 3 Install Woodruff key A C magneto rotor Washer A C magneto rotor bolt NOTE Clean the tapered portion of th...

Страница 214: ...not allow the sheave holder to touch the pro jection on the magneto rotor T R A C magneto rotor bolt 130 Nm 13 0 m kg 94 ft lb Sheave holder 90890 01701 YS 01880 A 1 2 3 5 Apply Sealant onto the A C magneto lead grommet Yamaha bond No 1215 90890 85505 Three Bond No 1215 6 Tighten A C magneto cover bolt NOTE Apply LOCTITE to the bolts black indicated by the marks on the A C magneto cover T R A C ma...

Страница 215: ... hose 1 2 Oil tank outlet hose 1 3 Oil pressure switch 1 4 Oil filter cartridge 1 5 Oil pan 1 6 Gasket 1 7 Dowel pin 2 8 Oil pump drive chain guide 1 9 Oil pump driven sprocket shaft 1 10 Oil pump driven sprocket 1 1 ESSO beacon 325 grease or Aeroshell grease 7A E E LT LT LT 1 5 6 7 8 9 10 11 13 12 7 2 3 4 30 Nm 3 0 m kg 22 ft lb 17 Nm 1 7 m kg 12 ft lb 15 Nm 1 5 m kg 11 ft lb 10 Nm 1 0 m kg 7 2 f...

Страница 216: ...Dowel pin 2 For installation reverse the removal proce dure 1 ESSO beacon 325 grease or Aeroshell grease 7A E E LT LT LT 1 5 6 7 8 9 10 11 13 12 7 2 3 4 30 Nm 3 0 m kg 22 ft lb 17 Nm 1 7 m kg 12 ft lb 15 Nm 1 5 m kg 11 ft lb 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb È É Ê Ë Ì É Ì È 13 È Ê Ë Ì New New New New New ...

Страница 217: ... valve 1 4 Oil pump inner rotor 1 1 5 Pin 2 6 Oil pump outer rotor 1 1 7 Oil pump housing cover 2 1 8 Oil pump inner rotor 2 2 9 Oil pump outer rotor 2 2 0 Oil pump shaft 1 A Check ball seat 1 B Check ball 1 C Spring 1 D Spacer 1 E Oil pump housing 1 For assembly reverse the disassembly pro cedure A 0 2 8 9 3 4 6 B C D E 1 5 7 È 5 New New New E E E E È 5 5 Nm 0 5 m kg 3 6 ft lb È ...

Страница 218: ...part s 2 Measure Inner rotor to outer rotor tip clearance a between inner rotor 1 and outer rotor 2 Outer rotor to oil pump housing clearance b between outer rotor 2 and pump housing 3 Out of specifications Replace oil pump assembly Inner rotor to outer rotor tip clear ance Less than 0 12 mm 0 005 in Outer rotor to oil pump housing clearance Oil pump outer rotor 0 09 0 15 mm 0 004 0 006 in 3 Inspe...

Страница 219: ...e the chain and sprocket as a set 7 Inspect Check ball seat Check ball Spring Spacer Damage wear Replace the defective part s 1 2 3 8 Inspect Oil strainer 1 Damage Replace Obstruction Wash and blow out with com pressed air Contaminants Clean with engine oil 1 INSTALLATION 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 Inspect Oil pump operation Unsmooth operati...

Страница 220: ...NOTE Align the slit a on the oil pump driven sprocket shaft with the projection b on the oil pump shaft 4 Install Dowel pins Gasket Oil pan Oil pan bolts NOTE Tighten the oil pan bolts in stages and in a criss cross pattern T R Oil pan bolt 10 Nm 1 0 m kg 7 2 ft lb a b 1 New ...

Страница 221: ...D STARTER CLUTCH 1 Primary sheave drive shaft cover 1 2 Gasket 1 3 Primary sheave drive shaft assembly 1 4 Lock washer 2 5 Right balancer weight 1 6 Balancer shaft driven gear 1 7 Left balancer weight 1 8 Balancer shaft 1 9 Lock washer 1 10 Balancer shaft drive gear 1 4 5 8 16 7 6 15 4 13 14 2 1 2 4 10 3 17 18 19 10 9 11 12 É É Ê Ë È Ê New LT LT 12 Nm 1 2 m kg 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb 75...

Страница 222: ...ring retainer 1 16 Bearing 1 17 Bearing 1 18 Circlip 1 19 Bearing 1 For installation reverse the removal proce dure 4 5 8 16 7 6 15 4 13 14 2 1 2 4 10 3 17 18 19 10 9 11 12 É É Ê Ë È Ê New LT LT 12 Nm 1 2 m kg 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb 75 Nm 7 5 m kg 54 ft lb 50 Nm 5 0 m kg 36 ft lb È É Ê Ë New New New New ...

Страница 223: ...ancer shaft drive gear 3 and balancer shaft driven gear 4 1 3 4 2 3 Straighten the lock washer tabs 4 Loosen Balancer shaft drive gear bolt 1 Balancer shaft driven gear nut 2 CAUTION The balancer shaft drive gear bolt and balancer shaft driven gear nut has left handed threads To loosen the bolt and nut turn it clockwise NOTE Place an aluminum plate 3 or 4 between the teeth of the balancer shaft dr...

Страница 224: ...e Splines 1 Wear damage Replace the secondary shaft Bearing contact surface 2 Scratches wear damage Replace the sec ondary shaft 5 Inspect Primary sheave drive shaft assembly Damage Replace 2 1 1 INSTALLATION 1 Install Balancer shaft drive gear Lock washer Balancer shaft drive gear bolt NOTE Align the shallow groove a in the balancer shaft drive gear with the low spline b of the crankshaft 2 Insta...

Страница 225: ...gear 4 Tighten Balancer shaft driven gear nut Right balancer weight nut Balancer shaft drive gear bolt CAUTION The right balancer weight nut balancer shaft driven gear nut and balancer shaft drive gear bolt has left handed threads Turn the retainer counterclockwise to tighten it NOTE Place an aluminum plate 1 or 2 between the teeth of the balancer shaft drive gear 3 and balancer shaft driven gear ...

Страница 226: ...Tighten Primary sheave drive shaft cover bolt NOTE Apply LOCTITE to the bolts black indicated by the marks on the primary sheave drive shaft cover T R Primary sheave drive shaft cover bolt 12 Nm 1 2 m kg 8 7 ft lb LOCTITE ...

Страница 227: ...A C MAGNETO ROTOR AND STARTER CLUTCH Oil pump Refer to OIL PAN AND OIL PUMP Balancer shaft Refer to BALANCER Starter motor Refer to STARTER MOTOR in CHAPTER 8 1 Timing chain guide intake side 1 2 Timing chain 1 3 Lower crankcase 1 4 Dowel pin 2 For installation reverse the removal proce dure 1 2 3 4 4 12 Nm 1 2 m kg 8 7 ft lb É È Specified angle 65 70 Final 15 Nm 1 5 m kg 11 ft lb 15 Nm 1 5 m kg 1...

Страница 228: ...e parts in the order listed below 1 Connecting rod cap 2 2 Big end bearing 4 3 Piston pin clip 4 4 Piston pin 2 5 Piston 2 6 Connecting rod 2 7 Top ring 2 8 2nd ring 2 9 Oil ring 2 For installation reverse the removal proce dure 1 2 2 6 4 3 5 8 7 9 3 È Specified angle 120 130 20 Nm 2 0 m kg 14 ft lb 1st 2nd New New E E E E E M M È ...

Страница 229: ...rder Job name Part name Q ty Remarks Crankshaft removal Remove the parts in the order listed below 1 Crankshaft 1 2 Crankshaft journal bearing 6 3 Upper crankcase 1 For installation reverse the removal proce dure 1 2 2 2 3 2 E E E E ...

Страница 230: ...CAUTION Tap on one side of the crankcase with a soft face hammer Tap only on reinforced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure that the crankcase halves separate evenly 3 Remove Dowel pins Crankshaft journal bearing NOTE Identify the position of each crankshaft journal lower bearing so that it can be reinstalled in its orig inal place...

Страница 231: ...n s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller 5 Piston pin puller 90890 01304 YU 01304 4 3 2 1 6 Remove Top ring 2nd ring Oil ring NOTE When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown 7 Remove Crankshaft Crankshaft journal bearing NOTE Identif...

Страница 232: ...n find the average of the measurements If out of specification replace the cylinder and the piston and piston rings as a set 2nd step Measure piston skirt diameter P with the micrometer a 11 0 mm 0 43 in from the bottom edge of the piston If out of specification replace the piston and piston rings as a set Cylinder bore C 77 000 77 010 mm 3 0315 3 0319 in Taper limit T 0 050 mm 0 0020 in Out of ro...

Страница 233: ...0 0022 in Limit 0 120 mm 0 0047 in 3 Measure Piston ring side clearance Use the thickness gauge 1 Out of specification Replace the piston and piston rings as a set NOTE Eliminate the carbon deposits from the piston ring grooves and rings before measuring the side clear ance Piston rings side clearance Top ring 0 030 0 065 mm 0 0012 0 0026 in 2nd ring 0 020 0 055 mm 0 0008 0 0022 in 4 Install Pisto...

Страница 234: ...s Replace the piston pin and then check the lubrication sys tem 7 Measure Piston pin outside diameter Out of specification Replace the piston pin Piston ring end gap Top ring 0 15 0 25 mm 0 006 0 010 in 2nd ring 0 30 0 45 mm 0 012 0 018 in Oil ring 0 10 0 40 mm 0 004 0 016 in Piston pin outside diameter 16 991 17 000 mm 0 6689 0 6693 in 8 Measure Piston pin bore inside diameter Out of specificatio...

Страница 235: ...outside diameter Piston pin to piston pin bore clear ance 0 002 0 022 mm 0 0001 0 0009 in Limit 0 072 mm 0 0028 in 10 Measure Crankshaft runout Use the V blocks and a dial gauge Out of specification Replace the crank shaft Dial gauge 90890 03097 YU 03097 Crankshaft runout 0 03 mm 0 0012 in 11 Inspect Crankshaft journal surfaces Crankshaft pin surfaces Bearing surfaces Scratches wear Replace the cr...

Страница 236: ...ir original posi tions Clean the crankshaft journal bearings crank shaft journals and bearing portions of the crankcase Place the upper crankcase upside down on a bench Crankshaft journal to crankshaft journal bearing clearance 0 020 0 044 mm 0 0008 0 0017 in Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crankcase NOTE Align the projections a of the crankshaft j...

Страница 237: ...Oil pan side M9 105 mm bolts 1 M6 70 mm bolts 2 M6 65 mm bolts 3 M6 50 mm bolts 4 M6 50 mm bolt 5 with LOCTITE M6 35 mm bolts 6 NOTE Lubricate the crankcase bolt threads with engine oil Remove the lower crankcase and the crank shaft journal lower bearings Measure the compressed Plastigauge width c on each crankshaft journal If the clearance is out of specification select replacement crankshaft jou...

Страница 238: ...e size for all of the bearings Selection of bearings For example if the crankcase J1 and crankshaft web J1 numbers are 4 and 2 respectively then the bearing size for J1 is 14 Measure Crankshaft pin to big end bearing clearance Out of specification Replace the big end bearings Bearing size for J1 J1 crankcase J1 crankshaft web 1 4 2 1 1 blue CRANKSHAFT JOURNAL BEARING COLOR CODE 0 white 1 blue 2 bl...

