Page 1 The best Service 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!
Page 2 SERVICE MANUAL PZ50W PZ50GTW PZ50FXW PZ50MW PZ50VTW PZ50MPW LIT-12618-02-58 8GC-28197-10...
Page 3: How To Use This Manual
NOTICE HOW TO USE THIS MANUAL This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and Particularly important information is distinguished in their qualified mechanics. It is not possible to put an this manual by the following notations: entire mechanic’s education into one manual, so it...
Page 4: Periodic Inspection And
ILLUSTRATED SYMBOLS (Refer to the illustration) INSP INFO Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Periodic inspection and adjustment POWR 3 Chassis CHAS 4 Power train 5 Engine 6 Cooling system 7 Fuel injection system...
Page 5 INDEX GENERAL INFORMATION INFO PERIODIC INSPECTION AND INSP ADJUSTMENT CHASSIS CHAS POWER TRAIN POWR ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM – ELECTRICAL ELEC SPECIFICATIONS SPEC...
Page 6: Table Of Contents
PZ50/PZ50GT/PZ50FX/PZ50M ....3-1 THROTTLE BODY PZ50VT/PZ50MP ........3-3 SYNCHRONIZATION ....... 2-13 ENGINE IDLE SPEED ADJUSTMENT..2-14 STEERING ............3-4 THROTTLE CABLE FREE PLAY PZ50W/PZ50GT/PZ50FX/PZ50M....3-4 ADJUSTMENT.......... 2-15 PZ50VT/PZ50MP ........3-6 THROTTLE OVERRIDE SYSTEM REMOVAL..........3-10 (T.O.R.S.) CHECK ........2-16 INSPECTION ..........3-10 COMPRESSION PRESSURE INSTALLATION.........
Page 7 PZ50VT “Europe”/PZ50MP....... 3-15 BRAKE CALIPER ASSEMBLY ....4-37 PZ50M ............3-16 BRAKE CALIPER INSTALLATION ... 4-37 INSPECTION ..........3-17 INSPECTION ..........4-39 BRAKE MASTER CYLINDER FRONT SUSPENSION ........3-18 ASSEMBLY..........4-39 PZ50/PZ50FX/PZ50M....... 3-18 INSTALLATION......... 4-39 PZ50GT/PZ50VT/PZ50MP ....... 3-20 HANDLING NOTES ........3-22 SLIDE RAIL SUSPENSION......
Page 8 CYLINDER HEAD........... 5-28 CHAPTER 7. REMOVAL ..........5-29 FUEL INJECTION SYSTEM INSPECTION ..........5-29 INSTALLATION ........5-30 FUEL INJECTION SYSTEM ......7-1 VALVES AND VALVE SPRINGS....5-32 WIRING DIAGRAM ........7-2 REMOVAL ..........5-33 ECU SELF-DIAGNOSTIC FUNCTION ..7-4 INSPECTION ..........5-34 SELF-DIAGNOSTIC FUNCTION TABLE..
Page 9 LIGHTING SYSTEM ........8-22 CHAPTER 9. CIRCUIT DIAGRAM........8-22 SPECIFICATIONS TROUBLESHOOTING......8-24 BULB(S)............ 8-26 HEADLIGHT BEAM SWITCH ....8-26 GENERAL SPECIFICATIONS......9-1 HEADLIGHT RELAY......... 8-27 LOAD CONTROL RELAY......8-27 MAINTENANCE SPECIFICATIONS....9-5 ENGINE ............9-5 SIGNAL SYSTEM........... 8-28 POWER TRAIN......... 9-10 CIRCUIT DIAGRAM........
Page 10: Chapter 1. General Information
MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame 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.
Page 11: Important Information
ALL REPLACEMENT PARTS We recommend using genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for assembly and adjustments.
Page 12: Gaskets, Oil Seals, And O-Rings
IMPORTANT INFORMATION INFO GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.
Page 13: Special Tools
SPECIAL TOOLS INFO SPECIAL TOOLS Some special tools are necessary for a completely accurate tune-up and assembly. Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques. NOTE: •...
Page 14 SPECIAL TOOLS INFO • Cooling system tester P/N: YU-24460-01 90890-01325 • Adapter P/N: YU-33984 90890-01352 This tester and its adapter are used for checking the cooling system. • Oil filter wrench P/N: YM-01469 90890-01469 This tool is needed to loosen or tighten the oil filter cartridge. •...
Page 15 SPECIAL TOOLS INFO • 40 and 50 mm bearing driver P/N: YM-04058 90890-04058 • Mechanical seal installer P/N: YM-04145 90890-04145 These tools are used to install the water pump seal. • Rotor holding tool P/N: YU-01235 90890-01235 This tool is used to hold the camshaft sprocket. •...
Page 16: For Power Train Service
• Engine mount spacer wrench P/N: YS-01516 90890-01516 Used to turn the engine mounting bolts when removing/installing engine. • Yamaha bond No. 1215 P/N: 90890-85505 ® (Three Bond No.1215 This bond is used to seal two mating surfaces (e.g., crankcase mating sur- faces.)
Page 17: For Fuel Injection Service
SPECIAL TOOLS INFO • Clutch bushing press P/N: YS-42424 This tool is used for removing and installing the post bushings (primary sheave cap bush, sliding sheave bush and torque cam bush). • Track clip installer P/N: YS-91045-C 90890-01721 This tool is used for installing the track clip. FOR FUEL INJECTION SERVICE •...
Page 18 SPECIAL TOOLS INFO • Digital circuit tester P/N: YU-A1927 90890-03174 This instrument is necessary for checking the electrical componenets.
Page 19: Periodic Inspection And Adjustment
Replace if necessary. ∗ Idle speed Check and adjust engine idle speed. ∗ Fuel injection Adjust synchronization. Check for leakage. ∗ Exhaust system Tighten or replace gasket if necessary. ∗ It is recommended that these items be serviced by a Yamaha dealer.
Page 20: General Maintenance And Lubrication Chart
Inspect ramp shoes/bushings for wear-for secondary. Replace if necessary. Lubricate with specified grease. ∗ Steering column bearing Lubricate with specified grease. ∗ Ski and front suspension Lubricate with specified grease. ∗ It is recommended that these items be serviced by a Yamaha dealer.
Page 21 Tool kit and recommended Check for proper placement. equipment ∗ It is recommended that these items be serviced by a Yamaha dealer. NOTE: Brake system: • After disassembling the master cylinder or caliper cylinder, always change the brake fluid. Regularly check the brake fluid level and add fluid if necessary.
Page 22: Engine
INSP SPARK PLUGS/FUEL LINE INSPECTION ENGINE SPARK PLUGS 1. 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) 2. Remove: • Spark plug caps •...
Page 23: Cooling System
INSP COOLING SYSTEM COOLING SYSTEM Coolant replacement NOTE: The coolant should be changed at least every sea- son. 1. Place the machine on a level surface. 2. Remove: • Right side panel • Right side cover Refer to “COWLINGS” in CHAPTER 3. 3.
Page 24 INSP COOLING SYSTEM 7. Connect: • Radiator outlet hose 1 8. Fill: • 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) CAUTION:...
Page 25 INSP COOLING SYSTEM/VALVE CLEARANCE ADJUSTMENT Air bleeding steps: • Remove the cap 1 on the radiator outlet pipe 1. • While slowly adding coolant to the coolant filler, drain the coolant until no more air bubbles appear. • Install the cap 1. •...
Page 26: Valve Clearance Adjustment
INSP VALVE CLEARANCE ADJUSTMENT 3. Remove: • Cylinder head cover Refer to “CAMSHAFTS” in CHAPTER 5. • Timing mark accessing screw 1 • Crankshaft end accessing screw 2 4. Measure: • Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake valve: 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in)
Page 27 INSP VALVE CLEARANCE ADJUSTMENT 5. Remove: • Intake camshaft • Exhaust camshaft NOTE: • Refer to “CAMSHAFTS” in CHAPTER 5. • When removing the timing chain and camshafts, fasten a wire to the timing chain to retrieve it if it falls into the crankcase.
Page 28 INSP VALVE CLEARANCE ADJUSTMENT EXAMPLE: Original valve pad number = 148 (thickness = 1.48 mm (0.058 in)) Rounded value = 150 • Locate the rounded number 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.
Page 29 INSP VALVE CLEARANCE ADJUSTMENT VALVE PAD SELECTION TABLE INTAKE Measured INSTALLED PAD NUMBER clearance ↓ 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 ~ 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 ~ 0.07...
Page 30 INSP VALVE CLEARANCE ADJUSTMENT • Install the new valve pad 1 and the valve lifter NOTE: • Apply molybdenum disulfide oil to the valve pad and the valve lifter. • The valve lifter must turn smoothly when rotated by hand. •...
Page 31: Throttle Body Synchronization
INSP THROTTLE BODY SYNCHRONIZATION THROTTLE BODY SYNCHRONIZATION NOTE: Prior to synchronizing the throttle bodies, the valve clearance and the engine idle speed should be properly adjusted. 1. Remove: • Headlight assembly (PZ50/PZ50GT/PZ50FX/ PZ50M) • Air filter case assembly Refer to “COWLINGS” in CHAPTER 3. 2.
Page 32: Engine Idle Speed Adjustment
THROTTLE BODY SYNCHRONIZATION/ INSP ENGINE IDLE SPEED ADJUSTMENT Adjustment steps: • Synchronize throttle body #1 and throttle body #2 by turning the synchronizing screws 1 in either direction until both gauges read the same. NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again.
Page 33: Throttle Cable Free Play Adjustment
ENGINE IDLE SPEED ADJUSTMENT/ INSP THROTTLE CABLE FREE PLAY ADJUSTMENT 3. Adjust: • Engine idle speed Adjustment steps: • Remove the rubber cap 1. • Turn the idle adjusting screw 2 in or out until the specified engine idle speed is obtained. Turning in →...
Page 34: Throttle Override System (T.o.r.s.) Check
THROTTLE CABLE FREE PLAY ADJUSTMENT/ INSP THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK • Tighten the locknut. NOTE: If the specified throttle cable free play cannot be obtained on the throttle body side of the cable, use the adjusting nut on the handlebar side. (PZ50/ PZ50GT/PZ50FX/PZ50M) Handlebar side adjustment steps: (PZ50/PZ50GT/PZ50FX/PZ50M)
Page 35: Compression Pressure Measurement
THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK/ INSP COMPRESSION PRESSURE MEASUREMENT WARNING If the engine does not run between 2,800 and 3,000 r/min, stop the engine by turning the main switch to the “OFF” position and check the electrical system. COMPRESSION PRESSURE MEASUREMENT NOTE: Insufficient compression pressure will result in a...
Page 36 INSP COMPRESSION PRESSURE MEASUREMENT 6. Measure: • Compression pressure Above the maximum pressure → Inspect the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure → Squirt a few drops of oil into the affected cylinder and measure again.
Page 37: Engine Oil Level Inspection
INSP ENGINE OIL LEVEL INSPECTION ENGINE OIL LEVEL INSPECTION 1. Inspect: • Engine oil level CAUTION: Do not run the engine with too much or not enough oil in the oil tank. Oil could flow into the air filter and the engine could be damaged. Inspection steps: •...
Page 38: Engine Oil Replacement
ENGINE OIL LEVEL INSPECTION/ INSP ENGINE OIL REPLACEMENT • Start the engine, warm it up for several minutes, and then turn it off. • Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
Page 39 INSP ENGINE OIL REPLACEMENT 8. Remove: • Cylinder head cap 1 9. Remove: • Oil pan engine oil drain bolt 1 10. Remove: • Oil tank engine oil drain bolt 1 11. Drain: • Engine oil (completely from the oil pan and oil tank) 12.
Page 40 INSP ENGINE OIL REPLACEMENT • Apply a thin coat of engine oil onto the O-ring 4 of the new oil filter cartridge. CAUTION: Make sure that the O-ring 4 is positioned cor- rectly in the groove of the oil filter cartridge. •...
Page 41: Cylinder Head Breather Hose Inspection
ENGINE OIL REPLACEMENT/CYLINDER HEAD BREATHER INSP HOSE INSPECTION/THROTTLE BODY JOINTS INSPECTION 17. Inspect: • Engine oil pressure Inspection steps: • Remove the exhaust pipe joint upper cover. Refer to “EXHAUST PIPE AND MUFFLER” in CHAPTER 5. • Slightly loosen the oil gallery bolt 1. •...
Page 42: Checking The Air Filter Element
INSP CHECKING THE AIR FILTER ELEMENT CHECKING THE AIR FILTER ELEMENT 1. Remove: • Air filter case cover Refer to “COWLINGS” in CHAPTER 3. 2. Lift up the air filter element frame and remove the air filter element. 3. Clean: •...
Page 43: Exhaust System Inspection
INSP EXHAUST SYSTEM INSPECTION EXHAUST SYSTEM INSPECTION 1. 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) 2. Inspect: • Exhaust pipe joints 1 •...
Page 44: Power Train
INSP SHEAVE OFFSET ADJUSTMENT POWER TRAIN SHEAVE OFFSET ADJUSTMENT 1. Remove: • Left side panel • Left side cover Refer to “COWLINGS” in CHAPTER 3. 2. Remove: • Drive V-belt 3. Measure: • Sheave offset a Use a straightedge that is approximately 470 mm (18.5 in) long, 20 mm (0.79 in) wide, and 4 mm (0.16 in) thick.
Page 45 INSP SHEAVE OFFSET ADJUSTMENT • Install secondary sheave, secondary sheave bolt and washer. Secondary sheave bolt: 60 Nm (6.0 m · kg, 43 ft · lb) • Recheck the sheave offset. If out of specifica- tion, repeat the above steps. NOTE: When adjusting the sheave offset, the secondary sheave free play (clearance) should be adjusted.
Page 46: Drive V-Belt
INSP DRIVE V-BELT DRIVE V-BELT WARNING When installing the new V-belt, make sure that it is positioned from 1.5 mm (0.06 in) above the edge of the secondary sheave to –0.5 mm (–0.02 in) below the edge a. If the V-belt is not positioned correctly, the clutch engagement speed will be changed.
Page 47: Engagement Speed Check
ENGAGEMENT SPEED CHECK/ INSP PARKING BRAKE ADJUSTMENT ENGAGEMENT SPEED CHECK 1. Place the machine on a level surface of hard- packed snow. 2. Inspect: • Clutch engagement speed Inspection steps: • Start the engine, and open the throttle lever gradually. •...