Страница 239: ...lower bearing into the connecting rod cap NOTE Align the projections a on the big end bearings with the notches b in the connecting rod and con necting rod cap Put a piece of Plastigauge 1 on the crank shaft pin Assemble the connecting rod halves NOTE Do not move the connecting rod or crankshaft until the clearance measurement has been com pleted Apply molybdenum disulfide grease onto the bolts th...

Страница 240: ... to reach the specified angle 120 130 WARNING When the bolt is tightened more than the speci fied angle do not loosen the bolt and then retighten it Replace the bolt with a new one and perform the procedure again CAUTION Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angles Remove the connecting rod and big end bear ings Measure ...

Страница 241: ...age Replace NOTE Thoroughly wash the crankcase halves in a mild solvent Thoroughly clean all the gasket surfaces and crankcase mating surfaces Oil delivery passages Obstruction Blow out with compressed air 17 Inspect Bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace 18 Inspect Timing chain Damage stiffness Replace the chain and sprocket as...

Страница 242: ...bricant Recommended lubricant Engine oil 3 Install Top ring 1 2nd ring 2 Upper oil ring rail 3 Oil ring expander 4 Lower oil ring rail 5 NOTE Be sure to install the piston rings so that the manu facturer s marks or numbers a face up 4 Install Piston 1 onto the respective connecting rod 2 Piston pin 3 Piston pin clip 4 NOTE Apply engine oil onto the piston pin Make sure that the Y mark a on the con...

Страница 243: ...de 6 Lubricate Piston Piston rings Cylinder 7 Lubricate Bolt threads Nut seats with the recommended lubricant 8 Lubricate Crankshaft pins Big end bearings Connecting rod inner surface with the recommended lubricant Recommended lubricant Engine oil Recommended lubricant Molybdenum disulfide grease Recommended lubricant Engine oil be c ad 90 90 45 È ...

Страница 244: ...ps Be sure to reinstall each big end bearing in its original place While compressing the piston rings with piston ring compressor 2 install the connecting rod assembly into the cylinder with the other hand Make sure that the Y marks a on the connect ing rods face towards the A C magneto Make sure that the characters b on both the con necting rod and connecting rod cap are aligned 10 Align Bolt hea...

Страница 245: ...d 2 Tighten the connecting rod bolt further to reach the specified angle 120 130 WARNING When the bolt is tightened more than the speci fied angle do not loosen the bolt and then retighten it Replace the bolt with a new one and perform the procedure again CAUTION Do not use a torque wrench to tighten the bolt to the specified angle Tighten the bolt until it is at the specified angles 12 Lubricate ...

Страница 246: ...0 08 0 12 in of the crankshaft journal bearings 14 Install Dowel pins Yamaha bond No 1215 90890 85505 Three Bond No 1215 15 Install Crankshaft journal bearings 1 into the lower crankcase NOTE Align the projections a on the crankshaft journal lower bearings with the notches b in the crank case Install each crankshaft journal lower bearing in its original place 16 Install Lower crankcase onto the up...

Страница 247: ...side É Oil pan side M9 105 mm bolts 1 M6 70 mm bolts 2 M6 65 mm bolts 3 M6 50 mm bolts 4 M6 50 mm bolt 5 with LOCTITE M6 35 mm bolts 6 NOTE Lubricate the crankcase bolt threads with engine oil T R Crankcase bolt Bolt 1 1st 15 Nm 1 5 m kg 11 ft lb 2nd 15 Nm 1 5 m kg 11 ft lb Final Specified angle 65 70 Bolt 2 6 12 Nm 1 2 m kg 8 7 ft lb 2 2 2 È 5 3 6 6 4 5 5 5 1 1 1 1 1 1 6 6 3 6 4 É ...

Страница 248: ...servoir 1 2 Radiator fan motor coupler 1 Disconnect PZ50M PZ50VT PZ50MP 3 Plastic band 3 4 Radiator inlet hose 1 5 Radiator outlet hose 1 1 6 Radiator assembly 1 7 Radiator fan motor 1 PZ50M PZ50VT PZ50MP 8 Oil cooler outlet hose 1 9 Oil cooler inlet hose 1 10 Oil cooler 1 New New LT 1 2 22 24 25 26 15 6 3 8 10 13 3 4 19 20 24 23 21 9 11 18 14 16 5 3 17 2 7 3 8 Nm 0 8 m kg 5 8 ft lb È 27 Nm 2 7 m ...

Страница 249: ...voir inlet hose 1 20 Coolant temperature connector 1 Disconnect 21 Thermostat assembly 1 22 Coolant reservoir inlet hose 1 23 Radiator outlet pipe 1 1 24 Radiator outlet hose 2 1 25 Radiator outlet pipe 2 1 26 Radiator outlet hose 3 1 27 Heat exchanger 1 For installation reverse the removal proce dure New New LT 1 2 22 24 25 26 15 6 3 8 10 13 3 4 19 20 24 23 21 9 11 18 14 16 5 3 17 2 7 3 8 Nm 0 8 ...

Страница 250: ... screwdriver 3 Check Radiator fan PZ50VT PZ50MP Damage Replace Malfunction Check and repair 4 Measure Filler cap opening pressure Cap opens with a pressure below the speci fied pressure Replace Measurement steps Attach the cooling system tester 1 to the cool ant filler cap 2 Apply the specified pressure for 10 seconds and make sure there is no pressure drop Filler cap opening pressure 93 3 122 7 k...

Страница 251: ...AT EXCHANGER INSTALLATION 1 Install Heat exchanger Use the rivet gun 2 Install O ring Oil cooler 1 NOTE Install the oil cooler with the manufacturer s mark a facing down T R Oil cooler bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE 1 a ...

Страница 252: ...or inlet hose 1 Disconnect 4 Throttle body heater inlet hose 1 Disconnect 5 Oil cooler outlet hose 1 Disconnect 6 Water pump inlet hose 1 Disconnect 7 Coolant reservoir outlet hose 1 Disconnect 8 Engine outlet hose 1 Disconnect 9 Thermostat housing cover 1 0 Thermostat 1 A Thermostat housing 1 For assembly reverse the disassembly pro cedure 9 0 A 1 3 6 5 2 4 7 8 10 Nm 1 0 m kg 7 2 ft lb È 23 Nm 2 ...

Страница 253: ... È Fully closed É Fully open Ê More than 7 mm 0 28 in NOTE If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause serious overheating or overcooling 2 Inspect Thermostat housing cover Thermostat housing Cracks damage Replace INSTALLATION 1 Install Thermostat into the thermostat housing NOTE Install the thermostat with its breather hole a aligned with the this plac...

Страница 254: ...t temperature sensor to the thermostat housing CAUTION Use extreme care when handling the coolant temperature sensor Replace any part that was dropped or subjected to a strong impact T R Coolant temperature sensor 23 Nm 2 3 m kg 17 ft lb ...

Страница 255: ...l tank Refer to OIL TANK in CHAPTER 5 Radiator Refer to RADIATOR AND HEAT EXCHANGER 1 Water pump inlet hose 1 Disconnect 2 Throttle body outlet hose 1 Disconnect 3 Water pump outlet hose 1 Disconnect 4 Water pump assembly 1 5 O ring 1 For installation reverse the removal proce dure 5 3 1 2 4 È LS New 12 Nm 1 2 m kg 8 7 ft lb È ...

Страница 256: ...mbly Remove the parts in the order listed below 1 Water pump housing cover 1 2 Gasket 1 3 Circlip 2 4 Impeller shaft assembly 1 5 Water pump seal 1 6 Oil seal 1 7 Bearing 1 8 Water pump housing 1 For assembly reverse the disassembly pro cedure New 1 2 4 New 5 6 7 3 8 New New E ...

Страница 257: ... and oil seal 2 from the inside of the water pump housing 3 3 Remove Rubber damper holder 1 Rubber damper 2 from the impeller with a thin flat head screwdriver NOTE Do not scratch the impeller shaft 1 2 INSPECTION 1 Inspect Water pump housing cover Water pump housing Impeller Rubber damper Rubber damper holder Water pump seal Oil seal Cracks damage wear Replace 2 Inspect Bearing Rough movement Rep...

Страница 258: ...at matches its outside diameter New 3 Install Water pump seal CAUTION Never apply oil or grease onto the water pump seal surface NOTE Install the water pump seal 1 with the mechani cal seal installer 4 and 40 and 50 mm bearing driver 5 Before installing the water pump seal apply Yamaha bond No 1215 2 to the water pump housing 3 È Push down Mechanical seal installer 90890 04145 YM 04145 40 and 50 m...

Страница 259: ...Measure Impeller shaft tilt Out of specification Repeat steps 4 and 5 CAUTION Make sure the rubber damper and rubber damper holder are flush with the impeller 1 Straightedge 2 Impeller Max impeller shaft tilt 0 15 mm 0 0059 in 1 2 INSTALLATION 1 Install Water pump NOTE Align the projection a on the impeller shaft assem bly with the slot in the driven gear shaft b a b ...

Страница 260: ...6 13 COOL ...

Страница 261: ...r 1 ignition coil 9 Cylinder 1 intake air pressure sensor 0 Throttle position sensor A Speed sensor B Injector 1 C Knock sensor D Oil pressure switch E Coolant temperature sensor F Crankshaft position sensor G Injector 2 H Cylinder 2 intake air pressure sensor I Intake air temperature sensor J Grip thumb warmer adjustment switch K Warning light J K 1 2 3 6 45 5 7 8 H 9 0 A B G E F I C D FUEL INJEC...

Страница 262: ... 20A 15A 3A 4A 7 5A R W Gy R R W BLACK A Gy R A A R B R B A BLACK DARK GREEN L P B L L P B L Gy R Gy R C B L B L C G W G W W B C Ch Ch Ch A BLACK BLACK W Lg Lg BLACK GRAY Y B L L BLACK GRAY R L R L B BLACK R B BLACK GRAY BLACK BLACK B R L BLACK E W R W R E W L W L W R W L B R W R W L B Y R B Y R Br R G Y L R W Br R Br R L L L R W G Y B L B L BLACK W W O B O B B R G W B G B O B L R G B R B Y R B Y ...

Страница 263: ...Speed sensor T Cylinder identification sensor U Cylinder 1 intake air pressure sensor V Cylinder 2 intake air pressure sensor W Knock sensor X Coolant temperature sensor Y Intake air temperature sensor Z Grip thumb warmer adjustment switch c Passenger grip warmer relay e Passenger grip warmer switch f Passenger grip warmer l Multi function meter m Warning light s Headlight t Headlight relay u Head...

Страница 264: ...t are pro grammed 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 Faultcode No Item Symptom Able unable to start Able unable to drive 11 Cylinder identification sensor No normal signals are received from the cylinder identification sensor U...

Страница 265: ...the meter Unable Unable 65 Knock sensor Knock sensor open or short circuit detected Able Able 81 Grip warmer Grip warmer open or short circuit detected Able Able 83 Thumb warmer Thumb warmer short circuit detected Able Able 84 T O R S Conditions requiring T O R S operation are detected Able Unable 85 Oil pressure switch Oil pressure switch open circuit detected Able Able 88 Drive position switch D...