Page 48: Brake Fluid Level Inspection
PARKING BRAKE ADJUSTMENT/ INSP BRAKE FLUID LEVEL INSPECTION 3. Adjust: • Parking brake cable Adjustment steps: • Loosen the locknut 1. • Turn the adjuster 2 in or out until the specified distance a is obtained. Turning in → Distance a is increased. Turning out →...
Page 49: Brake Pad Inspection
BRAKE FLUID LEVEL INSPECTION/ INSP BRAKE PAD INSPECTION NOTE: For a correct reading of the brake fluid level, make sure that the top of the handlebar brake master cyl- inder reservoir is horizontal. CAUTION: Brake fluid may corrode painted surfaces or plastic parts.
Page 50: Brake Hose Inspection
BRAKE HOSE INSPECTION/ INSP AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) BRAKE HOSE INSPECTION 1. Inspect: • Brake hose Cracks/damage/wear → Replace. 2. Check: • Fluid leakage Apply the brake lever several times. Fluid leakage → Replace the defective parts. AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) WARNING Bleed the brake system in the following cases:...
Page 51: Drive Chain
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/ INSP DRIVE CHAIN j. Tighten the bleed screw. Bleed screw: 6 Nm (0.6 m · kg, 4.3 ft · lb) NOTE: If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bub- bles in the system have disappeared.
Page 52 INSP DRIVE CHAIN • Remove the dipstick and check that the oil reaches the bottom of the dipstick. If the oil does not reach the bottom of the dipstick, add sufficient oil to raise it to the correct level. Recommended oil: Gear oil “GL-3”...
Page 53 INSP DRIVE CHAIN/TRACK TENSION ADJUSTMENT Chain slack adjustment 1. Adjust: • Drive chain slack Adjustment steps: • Loosen the locknut 1. • Turn the adjusting bolt 2 clockwise until it is fin- ger tight, and then loosen it 1/4 turn. •...
Page 54: Track Tension Adjustment
INSP TRACK TENSION ADJUSTMENT 3. Adjust: • Track deflection Adjustment steps: a. Place the machine onto a suitable stand to raise the track off of the ground. b. Loosen the rear axle nut 1. c. Start the engine and rotate the track once or twice.
Page 55: Slide Runner Inspection
SLIDE RUNNER INSPECTION/ INSP MAXIMIZING DRIVE TRACK LIFE SLIDE RUNNER INSPECTION 1. Inspect: • Slide runner 1 Cracks/damage/wear → Replace. 2. Measure: • Slide runner wear limit a Out of specification → Replace. Slide runner wear limit: 10.5 mm (0.41 in) MAXIMIZING DRIVE TRACK LIFE Recommendations Track tension...
Page 56 To minimize possible damage, consult your stud man- ufacturer for installation and stud pattern recom- mendations. Yamaha does not recommend track studding. 2-38...
Page 57: Chassis
INSP SKI/SKI RUNNER/STEERING SYSTEM CHASSIS SKI/SKI RUNNER 1. Inspect: • Ski • Ski runner Damage/wear → Replace. • Ski runner thickness a • Plastic ski thickness b Out of specification → Replace. Ski runner wear limit: 6 mm (0.24 in) Plastic ski wear limit: PZ50/PZ50GT/PZ50FX/PZ50VT “USA/Canada”:...
Page 58 INSP STEERING SYSTEM Toe-out adjustment 1. Place the machine on a level surface. 2. Measure: • Ski toe-out (a – c) • Ski stance b Point the skis forward. Out of specification → Adjust. Ski toe-out: 0 ~ 15 mm (0 ~ 0.59 in) Ski stance (center to center): PZ50/PZ50GT/PZ50FX/PZ50VT/ PZ50MP:...
Page 59: Lubrication
INSP LUBRICATION LUBRICATION Brake lever, throttle lever and throttle cable end 1. Lubricate the brake lever pivot, throttle lever and the ends of the throttle cables. Recommended lubricant: ESSO Beacon 325 Grease or Aeroshell Grease #7A WARNING Apply a dab of grease onto only the end of the cables.
Page 60: Electrical
INSP HEADLIGHT BEAM ADJUSTMENT/BATTERY INSPECTION ELECTRICAL HEADLIGHT BEAM ADJUSTMENT 1. Place the machine on a level surface. 2. Place the machine in front of a wall at the rec- ommended distance D. Refer to the table below. 3. Measure the distance H from the floor to the center of the headlight and place a mark on the wall at that height.
Page 61 INSP BATTERY INSPECTION First aid in case of bodily contact: External • SKIN – Wash with water. • EYES – Flush with water for 15 minutes and get immediate medical attention. Internal • Drink large quantities of water or milk fol- lowed with milk of magnesia, beaten egg or vegetable oil.
Page 62 INSP BATTERY INSPECTION 4. Inspect: • Battery charge Inspection steps: • Connect a pocket tester to the battery terminals. Positive tester probe → positive battery terminal Negative tester probe → negative battery terminal NOTE: • The charge state of a MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is discon- nected).
Page 63 INSP BATTERY INSPECTION 5. Charge: • Battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. CAUTION: • Make sure that the battery vent is free of obstructions. • Never remove the MF battery sealing caps. •...
Page 64 INSP BATTERY INSPECTION Charging method using a variable voltage charger Charger AMP meter NOTE: Measure the open-circuit Voltage should be measured 30 voltage prior to charging. minutes after the machine is stopped. Connect a charged and NOTE: AMP meter to the battery Set the charging voltage at 16 ~ 17 V.
Page 65 INSP BATTERY INSPECTION Charging method using a constant voltage charger NOTE: Voltage should be measured 30 Measure the open-circuit minutes after the machine is voltage prior to charging. stopped. Connect a charger and AMP meter to the battery and start charging. Make sure that the current is higher than the stan- dard charging current writ-...
Page 66 INSP BATTERY INSPECTION/FUSE INSPECTION 6. Install: • Battery 7. Connect: • Battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, then the negative battery lead 2. 8. Check: • Battery terminals Dirt → Clean with a wire brush. Loose connection →...
Page 67: Fuse Inspection
INSP FUSE INSPECTION 3. Replace: • Blown fuse Replacing steps: • Set the main switch to “OFF”. • Install a new fuse of the correct amperage. • Set the main switch to “ON” and verify if the electrical circuit is operational. •...
Page 68: Tuning
INSP CLUTCH TUNING CLUTCH L Blue P Pink High altitude R Red Specifications Model: PZ50/PZ50FX ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m È Elevation (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft) (8,000 ~ 10,000 ft)
Page 69 INSP CLUTCH L Blue P Pink R Red Specifications Model: PZ50GT ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m È Elevation (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft) (8,000 ~ 10,000 ft) ←...
Page 70 INSP CLUTCH G Green R Red Y Yellow Specifications Model: PZ50M ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m È Elevation (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft) (8,000 ~ 10,000 ft) ←...
Page 71 INSP CLUTCH L Blue Y Yellow Specifications Model: PZ50VT “USA/Canada” ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m È Elevation (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft) (8,000 ~ 10,000 ft) ←...
Page 72 INSP CLUTCH Go Gold L Blue Specifications Model: PZ50VT “Europe”/PZ50MP ~ 800 m 600 ~ 1,400 m 1,200 ~ 2,000 m 1,800 ~ 2,600 m 2,400 ~ 3,000 m È Elevation (~ 2,500 ft) (2,000 ~ 4,500 ft) (4,000 ~ 6,500 ft) (6,000 ~ 8,500 ft) (8,000 ~ 10,000 ft) ←...
Page 73 INSP CLUTCH/GEAR SELECTION The clutch may require tuning depending upon where the machine will be operated and the desired handling characteristics. The clutch can be tuned by changing the engagement and shifting speeds. Clutch engagement speed is defined as the engine speed at which the machine first begins to move from a complete stop.
Page 74: Gear Selection
INSP GEAR SELECTION 1 Chain and sprocket part number È Parts name É Teeth & links Ê Parts no. Ë Standard 17 teeth 8GC-17682-70 PZ50M “USA/Canada” PZ50/PZ50FX/ 18 teeth 8GC-17682-80 PZ50VT “Europe”/PZ50MP Ì Drive sprocket PZ50M “Europe”/ 19 teeth 8GC-17682-90 PZ50VT “USA/Canada”...
Page 75 INSP GEAR SELECTION 4 Secondary spring twist angle 90508-55007 (Red) È Seat É Sheave 35° 65° 95° 5° 45° 75° 105° 15° 55° 85° 115° 25° 90508-55012 (Brown)/90508-58007 (Blue)/90508-60015 (Yellow) È Seat É Sheave 40° 70° 100° 10° 50° 80° 110°...
Page 76 INSP GEAR SELECTION 6 Primary spring È Spring identification color code É Spring rate color Ê Preload color Ì Spring rate Ð Outside Í Preload Ï Wire gauge Ò Free length Ë Parts No. Î Color Ñ No. of coils Ó...
Page 77 INSP GEAR SELECTION 7 Clutch weight É Weight g (oz) È Parts No. Ê Shape & ID mark Ë Standard without bush and rivets 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...
Page 78 INSP GEAR SELECTION 8 Weight rivets Ê Length Ë Weight È Parts No. É Material Ì Standard Í Effects mm (in) g (oz) Î Increased force IN: PZ50VT “Europe”/PZ50MP 90261-06033 Steel 17.2 (0.677) 4.5 (0.159) CENTER, OUT: PZ50VT/ PZ50MP IN: PZ50M “Europe”/PZ50VT 90261-06034 Steel 13.9 (0.547)
Page 79: Front Suspension
INSP FRONT SUSPENSION FRONT SUSPENSION È Spring preload 1. Adjust: • Spring preload Adjustment steps: • Loosen the locknut 1. • Turn the spring seat 2 in or out. PZ50GT/PZ50MP Standard Spring seat Shorter ← → Longer distance É Harder ← →...
Page 80 INSP FRONT SUSPENSION CAUTION: Be sure that the left and right spring preload are the same. WARNING These shock absorber contain highly pressur- ized nitrogen gas. Do not tamper with or attempt to open the shock absorber assemblies. Do not subject the shock absorber assemblies to flames or high heat, which could cause it to explode.
Page 81 INSP FRONT SUSPENSION/REAR SUSPENSION Compression damping force adjustment (PZ50FX) The compression damping force can be adjusted by turning the adjuster 1. 12 clicks out 7 clicks out 2 clicks out Adjuster position Minimum Standard Maximum Turns out b* ← → Turns in a Compres- Soft ←...
Page 82: Rear Suspension
INSP REAR SUSPENSION Adjustment steps: È • Remove the stopper band bolts 1, nuts and washers. • Adjust the length of the stopper bands 2 by No.1 inserting the bolts in different holes. No.2 No.3 Standard setting: No.4 No. 1 hole (PZ50/PZ50MP) No.5 No.
Page 83 INSP REAR SUSPENSION Spring preload È 1. Adjust: • Spring preload Adjustment step: Front side • Loosen the locknut 1. • Turn the spring seat 2 in or out. PZ50GT “Europe” Standard Spring seat Shorter ← → Longer distance Harder ← →...
Page 84 INSP REAR SUSPENSION • Turn the adjusting ring 3 to the proper position. É PZ50/PZ50GT “USA/Canada”/PZ50M Spring adjuster position Softer ← → Harder Preload Standard PZ50VT “USA/Canada” Spring adjuster position Ê Softer ← → Harder Preload Standard WARNING This shock absorber contains highly pressur- ized nitrogen gas.
Page 85 INSP REAR SUSPENSION Rear suspension damping force adjustment The damping force can be adjusted by turning the adjuster 1. PZ50FX 20 clicks out 11 clicks out 1 click out Adjuster position Minimum Standard Maximum Turns out b* ← → Turns in a Damping Soft ←...
Page 86 INSP REAR SUSPENSION Control rod (PZ50VT/PZ50MP) 1. Adjust: • Control rod stroke a CAUTION: Make sure the adjusting bolt ends are set at the same position on each side. Adjustment steps: • Loosen the locknut 1. • Turn the adjusting nut 2 in or out to adjust the control rod stroke.
Page 87 INSP REAR SUSPENSION 2-up adjusting block (PZ50VT/PZ50MP) 1. Position: • 2-up adjusting blocks 2-up Solo (rider and (rider only) passenger) Position Spring force Soft Hard NOTE: Be sure to change the position of the 2-up adjusting blocks when there is no load (rider or cargo) on the snowmobile.
Page 88: Chassis
CHAS COWLINGS CHASSIS COWLINGS PZ50/PZ50GT/PZ50FX/PZ50M PZ50FX È: kg, 5.8 ft 8 Nm (0.8 m • • È È È È Order Job name/Part name Q’ty Remarks Cowling removal Remove the parts in the order listed below. Windshield PZ50GT Front panel Air filter case cover Headlight cover Left side panel...
Page 89 CHAS COWLINGS PZ50FX È: kg, 5.8 ft 8 Nm (0.8 m • • È È È È Q’ty Remarks Order Job name/Part name Cylinder-#1 intake air pressure sensor cou- Disconnect. pler Intake air temperature sensor coupler Disconnect. Cylinder head breather hose Disconnect.
Page 90: Pz50Vt/Pz50Mp
CHAS COWLINGS PZ50VT/PZ50MP È: kg, 5.8 ft 8 Nm (0.8 m • • È È Order Job name/Part name Q’ty Remarks Cowling removal Remove the parts in the order listed below. Air filter case cover Left side panel Right side panel Left side cover Right side cover Left lower cover...
Page 91: Steering
CHAS STEERING STEERING PZ50/PZ50GT/PZ50FX/PZ50M È: kg, 7.2 ft 10 Nm (1.0 m • • É É: kg, 11 ft 15 Nm (1.5 m • • Ê: kg, 11 ft 16 Nm (1.6 m • • Ë: 20 Nm (2.0 m kg, 14 ft •...
Page 92 CHAS STEERING È: kg, 7.2 ft 10 Nm (1.0 m • • É É: kg, 11 ft 15 Nm (1.5 m • • Ê: 16 Nm (1.6 m kg, 11 ft • • Ë: kg, 14 ft 20 Nm (2.0 m •...