Страница 266: ...ETAILS Turn the main switch off turn the main switch back on and then check if the fault code number is still dis played Repairs completed Fault code number not displayed Erasing the malfunction history The malfunction history is stored even if the main switch is turned off The malfunction history must be erased in the diagnostic mode Refer to the Diagnostic mode table Diagnostic code No 62 Operat...

Страница 267: ...ter disappear except the odometer tripmeter displays dIAG appears on the odometer tripmeter LCD 4 Check that dIAG appears and then simulta neously press the SELECT and RESET but tons for 2 seconds or more to activate the diagnostic mode The diagnostic code number 01 appears on the speedometer LCD 5 Select the diagnostic code number correspond ing to the fault code number by pressing the SELECT and...

Страница 268: ...rip warmer side of the grip thumb warmer adjustment switch to operate the actuator If the grip warmer side of the switch is pushed again while the actuator is operating the actu ator operation will stop and restart from the beginning 7 Turn the main switch off to cancel the diagnostic mode NOTE To perform a reliable diagnosis make sure to turn off the power supply before every check and then start...

Страница 269: ... 22 Intake air temperature sen sor open or short circuit detected Open or short circuit in wire harness Defective intake air temperature sensor Malfunction in ECU 05 25 Cylinder 2 intake air pres sure sensor open or short circuit detected Open or short circuit in wire harness Defective cylinder 2 intake air pressure sensor Malfunction in ECU 04 26 Cylinder 2 intake air pres sure sensor hose system...

Страница 270: ...l pressure switch open cir cuit detected Open circuit in wire harness Defective oil pressure switch Malfunction in ECU 88 Drive position switch short circuit detected Short circuit in gear motor sub wire harness Short circuit in wire harness Defective drive position switch Malfunction in ECU Improperly installed drive position switch Reverse position switch short circuit detected Short circuit in ...

Страница 271: ... temperature in the air filter case Compare it to the value dis played on the meter Minimum displayed value 30 C 06 Coolant temperature Displays the coolant temperature Check the temperature of the coolant Compare it to the value dis played on the meter Minimum displayed value 30 C 07 Vehicle speed pulse Displays the cumulative number of vehicle pulses that are generated when the tire is spun 0 99...

Страница 272: ...ector 2 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 This operation is performed each time the grip warmer side of the switch is pushed However if the grip warmer side of the switch is pushed again while the operation is being performed the operation will stop immediately ...

Страница 273: ...s being performed the operation will stop immediately and restart from the beginning After pushing the switch check the operating sound of the pas senger grip warmer relay five times 60 EEPROM fault code dis play Displays the cylinder number if an error is detected in the EEPROM CO adjustment value for the cylinder as fault code No 44 If both cylinders are defective the display alternates every 2 ...

Страница 274: ...r identifica tion sensor Check for looseness or pinching Starting the engine and operating it at idle 2 Connections Cylinder identification sensor coupler Wire harness ECU coupler Check the couplers for any pins that may have pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness Repair or ...

Страница 275: ...onnections Crankshaft position sensor coupler Wire harness ECU coupler Check the couplers for any pins that may have pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short cir cuit Between crankshaft position sensor coupler and ECU coupler Gray...

Страница 276: ... the main switch on 2 Open or short circuit in wire harness Repair or replace if there is an open or short cir cuit Between cylinder 1 intake air pressure sensor coupler and ECU coupler Black Blue Black Blue Pink White Pink White Blue Blue 3 Defective cylinder 1 intake air pressure sensor Execute the diagnostic mode code No 03 Replace if defective 1 Connect the pocket tester DC 20 V to the cyl ind...

Страница 277: ...tion sensor open or short circuit detected Diagnostic code No 01 throttle position sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of throttle position sensor Check for looseness or pinching Check that it is installed in the specified position Refer to THROTTLE BODY Turning the main switch on 2 Connections Throttle position sensor...

Страница 278: ...ler securely Turning the main switch on 2 Open or short circuit in wire harness and or sub wire harness 2 Repair or replace if there is an open or short cir cuit Between coolant temperature sensor coupler and ECU coupler Black Blue Black Blue Green White Green White 3 Defective coolant temperature sensor Execute the diagnostic mode code No 06 Replace if defective Refer to SIGNAL SYSTEM in CHAPTER ...

Страница 279: ...y Turning the main switch on 2 Open or short circuit in wire harness Repair or replace if there is an open or short cir cuit Between cylinder 2 intake air pressure sensor coupler and ECU coupler Black Blue Black Blue Pink Pink Blue Blue 3 Defective cylinder 2 intake air pressure sensor Execute the diagnostic mode code No 04 Replace if defective 1 Connect the pocket tester DC 20 V to the cyl inder ...

Страница 280: ...securely 3 Defective cylinder 2 intake air pressure sensor Execute the diagnostic mode code No 04 Replace if defective Refer to Fault code No 25 Fault code No 30 Symptom Engine stops when an oil pressure drop is detected Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Oil pressure dropped Place the snowmobile on a level surface and then c...

Страница 281: ...0 Test the primary and secondary coils for continu ity Replace if defective Refer to IGNITION SYSTEM in CHAPTER 8 Fault code No 34 Symptom Open circuit detected in the primary lead of the cylinder 2 ignition coil Diagnostic code No 31 cylinder 2 ignition coil Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Cylinder 2 ignition coil coupler Wire h...

Страница 282: ...malfunction repair it and connect the coupler securely Starting the engine and inputting the vehicle speed signals by oper ating the snow mobile at a low speed of 20 to 30 km h 2 Open or short circuit in wire harness Repair or replace if there is an open or short cir cuit Between speed sensor coupler and ECU coupler Blue Blue White Yellow White Yellow Black Blue Black Blue 3 Defective speed sensor...

Страница 283: ...fuel injection system relay coupler and ECU coupler Blue Red Blue Red Between fuel injection system relay coupler and engine stop switch coupler Red White Red White Between engine stop switch coupler and main switch coupler Brown Brown 3 Malfunction or open circuit in fuel injec tion system relay Execute the diagnostic mode code No 09 Replace if defective NOTE When the leads are disconnected the v...

Страница 284: ...out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Starting the engine and operating it at idle 2 Faulty battery Replace or charge the battery Refer to BATTERY INSPECTION in CHAPTER 2 3 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYSTEM in CHAPTER 8 4 Open or short circuit in wire harness Repair or repla...

Страница 285: ...upler and ECU coupler White White 4 Defective knock sensor Replace if defective Refer to KNOCK SENSOR in CHAPTER 8 Fault code No 81 Symptom Grip warmer open or short circuit detected Diagnostic code No 26 grip warmer operation Order Item components and probable cause Check or maintenance job Reinstatement method 1 Open or short circuit in wire harness Repair or replace if there is an open or short...

Страница 286: ...rive position switch short circuit detected Reverse position switch short circuit detected Diagnostic code No Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of switch Check for looseness or pinching Starting the engine and operating it at idle 2 Connections Drive position switch connector Reverse position switch connector Wire harness E...

Страница 287: ...ck or maintenance job Reinstatement method 1 Connections Wire harness ECU coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch on 2 Open or short circuit in wire harness Repair or replace if there is an open or short cir cuit Between speedometer unit co...

Страница 288: ...t it to shock or allow it to be dropped If it is dropped it must be replaced 2 Connect Pocket tester to the intake temperature sensor NOTE Set the tester selector to the Ω 100 position 3 Immerse the intake temperature sensor 1 in water 2 and check the intake temperature sen sor operation 3 Temperature gauge CAUTION Never heat the water to a temperature of 120 C 248 F or more 4 If the intake air te...

Страница 289: ... Throttle position sensor coupler 1 Disconnect 2 Fuel hose 2 3 Fuel return hose 1 Disconnect 4 Idle adjusting screw 1 5 Throttle cable 1 6 Plastic band 1 7 Throttle body heater inlet hose 1 8 Throttle body assembly 1 9 Throttle body heater outlet hose 1 Disconnect 10 Injector coupler 2 Disconnect 11 Throttle body joint 2 For installation reverse the removal proce dure 11 10 5 6 7 8 4 1 3 2 9 10 ...

Страница 290: ...ose 1 2 Idle adjusting screw 1 3 Throttle position sensor 1 4 Pressure regulator hose 1 5 Pressure regulator 1 6 Fuel strainer seat 1 7 Fuel strainer 1 8 Fuel rail 1 9 Injector 4 10 Throttle body heater hose 1 11 Air screw 2 12 Throttle body assembly 1 For installation reverse the removal proce dure New New New 2 12 10 9 1 4 5 8 3 New E E E 7 6 11 11 ...

Страница 291: ...ge Replace PRESSURE REGULATOR OPERATION 1 Remove Right side panel Refer to COWLINGS in CHAPTER 3 2 Inspect Fuel pump and pressure regulator operation Measurement steps Connect the pressure gauge 1 and fuel pres sure adapter 2 onto the fuel injection pipe Connect the mity vac to the pressure regulator 3 Start the engine Measure the fuel pressure Pressure gauge 90890 03153 YU 03153 Fuel pressure ada...

Страница 292: ...hrottle position sensor the engine idling speed should be properly adjusted 1 Inspect Throttle position sensor Checking steps Disconnect the throttle position sensor coupler Remove the throttle position sensor from the throttle body Connect the pocket tester Ω 1k to the throt tle position sensor Measure the maximum throttle position sensor resistance Out of specification Replace the throttle posi ...

Страница 293: ...he throttle position sensor voltage Adjust the throttle position sensor angle so the measured voltage is within the specified range After adjusting the throttle position sensor angle tighten the throttle position sensor screws Positive tester probe yellow terminal 1 Negative tester probe black blue terminal 2 Digital circuit tester 90890 03174 Throttle position sensor voltage 0 63 0 73 V yellow bl...

Страница 294: ...7 34 FI ...

Страница 295: ...HOWN IN THE MANUAL The terminal connections for switches main switch handlebar switch engine stop switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions a in the column and the switch lead colors b in the top row For each switch position indicates the terminals with continuity The example chart shows that There is continuity between the Br...

Страница 296: ...r W B L 40A 20A 15A 3A 4A 7 5A R W Gy R R W BLACK A Gy R A A R B R B A BLACK DARK GREEN L P B L L P B L Gy R Gy R C B L B L C G W G W W B C Ch Ch Ch A BLACK BLACK W Lg Lg BLACK GRAY Y B L L BLACK GRAY R L R L B BLACK R B BLACK GRAY BLACK BLACK B R L BLACK E W R W R E W L W L W R W L B R W R W L B Y R B Y R Br R G Y L R W Br R Br R L L L R W G Y B L B L BLACK W W O B O B B R G W B G B O B L R G B R...

Страница 297: ...T DIAGRAM 1 Crankshaft position sensor 4 Main switch 5 Main fuse 0 Battery B Engine stop switch C Throttle switch J ECU engine control unit K Cylinder 1 ignition coil L Spark plug M Cylinder 2 ignition coil R Throttle position sensor y Ignition fuse ...

Страница 298: ...nition system s wiring Refer to CIRCUIT DIAGRAM Correct the connection and or ECU NO SPARK OR WEAK SPARK OK FAULTY Replace the main fuse and or ignition fuse OK OUT OF SPECIFICATION Replace and or charge the battery Refer to BATTERY INSPECTION in CHAPTER 2 OK OUT OF SPECIFICATION Repair or replace the spark plug Refer to SPARK PLUGS in CHAPTER 2 OK OUT OF SPECIFICATION Replace the ignition coil OK...