Page 93: Pz50Vt/Pz50Mp
CHAS STEERING PZ50VT/PZ50MP É È: 10 Nm (1.0 m kg, 7.2 ft • • É: 15 Nm (1.5 m kg, 11 ft • • Ê: kg, 11 ft 16 Nm (1.6 m • • Ë: kg, 14 ft 20 Nm (2.0 m •...
Page 94 CHAS STEERING É È: kg, 7.2 ft 10 Nm (1.0 m • • É: kg, 11 ft 15 Nm (1.5 m • • Ê: kg, 11 ft 16 Nm (1.6 m • • Ë: kg, 14 ft 20 Nm (2.0 m •...
Page 95 CHAS STEERING 4 10 É È: kg, 15 ft 21 Nm (2.1 m • • É: kg, 17 ft 23 Nm (2.3 m • • Ê: kg, 18 ft 25 Nm (2.5 m • • Í Ë: kg, 20 ft 28 Nm (2.8 m •...
Page 96 CHAS STEERING 4 10 É È: kg, 15 ft 21 Nm (2.1 m • • É: kg, 17 ft 23 Nm (2.3 m • • Ê: kg, 18 ft 25 Nm (2.5 m • • Í Ë: kg, 20 ft 28 Nm (2.8 m •...
Page 97: Removal
CHAS STEERING REMOVAL 1. Straighten the lock washer tabs. INSPECTION 1. Inspect: • Handlebar • Steering column Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent column. This may dangerously weaken the column. 2. Inspect: • Bearings (steering column) •...
Page 98: Installation
CHAS STEERING INSTALLATION 1. Install: • Tie rod 1 • Locknuts 2 • Joints 3 È Tie rod part É Set length Ê Tie rod length b number 8GC-23830-00 (PZ50/PZ50GT/ 504.7 mm 433.2 mm PZ50FX/ (19.87 in) (17.06 in) PZ50VT/ È...
Page 99 CHAS STEERING 4. Install: • Steering arm 1 NOTE: Align the punch mark a on the steering arm 1 with the punch mark b on the pivot arm shaft 2. 5. Install: • Steering shaft 1 • Locknuts 2 • Joints 3 È...
Page 100 CHAS STEERING 7. Adjust: • Skis Adjustment steps: • Temporarily install the handlebar. • Hold the handlebar straight and check that the skis and relay arms are at right angles to the handlebar. • Install the steering linkage alignment plate 1. Steering linkage alignment plate: 90890-01515, YS-01515 •...
Page 101: Ski
CHAS PZ50/PZ50GT/PZ50FX/PZ50VT “USA/Canada” Order Job name/Part name Q’ty Remarks Ski removal Remove the parts in the order listed below. Cotter pin Bolt Collar Collar Washer Collar Ski stopper For installation, reverse the removal proce- dure. 3-14...
Page 102: Pz50Vt "Europe"/Pz50Mp
CHAS PZ50VT “Europe”/PZ50MP Order Job name/Part name Q’ty Remarks Ski removal Remove the parts in the order listed below. Cotter pin Bolt Collar Collar Washer Collar Ski stopper Ski stopper plate For installation, reverse the removal proce- dure. 3-15...
Page 103: Pz50M
CHAS PZ50M Order Job name/Part name Q’ty Remarks Ski removal Remove the parts in the order listed below. Cotter pin Bolt Collar Collar Washer Collar Ski stopper For installation, reverse the removal proce- dure. 3-16...
Page 104: Inspection
CHAS 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. 3-17...
Page 105: Front Suspension
CHAS FRONT SUSPENSION FRONT SUSPENSION PZ50/PZ50FX/PZ50M È: kg, 20 ft 28 Nm (2.8 m Ê: kg, 32 ft • • 45 Nm (4.5 m Ê • • É: kg, 24 ft 34 Nm (3.4 m Ë: kg, 43 ft • •...
Page 106 CHAS FRONT SUSPENSION È: kg, 20 ft Ê: 28 Nm (2.8 m • • kg, 32 ft Ê 45 Nm (4.5 m • • É: kg, 24 ft Ë: 34 Nm (3.4 m kg, 43 ft • • 60 Nm (6.0 m •...
Page 107: Pz50Gt/Pz50Vt/Pz50Mp
CHAS FRONT SUSPENSION PZ50GT/PZ50VT/PZ50MP È: kg, 5.1 ft Ë 7 Nm (0.7 m Ê: kg, 24 ft • • 34 Nm (3.4 m • • É: Ë 28 Nm (2.8 m kg, 20 ft kg, 32 ft • • 45 Nm (4.5 m •...
Page 108 CHAS FRONT SUSPENSION È: kg, 5.1 ft Ë 7 Nm (0.7 m Ê: kg, 24 ft • • 34 Nm (3.4 m • • É: Ë kg, 20 ft 28 Nm (2.8 m kg, 32 ft • • 45 Nm (4.5 m •...
Page 109: Handling Notes
CHAS FRONT SUSPENSION HANDLING NOTES WARNING PZ50GT/PZ50FX/PZ50VT “Europe”/PZ50MP This shock absorber contains highly com- pressed nitrogen gas. Before handling the shock absorber read and make sure that you understand the following information. The man- ufacturer cannot be held responsible for prop- erty damage or personal injury that may result from improper handling.
Page 110: Installation
CHAS FRONT SUSPENSION INSTALLATION È 1. Install: • Stabilizer 1 • Bushing 2 • Stabilizer holder 3 CAUTION: Always install the stabilizers, bushings, and stabilizer holders in the same positions on both sides of the snowmobile, otherwise poor han- dling and loss of stability may result. (PZ50GT/ PZ50VT/PZ50MP) É...
Page 111 CHAS FRONT SUSPENSION Ski alignment NOTE: Be sure to verify the 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...
Page 112: Chapter 4. Power Train
POWR PRIMARY SHEAVE AND DRIVE V-BELT POWER TRAIN PRIMARY SHEAVE AND DRIVE V-BELT È: kg, 85 ft 120 Nm (12.0 m • • kg, 43 ft 60 Nm (6.0 m • • È Q’ty Remarks Order Job name/Part name Primary sheave removal Remove the parts in the order listed below.
Page 113 POWR PRIMARY SHEAVE AND DRIVE V-BELT Q’ty Remarks Order Job name/Part name Primary sheave disassembly Remove the parts in the order listed below. Primary sheave cap Primary sheave spring Collar Roller Washer Collar Weight Washer Fixed sheave Stopper Sliding sheave Bushing Spider Left-handed thread.
Page 114: Removal
POWR PRIMARY SHEAVE AND DRIVE V-BELT REMOVAL 1. Remove: • Primary sheave assembly 1 NOTE: Use the primary sheave holder 2 and primary sheave puller 3. Sheave holder: 90890-01701, YS-01880-A Primary sheave puller: 90890-01898, YS-01881-A, YS-01881-1 DISASSEMBLY 1. Remove: • Fixed sheave 1 •...
Page 115: Inspection
POWR PRIMARY SHEAVE AND DRIVE V-BELT • Fit the primary sheave assembly onto the adapter and secure the supporting plates 8. NOTE: Securely fit the projections on the adapter into the fixed sheave holes. • Set the bar wrench 9 onto the spider and turn the special tool clockwise to loosen the spider.