Страница 299: ...lace the speedometer unit and or ECU T O R S OPERATES NO YES Check the affected item s NO YES Perform throttle body maintenance NO YES Repair or replace the throttle switch NO YES Adjust the throttle cable free play Refer to THROTTLE CABLE FREE PLAY ADJUSTMENT in CHAPTER 2 NO YES When the engine is revved with the V belt removed the speed sensor is diagnosed as mal functioning and T O R S operates...

Страница 300: ...rank the engine by turning the main switch to start and gradually increase the spark gap until a misfire occurs È For USA Canada É For Europe Dynamic spark tester YM 34487 Ignition checker 90890 06754 Ignition spark gap 6 0 mm 0 24 in È É IGNITION COIL 1 Disconnect Ignition coil coupler 2 Connect Pocket tester 3 Measure Primary coil resistance a Secondary coil resistance b Out of specification Rep...

Страница 301: ...connect Crankshaft position sensor coupler 2 Connect Pocket tester to the crankshaft position sensor coupler 3 Measure Crankshaft position sensor resistance Out of specification Replace Crankshaft position sensor resis tance 189 231 Ω at 20 C 68 F Gray Black ...

Страница 302: ...ied spark plug and spark plug cap Otherwise the T O R S will not work properly È Idling starting É Running Ê Trouble 1 Throttle position sensor throttle valve position 2 Throttle switch 3 Throttle cable a On b Off c Open d Closed NOTE When the T O R S is activated the warning light 4 and self diagnosis warning indicator 5 will flash and the two digit code 84 6 will flash in the clock display The T...

Страница 303: ... switch Switch position Continuity RUN pulled out Yes OFF pushed in No Ω 1 Br Br W THROTTLE SWITCH 1 Disconnect Throttle switch couplers 2 Connect Pocket tester 3 Check Throttle switch continuity Faulty Replace the right handlebar switch Throttle switch position Continuity Throttle lever is operated Yes Throttle lever is not operated No Ω 1 B L B Y IGNITION SYSTEM ...

Страница 304: ...GNITION SYSTEM MAIN SWITCH 1 Disconnect Main switch coupler 2 Connect Pocket tester 3 Check Main switch continuity Faulty Replace Continuity Switch position Color code Br R Br W R W OFF ON START Ω 1 R Br R W Br W ...

Страница 305: ...B R B Lg B G B Gy R Sb W 40A 20A 15A 3A 4A 7 5A R W A Gy R A Gy R Gy R C Ch Ch Ch A Lg Lg R B BLACK GRAY BLACK BLACK E W R W R E W L W L W R W L B R W R W L B Y R B Y R Br R G Y L R W Br R Br R L L L R W G Y B L B L BLACK W W O B O B B R G W B G B O B B R B Y R B Y R B Lg B W B B B B B B B Y R B R B B O B L R R R GR G Y Br B Br R B L R O B Br P BLACK B C E E 7 6 0 9 2 4 3 y z 5 A F G 8 J b a 1 D H...

Страница 306: ...ace the battery Refer to BATTERY INSPECTION in CHAPTER 2 Repair or replace the starter motor WARNING A wire for the jumper lead 1 must have the equivalent capacity as that of the battery lead or more otherwise it may cause the jumper lead to be burned This check is likely to produce sparks so be sure that no flammable gas or fluid is in the vicinity 3 Disconnect Starter relay coupler 4 Connect Sta...

Страница 307: ... main fuse and or ignition fuse OK Check the engine stop switch and main switch Refer to IGNITION SYSTEM FAULTY Replace the right handlebar switch and or main switch OK Check the electrical starting system s wiring Refer to CIRCUIT DIAGRAM Correct the connection FAULTY Properly connect or repair the electrical starting system s wiring ...

Страница 308: ...sconnect 2 Starter motor lead 1 Disconnect 3 Starter motor assembly 1 For installation reverse the removal proce dure Starter motor disassembly Remove the parts in the order listed below 1 Front bracket 1 2 O ring 1 3 O ring 2 4 Lock washer 1 5 Shim 6 Oil seal 1 7 Bearing 1 8 Rear bracket 1 9 Brush 1 3 0 Brush 2 1 C 5 3 8 6 7 1 2 0 9 B A 3 1 2 12 Nm 1 2 m kg 8 7 ft lb È 1 ESSO beacon 325 grease or...

Страница 309: ...Part name Q ty Remarks A Brush holder 1 B Armature assembly 1 C Starter motor yoke 1 For assembly reverse the disassembly pro cedure C 5 3 8 6 7 1 2 0 9 B A 3 1 2 12 Nm 1 2 m kg 8 7 ft lb È 1 ESSO beacon 325 grease or Aeroshell grease 7A È 3 New New New 4 ...

Страница 310: ... limit 23 5 mm 0 93 in 3 Measure Mica undercut insulation depth a between commutator segments Out of specification Scrape mica 1 to proper limits Use a hacksaw blade 2 that is ground to fit Mica undercut 1 5 mm 0 06 in 4 Measure Armature coil resistance insulation continuity Defect s Replace the starter motor Inspecting steps Connect the pocket tester for the continuity check 1 and the insulation ...

Страница 311: ...ective part s Brush length wear limit 3 65 mm 0 14 in Brush spring pressure 5 28 7 92 N 538 808 g 19 01 28 51 oz Assembly Reverse the Disassembly procedure Note the following points 1 Before installing the front bracket and rear bracket apply bearing grease to the bearing and bushing of the front bracket and rear bracket 2 Install Oil seal Lock washer 1 NOTE Align the projection a on the lock wash...

Страница 312: ...ELEC 3 Install O rings Rear bracket 1 Starter motor yoke 2 Front bracket 3 NOTE Align the match mark a on the rear bracket with the match mark b on the front bracket 1 3 2 b a New ELECTRICAL STARTING SYSTEM ...

Страница 313: ...Y L G Y Br L L R B R B Lg B G B Gy R Sb W 40A 20A 15A 3A 4A 7 5A R W A Gy R A Gy R Gy R C Ch Ch Ch A Lg Lg R B BLACK GRAY BLACK BLACK E W R W R E W L W L W R W L B R W R W L B Y R B Y R Br R G Y L R W Br R Br R L L L R W G Y B L B L BLACK W W O B O B B R G W B G B O B B R B Y R B Y R B Lg B W B B B B B B B Y R B R B B O B L R R R GR G Y Br B Br R B L R O B Br P BLACK B C E E 7 6 0 9 2 4 3 y z 5 A ...

Страница 314: ...table stand to raise the track off of the ground 4 Measure Charging voltage CAUTION Never disconnect the battery cables while the generator is operating otherwise the rectifier regulator will be damaged OK Charging voltage 14 V 5 000 r min OUT OF SPECIFICATION Check the main fuse Refer to FUSE INSPECTION in CHAPTER 2 Check the stator coil OK FAULTY Replace the main fuse and or the sta tor coil ass...

Страница 315: ...e battery disconnect the negative lead first Battery storage and maintenance tips Recharge the battery periodically Store the battery in a cool dry place Recharge the battery before reinstalling Refer to BATTERY INSPECTION in CHAPTER 2 A C MAGNETO 1 Disconnect A C magneto coupler 2 Connect Pocket tester to A C magneto coupler 3 Measure Stator coil resistance Out of specification Replace Stator coi...

Страница 316: ... W B L 40A 20A 15A 3A 4A 7 5A R W Gy R R W BLACK A Gy R A A R B R B A BLACK DARK GREEN L P B L L P B L Gy R Gy R C B L B L C G W G W W B C Ch Ch Ch A BLACK BLACK W Lg Lg BLACK GRAY Y B L L BLACK GRAY R L R L B BLACK R B BLACK GRAY BLACK BLACK B R L BLACK E W R W R E W L W L W R W L B R W R W L B Y R B Y R Br R G Y L R W Br R Br R L L L R W G Y B L B L BLACK W W O B O B B R G W B G B O B L R G B R ...

Страница 317: ...ator 4 Main switch 5 Main fuse 6 Load control relay 0 Battery B Engine stop switch J ECU engine control unit h Tail brake light l Multi function meter r High beam indicator light s Headlight t Headlight relay u Headlight beam switch y Ignition fuse Signal fuse Headlight fuse È PZ50VT PZ50MP ...

Страница 318: ...M Correct the connection and or replace the speedometer unit rectifier regulator and or ECU HEADLIGHT AND OR HIGH BEAM INDICATOR LIGHT AND OR METER LIGHT DO NOT COME ON OK NO CONTINUITY Replace the bulb s OK FAULTY Replace the main fuse ignition fuse and or head light fuse OK OUT OF SPECIFICATION Replace and or charge the battery Refer to BATTERY INSPECTION in CHAPTER 2 OK OUT OF SPECIFICATION Rep...

Страница 319: ...m s wiring Refer to CIRCUIT DIAGRAM Correct the connection and or replace the tail brake light rectifier regulator and or ECU TAIL LIGHT DOES NOT COME ON OK FAULTY Replace the main fuse ignition fuse and or signal fuse OK OUT OF SPECIFICATION Replace and or charge the battery Refer to BATTERY INSPECTION in CHAPTER 2 OK OUT OF SPECIFICATION Replace the stator coil assembly OK FAULTY Replace the rig...

Страница 320: ...s away from the bulb while it is on it will be hot Do not touch the bulb until it cools down 3 Check Bulb s Terminal Continuity 1 3 Yes 2 3 Yes HEADLIGHT BEAM SWITCH 1 Disconnect Headlight beam switch coupler 2 Connect Pocket tester to the headlight beam switch coupler 3 Check Headlight beam switch continuity Faulty Replace the left handlebar switch Switch position Continuity HI Yes LO No L G Ω 1 ...

Страница 321: ... replace it Positive tester probe Blue White 1 Negative tester probe Green 2 Positive battery terminal Light green 3 Negative battery terminal Black 4 Positive tester probe Blue White 5 Negative tester probe Yellow 6 1 2 L W Y Lg B G 6 5 4 3 L W Y Lg B G LOAD CONTROL RELAY 1 Remove Load control relay Inspection steps Connect the pocket tester Ω 1 and battery 12 V to the load control relay terminal...

Страница 322: ... W B L 40A 20A 15A 3A 4A 7 5A R W Gy R R W BLACK A Gy R A A R B R B A BLACK DARK GREEN L P B L L P B L Gy R Gy R C B L B L C G W G W W B C Ch Ch Ch A BLACK BLACK W Lg Lg BLACK GRAY Y B L L BLACK GRAY R L R L B BLACK R B BLACK GRAY BLACK BLACK B R L BLACK E W R W R E W L W L W R W L B R W R W L B Y R B Y R Br R G Y L R W Br R Br R L L L R W G Y B L B L BLACK W W O B O B B R G W B G B O B L R G B R ...

Страница 323: ...tch 1 J ECU engine control unit S Speed sensor W Knock sensor X Coolant temperature sensor g Brake light switch h Tail brake light i Fuel sender j Oil level switch l Multi function meter m Warning light n Low coolant temperature indi cator light o Knock control system indica tor light p Drive position indicator light 1 q Reverse position indicator light 1 y Ignition fuse Signal fuse 1 PZ50GT PZ50F...

Страница 324: ...signal system s wiring Refer to CIRCUIT DIAGRAM Correct the connection and or replace the tail brake light rectifier regulator and or ECU BRAKE LIGHT DOES NOT COME ON OK FAULTY Replace the main fuse ignition fuse and or signal fuse OK OUT OF SPECIFICATION Replace and or charge the battery Refer to BATTERY INSPECTION in CHAPTER 2 OK OUT OF SPECIFICATION Replace the stator coil assembly OK FAULTY Re...

Страница 325: ...rrect the connection and or replace the speedometer unit rectifier regulator and or ECU LOW COOLANT TEMPERATURE INDICATOR LIGHT COOLANT TEMPERATURE WARNING INDICATOR AND OR WARNING LIGHT DO NOT COME ON OK FAULTY Replace the main fuse and or ignition fuse OK OUT OF SPECIFICATION Replace and or charge the battery Refer to BATTERY INSPECTION in CHAPTER 2 OK OUT OF SPECIFICATION Replace the stator coi...

Страница 326: ...CUIT DIAGRAM Correct the connection and or replace the speedometer unit rectifier regulator and or ECU FUEL METER AND OR FUEL LEVEL WARNING INDICATOR AND OR WARNING LIGHT DO NOT COME ON OK FAULTY Replace the main fuse and or ignition fuse OK OUT OF SPECIFICATION Replace and or charge the battery Refer to BATTERY INSPECTION in CHAPTER 2 OK OUT OF SPECIFICATION Replace the stator coil assembly OK FA...

Страница 327: ...fer to CIRCUIT DIAGRAM Correct the connection and or replace the speedometer unit rectifier regulator and or ECU OIL LEVEL WARNING INDICATOR AND OR WARNING LIGHT DO NOT COME ON OK FAULTY Replace the main fuse and or ignition fuse OK OUT OF SPECIFICATION Replace and or charge the battery Refer to BATTERY INSPECTION in CHAPTER 2 OK OUT OF SPECIFICATION Replace the stator coil assembly OK FAULTY Repl...

Страница 328: ...iring Refer to CIRCUIT DIAGRAM Correct the connection and or replace the speedometer unit rectifier regulator and or ECU KNOCK CONTROL SYSTEM INDICATOR LIGHT DO NOT COME ON OK FAULTY Replace the main fuse and or ignition fuse OK OUT OF SPECIFICATION Replace and or charge the battery Refer to BATTERY INSPECTION in CHAPTER 2 OK OUT OF SPECIFICATION Replace the stator coil assembly OK FAULTY Replace ...

Страница 329: ...T DIAGRAM Correct the connection and or replace the speedometer unit rectifier regulator and or ECU DRIVE POSITION INDICATOR LIGHT AND OR REVERSE POSITION INDICATOR LIGHT DO NOT COME ON OK FAULTY Replace the main fuse and or ignition fuse OK OUT OF SPECIFICATION Replace and or charge the battery Refer to BATTERY INSPECTION in CHAPTER 2 OK OUT OF SPECIFICATION Replace the stator coil assembly OK FA...

Страница 330: ...system s wiring Refer to CIRCUIT DIAGRAM Correct the connection and or replace the speedometer unit rectifier regulator and or ECU SPEEDOMETER DOES NOT OPERATE OK FAULTY Replace the main fuse and or ignition fuse OK OUT OF SPECIFICATION Replace and or charge the battery Refer to BATTERY INSPECTION in CHAPTER 2 OK OUT OF SPECIFICATION Replace the stator coil assembly OK FAULTY Replace the left hand...

Страница 331: ...ing Refer to CIRCUIT DIAGRAM Correct the connection and or replace the rectifier regulator and or ECU BACK BUZZER DOES NOT SOUND PZ50GT PZ50FX PZ50M PZ50VT PZ50MP OK FAULTY Replace the main fuse ignition fuse and or signal fuse OK OUT OF SPECIFICATION Replace and or charge the battery Refer to BATTERY INSPECTION in CHAPTER 2 OK OUT OF SPECIFICATION Replace the stator coil assembly OK FAULTY Replac...

Страница 332: ...rate No L R G DRIVE POSITION SWITCH AND REVERSE POSITION SWITCH PZ50GT PZ50FX PZ50M PZ50VT PZ50MP 1 Remove Drive position switch and reverse position switch 2 Connect Pocket tester to the drive position switch and reverse posi tion switch 3 Check Drive position switch and reverse position switch continuity Faulty Replace DC BACK BUZZER PZ50GT PZ50FX PZ50M PZ50VT PZ50MP 1 Disconnect DC back buzzer ...

Страница 333: ...erse the coolant temperature sensor 2 in coolant 3 and check the coolant temperature sensor operation 4 Temperature gauge CAUTION Never heat the coolant to a temperature of 120 C 248 F or more 4 If the coolant temperature sensor operation is defective replace it 5 Install the coolant temperature sensor and con nect the coolant temperature sensor coupler CAUTION Do not overtighten the coolant tempe...

Страница 334: ...Switch position Good condition Bad condition È Down position É Up position Ch R B È É FUEL SENDER 1 Remove Fuel sender from the fuel tank 2 Connect Pocket tester to the fuel sender coupler 3 Measure Fuel sender resistance full a Fuel sender resistance empty b Out of specification Replace Fuel sender resistance full 10 12 Ω at 20 C 68 F Fuel sender resistance empty 179 185 Ω at 20 C 68 F a b Ω 1 B ...

Страница 335: ...White Yellow Negative tester probe Black Blue Positive battery terminal Blue Negative battery terminal Black Blue KNOCK SENSOR 1 Remove Knock sensor CAUTION Handle the knock sensor with special care Never subject it to shock or allow it to be dropped If it is dropped it must be replaced 2 Connect Pocket tester to the knock sensor coupler and sensor body 3 Measure Knock sensor resistance Out of spe...

Страница 336: ...W Br W B L 40A 20A 15A 3A 4A 7 5A R W Gy R R W BLACK A Gy R A A R B R B A BLACK DARK GREEN L P B L L P B L Gy R Gy R C B L B L C G W G W W B C Ch Ch Ch A BLACK BLACK W Lg Lg BLACK GRAY Y B L L BLACK GRAY R L R L B BLACK R B BLACK GRAY BLACK BLACK B R L BLACK E W R W R E W L W L W R W L B R W R W L B Y R B Y R Br R G Y L R W Br R Br R L L L R W G Y B L B L BLACK W W O B O B B R G W B G B O B L R G ...

Страница 337: ... Battery B Engine stop switch E Grip warmer F Thumb warmer J ECU engine control unit Z Grip thumb warmer adjust ment switch c Passenger grip warmer relay e Passenger grip warmer switch f Passenger grip warmer l Multi function meter y Ignition fuse Signal fuse È PZ50VT PZ50MP Ê PZ50VT STANDARD PZ50MP OPTION Ì PZ50 PZ50GT PZ50M PZ50VT PZ50MP Í PZ50FX ...

Страница 338: ...ring Refer to CIRCUIT DIAGRAM Correct the connection and or replace the speedometer unit rectifier regulator and or ECU GRIP WARMER AND THUMB WARMER DO NOT OPERATE OK FAULTY Replace the main fuse and or ignition fuse OK OUT OF SPECIFICATION Replace and or charge the battery Refer to BATTERY INSPECTION in CHAPTER 2 OK OUT OF SPECIFICATION Replace the stator coil assembly OK NO CONTINUITY Replace th...

Страница 339: ... to CIRCUIT DIAGRAM Correct the connection and or replace the rectifier regulator and or ECU PASSENGER GRIP WARMER DOES NOT OPERATE PZ50VT OK FAULTY Replace the main fuse ignition fuse and or signal fuse OK OUT OF SPECIFICATION Replace and or charge the battery Refer to BATTERY INSPECTION in CHAPTER 2 OK OUT OF SPECIFICATION Replace the stator coil assembly OK NO CONTINUITY Replace the right handl...

Страница 340: ...T PZ50M PZ50VT PZ50MP 1 53 1 87 Ω at 20 C 68 F Black Black PZ50FX 6 12 7 48 Ω at 20 C 68 F Black Black Thumb warmer resistance 37 0 45 2 Ω at 20 C 68 F White Black Ω 1 2 1 W B B B GRIP THUMB WARMER ADJUSTMENT SWITCH 1 Disconnect Grip thumb warmer adjustment switch coupler 2 Connect Pocket tester to the grip thumb warmer adjustment switch coupler 3 Check Grip thumb warmer adjustment switch conti nu...

Страница 341: ...nger grip warmer resistance high 8 82 10 78 Ω Green Black Passenger grip warmer resistance low 14 67 17 93 Ω Yellow Black Ω 1 G Y B PASSENGER GRIP WARMER SWITCH PZ50VT 1 Disconnect Passenger grip warmer switch coupler 2 Connect Pocket tester to the passenger grip warmer switch coupler 3 Check Passenger grip warmer switch continuity Faulty Replace Continuity Switch position Color code G R O B Y L L...

Страница 342: ...and battery 12 V to the passenger grip warmer relay termi nals as shown If passenger grip warmer relay does not have continuity between the blue red and orange black terminals replace it Positive battery terminal Blue Red 1 Negative battery terminal Yellow Blue 2 Positive tester probe Blue Red 3 Negative tester probe Orange Black 4 4 3 2 1 L R O B L R Y L ...

Страница 343: ...8 49 ELEC ...

Страница 344: ...g B G B Gy R Sb W Br W B L 40A 20A 15A 3A 4A 7 5A R W Gy R R W BLACK A Gy R A A R B R B A BLACK L P B L L P B L Gy R Gy R C B L B L C G W G W W B C Ch Ch Ch A BLACK BLACK W Lg Lg BLACK GRAY Y B L L BLACK GRAY R L R L B BLACK R B BLACK GRAY BLACK BLACK B R L BLACK E W R W R E W L W L W R W L B R W R W L B Y R B Y R Br R G Y L R W Br R Br R L L L R W G Y B L B L BLACK W W O B O B B R G W B G B O B L...

Страница 345: ...IRCUIT DIAGRAM 2 A C magneto 3 Rectifier regulator 4 Main switch 5 Main fuse 6 Load control relay 0 Battery A Diode J ECU engine control unit X Coolant temperature sensor v Radiator fan motor w Radiator fan motor relay y Ignition fuse z Radiator fan motor fuse É PZ50M PZ50VT PZ50MP ...

Страница 346: ...AL SYSTEM Check the load control relay Refer to LIGHTING SYSTEM Correct the connection and or replace the rectifier regulator and or the ECU THE RADIATOR FAN MOTOR DOES NOT MOVE OK FAULTY Replace the main fuse ignition fuse and or radia tor fan motor fuse OK OUT OF SPECIFICATION Replace and or charge the battery Refer to BATTERY INSPECTION in CHAPTER 2 OK OUT OF SPECIFICATION Replace the stator co...

Страница 347: ...tery terminal Black 2 RADIATOR FAN MOTOR RELAY 1 Remove Radiator fan motor relay Inspection steps Connect the pocket tester Ω 1 and battery 12 V to the radiator fan motor relay terminals as shown If radiator fan motor relay does not have conti nuity between the brown red and blue terminals replace it Positive battery terminal Red White 1 Negative battery terminal Green Yellow 2 Positive tester pro...