Page 116 POWR PRIMARY SHEAVE AND DRIVE V-BELT 2. Inspect: • Primary sheave spring 1 Cracks/damage → Replace. 3. Measure: • Primary sheave spring (standard) free length Out of specification → Replace the primary sheave spring. Primary sheave spring (standard) free length: PZ50/PZ50GT/PZ50FX: 72.1 mm (2.84 in) PZ50M:...
Page 117: Assembly
POWR PRIMARY SHEAVE AND DRIVE V-BELT Rivet replacement steps: • Remove old rivet with the appropriate drill. • Insert the rivet 1 from the ID mark 2 side. • Press or peen the rivet head so that the diame- ter a of the rivet head measures 8.2 mm (0.32 in) or larger.
Page 118 POWR PRIMARY SHEAVE AND DRIVE V-BELT 2. Install: • Fixed sheave (onto the spider) NOTE: • Clean the threads. ® • Apply LOCTITE #648 to the fixed sheave as shown. CAUTION: ® LOCTITE should be applied only to the speci- fied area.
Page 119 POWR PRIMARY SHEAVE AND DRIVE V-BELT • Tighten the spider to specification using the bar wrench 3. Spider: 200 Nm (20.0 m · kg, 145 ft · lb) CAUTION: The spider has a left-handed thread. WARNING • Do not operate the primary sheave until the ®...
Page 120: Installation
POWR PRIMARY SHEAVE AND DRIVE V-BELT INSTALLATION 1. Install: • Primary sheave assembly CAUTION: Be sure to remove any oil or grease from the tapered portion of the crankshaft and spider using a cloth dampened with thinner. 2. Apply: • Engine oil (to threads of primary sheave bolt) 3.
Page 121: Secondary Sheave
POWR SECONDARY SHEAVE SECONDARY SHEAVE Q’ty Remarks Order Job name/Part name Secondary sheave removal Remove the parts in the order listed below. NOTE: Apply the brake to lock the secondary sheave. V-belt Refer to “PRIMARY SHEAVE AND DRIVE V- BELT”. Washer Shim (left) —...
Page 122 POWR SECONDARY SHEAVE È: kg, 5.1 ft 7 Nm (0.7 m • • È : 1 ESSO beacon 325 grease or Aeroshell grease #7A Q’ty Remarks Order Job name/Part name Secondary sheave disassembly Remove the parts in the order listed below. Circlip Washer Spring seat...
Page 123: Disassembly
POWR SECONDARY SHEAVE DISASSEMBLY WARNING • Use extreme CAUTION when disassembling the secondary sheave since serious injury can occur due to the sudden release of spring tension. Use the sheave compressor to con- tain the spring tension before removing the spring seat circlip.
Page 124: Assembly
POWR SECONDARY SHEAVE 5. Measure: • Ramp shoe thickness a Out of specification → Replace the ramp shoe. Wear limit: 1.0 mm (0.04 in) ASSEMBLY 1. Install: • Secondary sheave spring 1 • Spring seat 2 NOTE: Hook the end of the secondary sheave spring into the spring holes in the sliding sheave.
Page 125: Installation
POWR SECONDARY SHEAVE INSTALLATION 1. Lubricate: • Splines (fixed sheave) Recommended grease: ESSO beacon 325 grease or Aeroshell grease #7A 2. Tighten: • Secondary sheave bolt Secondary sheave bolt: 60 Nm (6.0 m · kg, 43 ft · lb) 3. Adjust: •...
Page 126: Drive Chain
POWR DRIVE CHAIN DRIVE CHAIN È: kg, 11 ft 16 Nm (1.6 m • • É: kg, 17 ft 24 Nm (2.4 m • • Ê: kg, 18 ft 25 Nm (2.5 m • • Ë: 48 Nm (4.8 m kg, 35 ft •...
Page 127: Removal
POWR DRIVE CHAIN REMOVAL 1. Remove: • Driven sprocket 1 NOTE: While holding the front axle assembly with spanner wrench 2, loosen the driven sprocket bolt. INSPECTION 1. Inspect: • Drive chain cover Cracks/damage → Replace. • Oil seals (drive chain cover) Wear/damage →...
Page 128 POWR DRIVE CHAIN 3. Measure: • 14 link section a of the drive chain Using a spring scale, pull on the drive chain with 36 kg (80 lb) of force b. Out of specification → Replace the drive chain. Maximum 14 link drive chain section length: 133.35 mm (5.25 in) Limit: 137.35 mm (5.41 in)
Page 129: Installation
POWR DRIVE CHAIN INSTALLATION 1. During installation, pay attention to the follow- ing. È Make sure that the bearing seals face towards the drive chain as shown. É Properly install the rubber seal onto the drive chain É housing, making sure 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.
Page 130: Secondary Shaft
POWR SECONDARY SHAFT SECONDARY SHAFT PZ50 È: kg, 17 ft 24 Nm (2.4 m • • È : 1 ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty Remarks Secondary shaft removal Remove the parts in the order listed below. Secondary sheave assembly Refer to “SECONDARY SHEAVE”.
Page 131: Removal
POWR SECONDARY SHAFT REMOVAL 1. Remove: • Drive chain parts Refer to “DRIVE CHAIN”. • Secondary sheave assembly Refer to “SECONDARY SHEAVE”. 2. Remove: • Bearing housing • Secondary shaft 1 NOTE: Remove the secondary shaft 1 from the right side of the machine.
Page 132 POWR SECONDARY SHAFT 3. Tighten: • Bearing holder bolts 1 Bearing holder bolt: 24 Nm (2.4 m · kg, 17 ft · lb) 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.
Page 133: Secondary Shaft And Drive Chain Installation
POWR SECONDARY SHAFT SECONDARY SHAFT AND DRIVE CHAIN INSTALLATION 1. Install: • Secondary shaft • Drive chain parts È Installation steps: • Install the secondary shaft. • Install the drive chain parts. • Install the drive chain, drive sprocket and driven sprocket.
Page 134: Secondary Shaft And Reverse Gear Case
POWR SECONDARY SHAFT AND REVERSE GEAR CASE SECONDARY SHAFT AND REVERSE GEAR CASE PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP È: kg, 6.5 ft 9 Nm (0.9 m • • É: 10 Nm (1.0 m kg, 7.2 ft • • Ê: 17 Nm (1.7 m kg, 12 ft •...
Page 135 POWR SECONDARY SHAFT AND REVERSE GEAR CASE È: kg, 6.5 ft 9 Nm (0.9 m • • É: kg, 7.2 ft 10 Nm (1.0 m • • Ê: kg, 12 ft 17 Nm (1.7 m • • É Ë: 24 Nm (2.4 m kg, 17 ft •...
Page 136 POWR SECONDARY SHAFT AND REVERSE GEAR CASE È: kg, 4.3 ft 6 Nm (0.6 m • • É: kg, 12 ft 17 Nm (1.7 m • • É È É : 1 ESSO beacon 325 grease or Aeroshell grease #7A Q’ty Remarks Order...
Page 137 POWR SECONDARY SHAFT AND REVERSE GEAR CASE È: kg, 4.3 ft 6 Nm (0.6 m • • É: kg, 12 ft 17 Nm (1.7 m • • É È É : 1 ESSO beacon 325 grease or Aeroshell grease #7A Q’ty Remarks Order...
Page 138: Removal
POWR SECONDARY SHAFT AND REVERSE GEAR CASE REMOVAL 1. Check that the gear motor is in the drive posi- tion. NOTE: Before removing the gear motor from the reverse gear case, make sure that the drive position indica- tor light on the speedometer unit is on. 2.