Страница 348: ...O Y R Y L G Y Br L L R B R B Lg B G B Gy R Sb W Br W B L 40A 20A 15A 3A 4A 7 5A R W Gy R R W BLACK A Gy R A A R B R B A BLACK DARK GREEN L P B L L P B L Gy R Gy R C B L B L C G W G W W B C Ch Ch Ch A BLACK BLACK W Lg Lg BLACK GRAY Y B L L BLACK GRAY R L R L B BLACK R B BLACK GRAY BLACK BLACK B R L BLACK E W R W R E W L W L W R W L B R W R W L B Y R B Y R Br R G Y L R W Br R Br R L L L R W G Y B L ...

Страница 349: ...T PZ50FX PZ50M PZ50VT PZ50MP CIRCUIT DIAGRAM 2 A C magneto 3 Rectifier regulator 4 Main switch 5 Main fuse 6 Load control relay 0 Battery H Drive position switch I Reverse position switch J ECU engine control unit Gear motor relay 1 Gear motor relay 2 Gear motor relay 3 Gear motor y Ignition fuse Gear motor fuse ...

Страница 350: ...Check the drive reverse selecting system s wiring Refer to CIRCUIT DIAGRAM Correct the connection and or replace the rectifier regulator and or ECU CANNOT SHIFT TO DRIVE OR REVERSE OK FAULTY Replace the main fuse ignition fuse and or gear motor fuse OK OUT OF SPECIFICATION Replace and or charge the battery Refer to BATTERY INSPECTION in CHAPTER 2 OK OUT OF SPECIFICATION Replace the stator coil ass...

Страница 351: ...e Incorrect Replace the gear motor NOTE The pinion gear should rotate clockwise and stop in the reverse position Drive position inspection steps É Connect the battery 12 V to the gear motor terminals as shown Check that the pinion gear 3 turns counter clockwise Incorrect Replace the gear motor NOTE The pinion gear should rotate counterclockwise and stop in the drive position 2 Install Gear motor R...

Страница 352: ...ity between the red green and yellow red termi nals replace it Positive tester probe Red Green 1 Negative tester probe Brown Red 2 Positive battery terminal Red Green 3 Negative battery terminal Brown Black 4 Positive tester probe Red Green 5 Negative tester probe Yellow Red 6 1 2 R G Y R Br R R G Br B 6 5 4 3 R G Y R Br R R G Br B GEAR MOTOR RELAY 2 1 Remove Gear motor relay 2 with the black coup...

Страница 353: ...Sky blue White 4 Positive tester probe Sky blue 5 Negative tester probe Red Green 6 6 5 4 3 Sb R G B R G Sb W GEAR MOTOR RELAY 3 1 Remove Gear motor relay 3 Inspection steps Connect the pocket tester Ω 1 and battery 12 V to the gear motor relay 3 terminals as shown If gear motor relay 3 does not have continuity between the black and blue black terminals replace it Positive battery terminal Yellow ...

Страница 354: ...A Canada 1 165 mm 45 9 in PZ50M 1 265 mm 49 8 in PZ50VT Europe PZ50MP Overall height 1 190 mm 46 9 in PZ50 PZ50FX 1 340 mm 52 8 in PZ50GT PZ50M 1 380 mm 54 3 in PZ50VT PZ50MP Weight Dry weight 215 kg 474 0 lb PZ50 USA Canada 217 kg 478 4 lb PZ50 Europe 221 kg 487 2 lb PZ50GT USA Canada PZ50FX USA Canada 222 kg 489 4 lb PZ50GT Europe PZ50FX Europe 233 kg 513 7 lb PZ50M USA Canada 234 kg 515 9 lb PZ...

Страница 355: ...US qt With oil filter replacement 2 63 L 2 31 Imp qt 2 78 US qt Total amount 3 00 L 2 64 Imp qt 3 17 US qt Oil tank capacity 2 00 L 1 76 Imp qt 2 11 US qt Oil filter Oil filter type Cartridge paper Drive chain oil Type Gear oil GL 3 75W or 80W Capacity 0 25 L 0 22 Imp qt 0 26 US qt Coolant Filler cap opening pressure 93 3 122 7 kPa 0 93 1 23 kg cm2 13 2 17 5 psi Capacity 3 60 L 3 17 Imp qt 3 81 US...

Страница 356: ...T Europe PZ50MP Chassis Frame type Monocoque Caster 18 0 Ski stance center to center 1 080 mm 42 5 in PZ50 PZ50GT PZ50FX PZ50VT PZ50MP 980 mm 38 6 in PZ50M Suspension Front suspension type Double wishbone Rear suspension type Slide rail suspension Track Track type Internal drive type Track width 355 6 mm 14 00 in PZ50 PZ50GT PZ50FX PZ50M 381 0 mm 15 00 in PZ50VT 406 4 mm 16 00 in PZ50MP Length on ...

Страница 357: ... Meter light LED Warning light LED High beam indicator light LED Low coolant temperature indicator light LED Knock control system indicator light LED Drive position indicator light LED PZ50GT PZ50FX PZ50M PZ50VT PZ50MP Reverse position indicator light LED PZ50GT PZ50FX PZ50M PZ50VT PZ50MP Model PZ50 PZ50GT PZ50FX PZ50M PZ50VT PZ50MP ...

Страница 358: ...ft Drive system Chain drive left Camshaft cap inside diameter 22 000 22 021 mm 0 8661 0 8670 in Camshaft journal diameter 21 959 21 972 mm 0 8645 0 8650 in Camshaft journal to camshaft cap clear ance 0 028 0 062 mm 0 0011 0 0024 in Camshaft dimensions Intake A 30 450 30 550 mm 1 1988 1 2028 in Limit 30 350 mm 1 1949 in B 22 610 22 710 mm 0 8902 0 8941 in Limit 22 510 mm 0 8862 in Exhaust A 30 700 ...

Страница 359: ...st 0 5 0 9 mm 0 0197 0 0354 in Valve stem diameter Intake 3 975 3 990 mm 0 1565 0 1571 in Limit 3 945 mm 0 1553 in Exhaust 3 960 3 975 mm 0 1559 0 1565 in Limit 3 930 mm 0 1547 in Valve guide inside diameter Intake 4 000 4 012 mm 0 1575 0 1580 in Limit 4 050 mm 0 1594 in Exhaust 4 000 4 012 mm 0 1575 0 1580 in Limit 4 050 mm 0 1594 in Valve stem to valve guide clearance Intake 0 010 0 037 mm 0 000...

Страница 360: ...0 8854 in Limit 22 457 mm 0 8841 in Valve lifter hole inside diameter Intake 20 000 20 018 mm 0 7874 0 7881 in Limit 20 048 mm 0 7893 in Exhaust 22 500 22 518 mm 0 8858 0 8865 in Limit 22 548 mm 0 8877 in Piston Piston size D 76 955 76 970 mm 3 0297 3 0303 in Measuring point H 11 0 mm 0 43 in Piston to cylinder clearance 0 030 0 055 mm 0 0012 0 0022 in Limit 0 120 mm 0 0047 in Piston pin bore off ...

Страница 361: ...ing 2nd ring Ferox coating Connecting rod Small end diameter 17 005 17 018 mm 0 6695 0 6700 in Big end diameter 37 000 37 016 mm 1 4567 1 4573 in Crankshaft pin to big end bearing clearance 0 034 0 058 mm 0 0013 0 0023 in Bearing color code 0 White 1 Blue 2 Black 3 Brown Crank pin Crank pin outside diameter 33 976 34 000 1 3376 1 3386 in Crankshaft Measuring point 1 57 5 mm 2 26 in Measuring point...

Страница 362: ...09 0 15 mm 0 004 0 006 in Relief valve operating pressure 430 550 kPa 4 3 5 5 kg cm2 61 1 78 2 psi Oil pressure hot 50 kPa 0 5 kg cm2 7 11 psi at 1 500 r min Cooling system Filler cap opening pressure 93 3 122 7 kPa 0 93 1 23 kg cm2 13 2 17 5 psi Thermostat opening temperature 80 0 84 0 C 176 0 183 2 F Valve lift 7 0 mm 95 0 C 0 28 in 203 0 F Water pump type Single suction centrifugal pump Impelle...

Страница 363: ...it B 32 5 mm 1 28 in Primary sheave spring Part number 90501 606G9 PZ50 PZ50GT PZ50FX 90501 605G7 PZ50M 90501 556G7 PZ50VT USA Canada 90501 526G4 PZ50VT Europe PZ50MP Color code Pink Blue Pink PZ50 PZ50GT PZ50FX Green Yellow Green PZ50M Yellow Blue Yellow PZ50VT USA Canada Blue Gold Blue PZ50VT Europe PZ50MP Outside diameter 60 0 mm 2 36 in Wire diameter 6 0 mm 0 236 in PZ50 PZ50GT PZ50FX PZ50M 5 ...

Страница 364: ...50VT PZ50MP Material Steel Size 13 3 mm 0 524 in PZ50 PZ50GT PZ50FX 10 3 mm 0 406 in PZ50M USA Canada 13 9 mm 0 547 in PZ50M Europe 17 2 mm 0 677 in PZ50VT PZ50MP Quantity 3 pcs Hole quantity 3 pcs Center None PZ50M Part number 90261 06015 PZ50 PZ50GT PZ50FX 90261 06033 PZ50VT PZ50MP Material Steel Size 10 3 mm 0 406 in PZ50 PZ50GT PZ50FX 17 2 mm 0 677 in PZ50VT PZ50MP Quantity 3 pcs Hole quantity...

Страница 365: ...rad 931 kg mm rad 52 137 lb in rad PZ50 PZ50GT PZ50FX PZ50M 10 098 N mm rad 1 030 kg mm rad 57 659 lb in rad PZ50VT PZ50MP Number of coils 5 33 PZ50 PZ50GT PZ50FX PZ50M 5 99 PZ50VT PZ50MP Free length 85 mm 3 35 in Torque cam angle 39 PZ50 PZ50GT PZ50FX 37 PZ50M PZ50VT PZ50MP Drive chain Type Borg Warner Morse TEC 23RH302 5 80ASM PZ50 PZ50GT PZ50FX PZ50M Borg Warner Morse TEC 23RH302 5 82ASM PZ50VT...

Страница 366: ... 8 70 in PZ50 PZ50FX 209 0 mm 8 23 in PZ50GT 205 0 mm 8 07 in PZ50M 184 0 mm 7 24 in PZ50VT 216 0 mm 8 50 in PZ50MP Rear travel 412 0 mm 16 22 in PZ50 PZ50FX 407 0 mm 16 02 in PZ50GT 364 0 mm 14 33 in PZ50M 292 0 mm 11 50 in PZ50VT 313 0 mm 12 32 in PZ50MP Suspension spring rate Front 40 00 N mm 4 08 kg mm 228 40 lb in PZ50 PZ50FX 25 00 N mm 2 55 kg mm 142 75 lb in PZ50GT USA Canada 18 00 N mm 1 8...

Страница 367: ...6 lb 0 3 m s PZ50GT Europe 610 0 N 0 3 m s 62 2 kg 0 3 m s 137 1 lb 0 3 m s PZ50FX PZ50M 760 0 N 0 3 m s 77 5 kg 0 3 m s 170 8 lb 0 3 m s PZ50VT USA Canada PZ50MP 520 0 N 0 3 m s 53 0 kg 0 3 m s 116 9 lb 0 3 m s PZ50VT Europe Compression 690 0 N 0 3 m s 70 4 kg 0 3 m s 155 1 lb 0 3 m s PZ50 500 0 N 0 3 m s 51 0 kg 0 3 m s 112 4 lb 0 3 m s PZ50GT USA Canada 400 0 N 0 3 m s 40 8 kg 0 3 m s 89 9 lb 0...

Страница 368: ... 1 470 0 N 0 3 m s 149 9 kg 0 3 m s 330 5 lb 0 3 m s PZ50FX 710 0 N 0 3 m s 72 4 kg 0 3 m s 159 6 lb 0 3 m s PZ50M 530 0 N 0 3 m s 54 0 kg 0 3 m s 119 1 lb 0 3 m s PZ50VT USA Canada 840 0 N 0 3 m s 85 7 kg 0 3 m s 188 8 lb 0 3 m s PZ50VT Europe PZ50MP Slide runner Thickness 18 3 mm 0 72 in Wear limit 10 5 mm 0 41 in Track sprocket wheel Material Quadruple polyethylene Number of teeth 9 T PZ50 PZ50...

Страница 369: ...0 in PZ50 PZ50GT PZ50FX PZ50VT USA Canada 182 0 mm 7 17 in PZ50M 180 0 mm 7 09 in PZ50VT Europe PZ50MP Ski runner material Steel Ski cover No Ski runner wear limit 6 mm 0 24 in Plastic ski wear limit 13 mm 0 51 in PZ50 PZ50GT PZ50FX PZ50VT USA Canada 24 mm 0 95 in PZ50M PZ50VT Europe PZ50MP Ski suspension front suspension Type Independent wishbone Travel 235 0 mm 9 25 in PZ50 PZ50FX 214 0 mm 8 43 ...

Страница 370: ...2 lb 0 3 m s PZ50M 640 N 0 3 m s 65 3 kg 0 3 m s 143 9 lb 0 3 m s PZ50VT USA Canada 740 N 0 3 m s 75 5 kg 0 3 m s 166 4 lb 0 3 m s PZ50VT Europe 730 N 0 3 m s 74 4 kg 0 3 m s 164 1 lb 0 3 m s PZ50MP Compression 890 N 0 3 m s 90 8 kg 0 3 m s 200 1 lb 0 3 m s PZ50 670 N 0 3 m s 68 3 kg 0 3 m s 150 6 lb 0 3 m s PZ50GT 885 N 0 3 m s 90 2 kg 0 3 m s 198 9 lb 0 3 m s PZ50FX 850 N 0 3 m s 86 7 kg 0 3 m s...

Страница 371: ...ISHI PZ50 PZ50GT PZ50FX PZ50VT PZ50MP F8T83572 MITSUBISHI PZ50M Rectifier regulator Type Short circuit type Model Manufacturer FH012 SHINDENGEN No load regulated voltage DC 14 2 14 8 V Capacity DC 50 A Withstand voltage 40 V Battery Specific gravity 1 32 Manufacturer YUASA Type YTX14 BS 12V 12Ah Ten hour rate amperage 12 A Electric starter system Type Constant mesh type Starter motor Model Manufac...

Страница 372: ...senger grip warmer Heater resistance high 8 82 10 78 Ω Green Black PZ50VT Heater resistance low 14 67 17 93 Ω Yellow Black PZ50VT Circuit breaker Type Fuse Amperage for individual circuit Main fuse 40 A 1 Fuel injection system fuse 10 A 1 Headlight fuse 20 A 1 Signal fuse 7 5 A 1 Ignition fuse 20 A 1 Auxiliary DC jack fuse 3 A 1 PZ50GT PZ50FX PZ50M PZ50VT PZ50MP Radiator fan motor fuse 15 A 1 PZ50...

Страница 373: ...ion sensor Model Manufacture 8GC MITSUBISHI Resistance 189 231 Ω at 20 C 68 F Gray Black Intake air pressure sensor Model Manufacture 5PS DENSO Intake air temperature sensor Model Manufacture 8FP MITSUBISHI Resistance 290 390 kΩ at 80 C 176 F Knock sensor Model Manufacture 8GC MITSUBISHI Resistance 504 616 kΩ at 20 C 68 F Model PZ50 PZ50GT PZ50FX PZ50M PZ50VT PZ50MP ...

Страница 374: ... 10 1 0 7 2 Apply LOCTITE Rear engine mounting bolt spacer 7 0 7 5 1 Engine mounting nut 40 4 0 29 Engine mounting bracket 23 2 3 17 Oil pan 10 1 0 7 2 Oil pan engine oil drain bolt 30 3 0 22 Oil filter cartridge 17 1 7 12 Oil filter bolt 30 3 0 22 Oil pressure switch 15 1 5 11 Oil pump 12 1 2 8 7 OIl pump drive chain guide 10 1 0 7 2 Apply LOCTITE Oil pump housing cover 5 0 5 3 6 Oil tank engine ...

Страница 375: ...t lb and then tighten the connecting rod nuts further to reach the specified angle 120 130 Bearing retainer 10 1 0 7 2 Apply LOCTITE Right balancer weight 50 5 0 36 Connecting rod and cap See NOTE 3 A C magneto rotor 130 13 0 94 Apply the engine oil A C magneto rotor cover bolt M6 1 0 7 12 1 2 8 7 A C magneto rotor cover bolt M6 1 0 6 12 1 2 8 7 Apply LOCTITE Starter clutch 12 1 2 8 7 Apply LOCTIT...

Страница 376: ... switch 17 1 7 12 PZ50GT PZ50FX PZ50M PZ50VT PZ50MP Reverse position switch 17 1 7 12 PZ50GT PZ50FX PZ50M PZ50VT PZ50MP Battery bracket 23 2 3 17 Brake caliper bracket and drive chain cover 48 4 8 35 Brake caliper bleed screw 6 0 6 4 3 Brake caliper retaining pin 18 1 8 13 Brake hose union bolt 30 3 0 22 Parking brake assembly and drive chain cover 10 1 0 7 2 Lever and parking brake assembly 16 1 ...

Страница 377: ...T PZ50MP Shock absorber and rear pivot arm 49 4 9 35 2 up adjusting block 60 6 0 43 PZ50VT PZ50MP Set bolt collar 9 0 9 6 5 PZ50VT PZ50MP Rear pivot arm joint 35 3 5 25 PZ50 PZ50GT PZ50FX PZ50M Rear pivot arm and rear pivot arm bracket 72 7 2 52 Apply LOCTITE PZ50 PZ50GT PZ50FX PZ50M Rear pivot arm bracket and sliding frame 72 7 2 52 Apply LOCTITE PZ50 PZ50GT PZ50FX PZ50M Rear pivot arm bracket st...

Страница 378: ...PZ50VT PZ50MP Rear carrier 23 2 3 17 PZ50VT PZ50MP Tail brake light assembly 10 1 0 7 2 PZ50VT PZ50MP Handlebar holder 15 1 5 11 Multi function meter bracket 20 2 0 14 Steering joint and steering joint bracket 21 2 1 15 PZ50VT PZ50MP Steering joint bracket and steering column 16 1 6 11 PZ50VT PZ50MP Steering column and relay rod 21 2 1 15 Relay rod and steering control arm 21 2 1 15 Steering colum...

Страница 379: ...rm ball joint and steering knuckle 45 4 5 32 Lower arm and frame 65 6 5 47 Lower arm and steering knuckle 65 6 5 47 Stabilizer and stabilizer joint 45 4 5 32 PZ50 PZ50FX PZ50M Stabilizer joint and lower arm 34 3 4 25 PZ50 PZ50FX PZ50M Stabilizer bracket 7 0 7 5 1 PZ50GT PZ50VT PZ50MP Stabilizer holder 34 3 4 25 Parts to be tightened Tightening torque Remarks Nm m kg ft lb ...

Страница 380: ...dry threads Components should be at room temperature A Distance across flats B Outside thread diameter DEFINITION OF UNITS A nut B bolt General torque specifications Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 0 94 Unit Read Definition Measurement mm cm Millimeter Centimeter 10 3 meter 10 2 meter Lengt...

Страница 381: ...9 28 SPEC GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS ...

Страница 382: ...9 29 SPEC CABLE ROUTING E F G H I J K 6 8 7 0 A B 9 C D 1 2 3 4 5 L M N O P Q R S T U V W Y X Z ...

Страница 383: ... fuel tank breather hose to the steering gate with the plastic band 9 To the oil level switch 0 Fasten the sub wire harness parking brake cable and brake hose to the steering gate with the plastic band A Main switch B Fuel tank breather hose C Throttle cable D To the brake caliper E To the tail brake light F Fuel pump lead G Fuel hose H Fasten the fuel pump lead at the white tape to the fuel hose ...

Страница 384: ...9 31 SPEC CABLE ROUTING E F G H I J K 6 8 7 0 A B 9 C D 1 2 3 4 5 L M N O P Q R S T U V W Y X Z ...

Страница 385: ... ground lead ter minal and the Rectifier regulator using the same nut S Sub wire harness coupler T Left handlebar switch lead cou plers U Rectifier regulator V Connect the wire harness cou pler to the Rectifier regulator coupler shown in the illustration W A C magneto lead coupler X Fuel pump lead coupler Y Intake air pressure sensor cou pler Z Headlight coupler Intake air temperature sensor coupl...

Страница 386: ...9 33 SPEC CABLE ROUTING E F G H I J K 8 9 0 A B C D 1 2 3 4 5 6 7 L M N O P Q R S T U V W X Y Z ...

Страница 387: ... plers 9 Route the fuel hose and sub wire harness over the wire harness and fuel tank breather hose 0 Fasten the sub wire harness parking brake cable and brake hose to the steering gate with the plastic band A Fasten the sub wire harness and fuel tank breather hose to the steering gate with the plastic band B To parking brake C Fuel tank breather hose D Main switch E Tail brake light harness coupl...

Страница 388: ...9 35 SPEC CABLE ROUTING E F G H I J K 8 9 0 A B C D 1 2 3 4 5 6 7 L M N O P Q R S T U V W X Y Z ...

Страница 389: ...hose along the steering gate T Speed sensor coupler U Left handlebar switch lead cou plers V Install the frame ground lead ter minal and the Rectifier regulator using the same nut W Sub wire harness coupler X Rectifier regulator Y Crankshaft position sensor cou pler Z Fuel pump coupler Intake air pressure sensor cou pler Intake air temperature sensor coupler To the Headlight _ Fasten the headlight...

Страница 390: ...9 37 SPEC CABLE ROUTING A E H I J K L M 7 9 8 0 A B C D 1 2 3 4 5 6 N G F A W X Y Z O P Q R S T U V ...

Страница 391: ...50FX PZ50M PZ50VT PZ50MP 8 Fuel tank breather hose 9 Wire harness 0 Fasten the wire harness and fuel tank breather hose to the steer ing gate with the plastic band making sure to fasten the hose before and after the bend in the hose A Route the wire harness under the steering gate B Cylinder 1 ignition coil lead C Fasten the cylinder identification sensor lead to the cylinder head cover with the p...