Page 139: Inspection
POWR SECONDARY SHAFT AND REVERSE GEAR CASE INSPECTION 1. Inspect: • Secondary shaft Scratches (excessive)/damage → Replace. • Splines Wear/damage → Replace the secondary shaft. • Bearing contact surface Scratches/wear/damage → Replace the sec- ondary shaft. Refer to “SECONDARY SHAFT”. 2.
Page 140: Installation
POWR SECONDARY SHAFT AND REVERSE GEAR CASE INSTALLATION 1. Install: • Secondary shaft assembly Installation steps: • Install the secondary shaft assembly. • Install the secondary shaft assembly bolts 1. • Install the bearing holder bolts 2. • Tighten the secondary shaft assembly bolts 1. Secondary shaft assembly bolt: 10 Nm (1.0 m ·...
Page 141: Secondary Shaft And Drive Chain Installation
POWR SECONDARY SHAFT AND REVERSE GEAR CASE 3. Install: • Drive chain parts Refer 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.
Page 142: Brake
POWR BRAKE BRAKE È: kg, 17 ft 23 Nm (2.3 m • • È È Q’ty Remarks Order Job name/Part name Battery bracket removal Remove the parts in the order listed below. Battery Refer to “BATTERY INSPECTION” in CHAP- TER 2. Starter relay Main fuse Fuse box...
Page 143 POWR BRAKE È: kg, 4.3 ft 6 Nm (0.6 m • • É: 18 Nm (1.8 m kg, 13 ft • • Ê: kg, 35 ft 48 Nm (4.8 m • • È É Ê Ê Q’ty Remarks Order Job name/Part name Brake pad removal Remove the parts in the order listed below.
Page 144: Brake Pad Replacement
POWR BRAKE CAUTION: Disc brake components rarely require disas- sembly. DO NOT: • Do not disassemble components unless absolutely necessary. • Do not use solvents on internal brake compo- nents. • Do not use contaminated brake fluid for cleaning. • Use only clean brake fluid. •...
Page 145 POWR BRAKE 2. Install: • Brake pads • Pad spring Installation steps: • Connect a suitable hose 1 tightly to the caliper bleed screw 2. Put the other end of this hose into an open container. • Loosen the caliper bleed screws and push the pistons into the caliper with your finger.
Page 146 POWR BRAKE È Ë Ì Ê È: kg, 4.3 ft 6 Nm (0.6 m • • É: kg, 7.2 ft 10 Nm (1.0 m • • Ê: 16 Nm (1.6 m kg, 12 ft • • Ì É Ë: 30 Nm (3.0 m kg, 22 ft •...
Page 147: Brake Caliper Disassembly
POWR BRAKE BRAKE CALIPER DISASSEMBLY NOTE: Before disassembling a caliper, drain brake fluid from brake hose, master cylinder, brake caliper and brake reservoir of their brake fluid. 1. Remove: • Pistons • Piston seals Removal steps: • Using a wood of piece, lock the piston. •...
Page 148: Brake Caliper Assembly
POWR BRAKE 1. Inspect: • Caliper piston Scratches/rust/wear → Replace the caliper assembly. • Caliper cylinder → Wear/scratches Replace caliper assembly. • Caliper body Cracks/damage → Replace. • Oil delivery passage (caliper body) Blow out with compressed air. WARNING Replace the piston seals and dust seals when- ever a caliper is disassembled.
Page 149 POWR BRAKE Q’ty Remarks Order Job name/Part name Brake master cylinder removal Remove the parts in the order listed below. Brake fluid Drain. Left handlebar switch Refer to “STEERING” in CHAPTER 3. Brake light switch Brake lever Brake hose Holder Parking brake cable Disconnect.
Page 150: Inspection
POWR BRAKE INSPECTION 1. Inspect: • Master cylinder 1 Wear/scratches → Replace the master cylin- der assembly. • Master cylinder body 2 Cracks/damage → Replace. • Oil delivery passage (master cylinder body) Blow out with compressed air. 2. Inspect: • Master cylinder kit Scratches/wear/damage →...
Page 151: Slide Rail Suspension
POWR SLIDE RAIL SUSPENSION SLIDE RAIL SUSPENSION PZ50/PZ50GT/PZ50FX/PZ50M È: kg, 52 ft 72 Nm (7.2 m • • É: kg, 80 ft 110 Nm (11.0 m • • É È : 1 ESSO beacon 325 grease or Aeroshell grease #7A Order Job name/Part name Q’ty...
Page 152 POWR SLIDE RAIL SUSPENSION È: kg, 2.9 ft 4 Nm (0.4 m • • É: kg, 35 ft 49 Nm (4.9 m • • Ê: kg, 43 ft 60 Nm (6.0 m • • Ë: 110 Nm (11.0 m kg, 80 ft •...
Page 153 POWR SLIDE RAIL SUSPENSION È È: kg, 4.3 ft 6 Nm (0.6 m • • É: kg, 43 ft 60 Nm (6.0 m • • Ê: kg, 52 ft 72 Nm (7.2 m • • É Ê É È Ê É...
Page 154 POWR SLIDE RAIL SUSPENSION È: kg, 25 ft 35 Nm (3.5 m • • É: kg, 35 ft 49 Nm (4.9 m • • Ë Ê: kg, 43 ft 60 Nm (6.0 m • • Ë: kg, 52 ft 72 Nm (7.2 m •...
Page 155 POWR SLIDE RAIL SUSPENSION È: kg, 43 ft 60 Nm (6.0 m • • É: 75 Nm (7.5 m kg, 54 ft • • PZ50M È É È PZ50M PZ50M Q’ty Remarks Order Job name/Part name Rear axle Guide wheel Guide wheel Collar Tension adjuster...
Page 156: Pz50Vt/Pz50Mp
POWR SLIDE RAIL SUSPENSION PZ50VT/PZ50MP È: 72 Nm (7.2 m kg, 52 ft • • È È Order Job 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.
Page 157 POWR SLIDE RAIL SUSPENSION È: kg, 2.9 ft 4 Nm (0.4 m É • • É: 6 Nm (0.6 m kg, 4.3 ft Ë • • Ê: kg, 35 ft 49 Nm (4.9 m • • Ë: kg, 43 ft 60 Nm (6.0 m •...
Page 158 POWR SLIDE RAIL SUSPENSION È: kg, 2.9 ft 4 Nm (0.4 m É • • É: 6 Nm (0.6 m kg, 4.3 ft Ë • • Ê: kg, 35 ft 49 Nm (4.9 m • • Ë: kg, 43 ft 60 Nm (6.0 m •...
Page 159 POWR SLIDE RAIL SUSPENSION Ë: È: kg, 4.3 ft kg, 35 ft 6 Nm (0.6 m 49 Nm (4.9 m • • • • É: Ì: kg, 6.5 ft kg, 43 ft 9 Nm (0.9 m 60 Nm (6.0 m •...
Page 160 POWR SLIDE RAIL SUSPENSION Ë: È: kg, 4.3 ft kg, 35 ft 6 Nm (0.6 m 49 Nm (4.9 m • • • • É: Ì: kg, 6.5 ft kg, 43 ft 9 Nm (0.9 m 60 Nm (6.0 m •...