Страница 392: ...9 39 SPEC A E H I J K L M 7 9 8 0 A B C D 1 2 3 4 5 6 N G F A W X Y Z O P Q R S T U V CABLE ROUTING ...

Страница 393: ... handlebar switch S To the sub wire harness T Location where the sub wire har ness branches off from the wire harness U To the speed sensor V To the frame ground lead W Fasten the cylinder identification sensor lead and wire harness with the plastic band as shown in the illustration making sure to position the band halfway between where the lead and where the sub wire harness branch off from the w...

Страница 394: ...9 41 SPEC CABLE ROUTING A B E E F G H I J K 8 8 9 9 9 0 0 0 A A A B B C C D 1 1 2 2 3 3 3 4 5 6 6 7 L M N O P Q R S A B ...

Страница 395: ...d lead A Wire harness B Speed sensor coupler C Fuel tank breather hose D Fasten the speed sensor lead and fuel tank breather hose to the frame rear cross member with the plastic band E To the auxiliary DC jack PZ50GT PZ50FX PZ50M PZ50VT PZ50MP F Fasten the speed sensor lead and fuel tank breather hose with the holder G Drive guard H Fasten the speed sensor lead and fuel tank breather hose with a p...

Страница 396: ...9 43 SPEC CABLE ROUTING A B E E F G H I J K 8 8 9 9 9 0 0 0 A A A B B C C D 1 1 2 2 3 3 3 4 5 6 6 7 L M N O P Q R S A B ...

Страница 397: ... cross member with the plastic band PZ50VT PZ50MP O Fasten the fuel tank breather hose auxiliary DC jack lead and speed sensor with the plastic band PZ50VT PZ50MP P To the left handlebar switch Q Frame rear cross member R To the speed sensor S Align the paint mark on the fuel tank breather hose with the top of the grommet ...

Страница 398: ...9 45 SPEC CABLE ROUTING F D G H I J K 8 9 0 A B C E 1 2 3 4 5 6 7 L M N N O O O P Q Q R R T S U T V W X Y Z a b c d e f g g g h h h i i i j j k k l l m m n PZ50 PZ50VT PZ50MP PZ50GT PZ50FX PZ50M ...

Страница 399: ...upler PZ50M PZ50VT PZ50MP D Knock sensor coupler E Radiator inlet hose F Fasten the wire harness radiator fan motor lead and knock sensor lead to the radiator outlet pipe with the plastic band making sure to align the radiator fan motor coupler with the wire har ness joint coupler Install the plastic band with its buckle posi tioned to the outside of the pipe and its end facing rearward PZ50M PZ50...

Страница 400: ...9 47 SPEC CABLE ROUTING F D G H I J K 8 9 0 A B C E 1 2 3 4 5 6 7 L M N N O O O P Q Q R R T S U T V W X Y Z a b c d e f g g g h h h i i i j j k k l l m m n PZ50 PZ50VT PZ50MP PZ50GT PZ50FX PZ50M ...

Страница 401: ...nd wire harness at the white tape to the oil tank with the plastic band Face the end of the plastic band upward Q Positive battery lead coupler R Negative battery lead coupler S Fasten the fuse box lead and negative battery leads with the plastic band The buckle of the plastic band on the right side of the leads T ECU lead U ECU V DC back buzzer lead PZ50GT PZ50FX PZ50M PZ50VT PZ50MP W Positive ba...

Страница 402: ...9 49 SPEC CABLE ROUTING F D G H I J K 8 9 0 A B C E 1 2 3 4 5 6 7 L M N N O O O P Q Q R R T S U T V W X Y Z a b c d e f g g g h h h i i i j j k k l l m m n PZ50 PZ50VT PZ50MP PZ50GT PZ50FX PZ50M ...

Страница 403: ...Z50FX PZ50M PZ50VT PZ50MP a Fasten the wire harness brake hose and parking brake cable with the plastic band b Battery c Fuse box d Main fuse e Starter relay f Starter relay lead g Load control relay h Fuel injection system relay i Headlight relay j Radiator fan motor relay PZ50GT PZ50FX PZ50M PZ50VT PZ50MP k Gear motor relay 1 PZ50GT PZ50FX PZ50M PZ50VT PZ50MP l Gear motor relay 2 PZ50GT PZ50FX P...

Страница 404: ...9 51 SPEC CABLE ROUTING C F G H I I J K L 9 0 A B C C C D E 1 1 1 2 3 4 5 5 5 6 6 6 7 M N O P Q R S T U V W X Y Z a b b b c c c c d e f g h i A A B B C A A B B 8 ...

Страница 405: ...ft handlebar switch leads behind the handlebar 0 Brake master cylinder A Left grip warmer B Brake light switch C Corrugated tube left grip warmer lead grip thumb warmer adjust ment switch lead brake light switch lead and headlight beam switch lead D Auxiliary DC jack PZ50GT PZ50FX PZ50M E Rectifier regulator F Cylinder identification sensor coupler G A C magneto coupler H Speed sensor lead I Press...

Страница 406: ...9 53 SPEC C F G H I I J K L 9 0 A B C C C D E 1 1 1 2 3 4 5 5 5 6 6 6 7 M N O P Q R S T U V W X Y Z a b b b c c c c d e f g h i A A B B C A A B B 8 CABLE ROUTING ...

Страница 407: ...utlet hose V Oil tank inlet hose W Throttle body heater outlet hose X Water pump inlet hose Y To the wire harness Z Route the water pump outlet hose and throttle body heater outlet hose behind the engine mounting bracket Coolant temperature sensor Throttle body heater inlet hose Thermostat cover _ To the parking brake a To the brake caliper b Brake hose c Throttle cable d Main switch e Pass the co...

Страница 408: ...9 55 SPEC CABLE ROUTING C F G H I I J K L 9 0 A B C C C D E 1 1 1 2 3 4 5 5 5 6 6 6 7 M N O P Q R S T U V W X Y Z a b b b c c c c d e f g h i A A B B C A A B B 8 ...

Страница 409: ...cing to the right Be sure to position the corrugated tube engine stop switch lead throttle switch lead right grip warmer lead and thumb warmer lead and corrugated tube left grip warmer lead grip thumb warmer adjustment switch lead brake light switch lead and headlight beam switch lead towards the front and fasten the throttle cable at the throttle cable adjusting nut h Position the corrugated tube...

Страница 410: ...9 57 SPEC CABLE ROUTING C E F G H H I J K 8 9 0 A B B B C D 1 1 1 2 3 4 5 5 5 6 6 6 7 L M N O P Q R S T U V W X Y Z _ a a a b b b b c d e e f g A A B B C A A B B ...

Страница 411: ...ch B Corrugated tube left grip warmer lead grip thumb warmer adjust ment switch lead brake light switch lead and headlight beam switch lead C Auxiliary DC jack D Rectifier regulator E Cylinder identification sensor coupler F A C magneto coupler G Speed sensor lead H Pressure regulator hose I Fuel tank breather hose J Throttle position sensor K Throttle body heater hose L Fasten the A C magneto lea...

Страница 412: ...9 59 SPEC CABLE ROUTING C E F G H H I J K 8 9 0 A B B B C D 1 1 1 2 3 4 5 5 5 6 6 6 7 L M N O P Q R S T U V W X Y Z _ a a a b b b b c d e e f g A A B B C A A B B ...

Страница 413: ...se W Water pump inlet hose X To the wire harness Y Route the water pump outlet hose and throttle body heater outlet hose behind the engine mounting bracket Z Coolant temperature sensor Throttle body heater inlet hose Thermostat cover To the parking brake _ To the brake caliper a Brake hose b Throttle cable c Main switch d Pass the corrugated tube engine stop switch lead throttle switch lead right ...

Страница 414: ...9 61 SPEC CABLE ROUTING C E F G H H I J K 8 9 0 A B B B C D 1 1 1 2 3 4 5 5 5 6 6 6 7 L M N O P Q R S T U V W X Y Z _ a a a b b b b c d e e f g A A B B C A A B B ...

Страница 415: ...s end facing to the right Be sure to position the corrugated tube engine stop switch lead throttle switch lead right grip warmer lead and thumb warmer lead and corrugated tube left grip warmer lead grip thumb warmer adjustment switch lead brake light switch lead and headlight beam switch lead towards the front and fasten the throttle cable at the throttle cable adjusting nut g Position the corruga...

Страница 416: ...9 63 SPEC CABLE ROUTING 1 2 3 4 5 6 ...

Страница 417: ...eadlight lead at the white tape to the shroud frame with the plastic band making sure to position the band near the bracket 5 Fasten the headlight lead to the shroud frame with the plastic band making sure to route the lead along the bend in the frame 6 Route the headlight lead to the inside of the shroud frame ...

Страница 418: ...9 65 SPEC CABLE ROUTING 8 9 1 2 3 4 4 5 6 7 PZ50 PZ50GT PZ50FX PZ50M PZ50VT PZ50MP ...

Страница 419: ...with the plastic band Face the end of the plastic band downward 4 Tail brake light 5 Passenger grip warmer switch coupler 6 Connect the passenger grip warmer coupler and then place it in the rear lower cover 7 Passenger grip warmer switch 8 Fasten the tail brake light lead to the rear carrier with the plastic band 9 Connect the tail brake light cou pler and then place it in the tail brake light co...

Страница 420: ... 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 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 G W Gy B Y W Y Y W W L P W R L Y G Ch B L L Y Lg R W Br W L W P Y L L W B R W O Y R Br L L R B R B Lg B G B Gy R Br W B L 40A 20A 20A 7 5A R W Gy R R W BLACK...

Страница 421: ...humb warmer adjustment switch X CO adjustment coupler Y Engine ground Z Frame ground Brake light switch Tail brake light Fuel sender _ Oil level switch a Speedometer unit b Multi function meter c Warning light d Low coolant temperature indica tor light e Knock control system indicator light f High beam indicator light g Headlight h Headlight relay i Headlight beam switch j Ignition fuse k Signal f...

Страница 422: ... Gy R Sb W Br W B L 40A 20A 15A 3A 4A 7 5A R W Gy R R W BLACK A Gy R A A R B R B A BLACK DARK GREEN L P B L L P B L Gy R Gy R C B L B L C G W G W W B C Ch Ch Ch A BLACK BLACK W Lg Lg BLACK GRAY Y B L L BLACK GRAY R L R L B BLACK R B BLACK GRAY BLACK BLACK B R L BLACK E W R W R E W L W L W R W L B R W R W L B Y R B Y R Br R G Y L R W Br R Br R L L L R W G Y B L B L BLACK W W O B O B B R G W B G B O...

Страница 423: ...ight i Fuel sender j Oil level switch k Speedometer unit l Multi function meter m Warning light n Low coolant temper ature indicator light o Knock control sys tem indicator light p Drive position indi cator light q Reverse position indicator light r High beam indicator light s Headlight t Headlight relay u Headlight beam switch v Radiator fan motor w Radiator fan motor relay x Auxiliary DC jack y ...

Страница 424: ...E MANUAL PZ50W PZ50GTW PZ50FXW PZ50MW PZ50VTW PZ50MPW LIT 12618 02 58 8GC 28197 10 PRINTED ON RECYCLED PAPER PRINTED IN U S A 2006 07 CR E YAMAHA MOTOR CO LTD Cover_SMB fm Page 1 Thursday July 27 2006 9 56 AM ...

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