Page 161 POWR SLIDE RAIL SUSPENSION È: kg, 54 ft 75 Nm (7.5 m • • È Q’ty Remarks Order Job name/Part name Rear axle Guide wheel Collar Collar Guide wheel Collar Tension adjuster Sliding frame For assembly, reverse the disassembly pro- cedure.
Page 162: Removal
POWR SLIDE RAIL SUSPENSION REMOVAL 1. Unhook the torsion spring 1 (PZ50/PZ50GT/PZ50FX/PZ50M) NOTE: For PZ50/PZ50GT/PZ50FX/PZ50M Rotate the spring end guide 2 in the direction of the arrow shown to unhook the end of the torsion spring. INSPECTION 1. Inspect: • Suspension wheel •...
Page 163 POWR SLIDE RAIL SUSPENSION 2. Install: • Control rods 1 (PZ50VT/PZ50MP) NOTE: Install the control rods with the water drain holes a facing downward. 3. Install: • Rear pivot arm joint 1 (PZ50/PZ50GT/PZ50FX/PZ50M) NOTE: Align the punch mark a in the rear pivot arm joint with the punch mark b in the rear pivot arm.
Page 164 POWR SLIDE RAIL SUSPENSION 6. Install: • 2-up adjusting block 1 (PZ50VT/PZ50MP) NOTE: Install 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.
Page 165 POWR SLIDE RAIL SUSPENSION 7. Install: È • 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 É Stopper band nut: 4 Nm (0.4 m ·...
Page 166: Installation
POWR SLIDE RAIL SUSPENSION INSTALLATION 1. Adjust: • Track tension Refer to “TRACK TENSION ADJUSTMENT” in CHAPTER 2. Control rod part numbers (PZ50VT/PZ50MP) È Control rod 1 É Length a mm (in) Ê Length b mm (in) Ë Length c mm (in) 2.5P ×...
Page 167: Front Axle And Track
POWR FRONT AXLE AND TRACK FRONT AXLE AND TRACK É È: kg, 6.5 ft 9 Nm (0.9 m • • É É: kg, 17 ft 24 Nm (2.4 m • • Ê: 40 Nm (4.0 m kg, 29 ft • •...
Page 168: Inspection
POWR FRONT AXLE AND TRACK INSPECTION 1. Inspect: • Track 1 • Slide metal 2 Wear/cracks/damage → Replace. 2. Inspect: • Sprocket wheels 1 Wear/break/damage → Replace. • Front axle 2 Bends/scratches (excessive)/damage → Replace. 3. Inspect: • Bearing Pitting/damage → Replace. INSTALLATION 1.
Page 169 POWR FRONT AXLE AND TRACK 2. Install: È • Sprocket wheels • Guide wheels NOTE: • When pressing the sprocket wheels onto the front axle, align the lugs on each sprocket wheel. • Position each sprocket wheel on the axle as 123.7 mm 60 mm 122.4 mm...
Page 170: Chapter 5. Engine
SEAT AND FUEL TANK ENGINE SEAT AND FUEL TANK PZ50/PZ50GT/PZ50FX/PZ50M È: kg, 5.1 ft 7 Nm (0.7 m • • È É: kg, 7.2 ft 10 Nm (1.0 m • • É È É Order Job name/Part name Q’ty Remarks Seat and fuel tank removal Remove the parts in the order listed below.
Page 171 SEAT AND FUEL TANK È: kg, 5.1 ft 7 Nm (0.7 m • • È É: kg, 7.2 ft 10 Nm (1.0 m • • É È É Q’ty Remarks Order Job name/Part name Plastic band Fuel tank assembly Fuel sender coupler Disconnect.
Page 172: Backrest And Passenger Seat
BACKREST AND PASSENGER SEAT BACKREST AND PASSENGER SEAT PZ50VT/PZ50MP È: Ë: 7 Nm (0.7 m kg, 5.1 ft 23 Nm (2.3 m kg, 17 ft • • • • É: 8 Nm (0.8 m kg, 5.8 ft È • • È...
Page 173 BACKREST AND PASSENGER SEAT È: Ë: kg, 5.1 ft kg, 17 ft 7 Nm (0.7 m 23 Nm (2.3 m • • • • É: kg, 5.8 ft 8 Nm (0.8 m È • • È Ê: kg, 7.2 ft 10 Nm (1.0 m •...
Page 174: Rider Seat And Fuel Tank
RIDER SEAT AND FUEL TANK RIDER SEAT AND FUEL TANK PZ50VT/PZ50MP È: Ë: kg, 5.1 ft kg, 8.0 ft 7 Nm (0.7 m 11 Nm (1.1 m È • • • • É: kg, 5.8 ft 8 Nm (0.8 m •...
Page 175 RIDER SEAT AND FUEL TANK È: Ë: 7 Nm (0.7 m kg, 5.1 ft 11 Nm (1.1 m kg, 8.0 ft È • • • • É: kg, 5.8 ft 8 Nm (0.8 m • • Ê: kg, 7.2 ft 10 Nm (1.0 m •...
Page 176: Removal
RIDER SEAT AND FUEL TANK REMOVAL 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose connector holder • Fuel hose CAUTION: • Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools.
Page 177: Installation
RIDER SEAT AND FUEL TANK INSTALLATION 1. Install: • Fuel pump gasket • Fuel pump • Fuel pump bracket Fuel pump nut: 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: • Do not damage the installation surface of the fuel tank when installing the fuel pump.
Page 178: Exhaust Pipe And Muffler
EXHAUST PIPE AND MUFFLER EXHAUST PIPE AND MUFFLER PZ50/PZ50GT/PZ50FX/PZ50M Ê È: kg, 4.3 ft 6 Nm (0.6 m • • Ê É: kg, 5.8 ft 8 Nm (0.8 m • • Î Ì Ê: kg, 7.2 ft 10 Nm (1.0 m •...
Page 179: Pz50Vt/Pz50Mp
EXHAUST PIPE AND MUFFLER PZ50VT/PZ50MP É È: kg, 4.3 ft 6 Nm (0.6 m • • Ë É: kg, 5.1 ft 7 Nm (0.7 m • • Ê: kg, 5.8 ft 8 Nm (0.8 m • • Ë: kg, 7.2 ft 10 Nm (1.0 m •...
Page 180: Installation
EXHAUST PIPE AND MUFFLER INSTALLATION 1. Install: • Muffler damper holder (temporarily) 2. Install: • Exhaust pipe/muffler assembly È NOTE: Position the exhaust pipe bolt 1 at the rear of the hole a in the seat rail assembly, and then finger tighten it.
Page 181: Oil Tank
OIL TANK OIL TANK È: kg, 7.2 ft 10 Nm (1.0 m • • É: kg, 11 ft 16 Nm (1.6 m • • È É Q’ty Remarks Order Job name/Part name Oil tank removal Remove the parts in the order listed below. Right side panel Refer to “COWLINGS”...
Page 182: Engine Assembly
ENGINE ASSEMBLY ENGINE ASSEMBLY HOSE AND LEADS È: kg, 5.1 ft 7 Nm (0.7 m • • È È Order Job name/Part name Q’ty Remarks Hose and leads removal Remove the parts in the order listed below. Coolant Drain. Refer to “COOLING SYSTEM” in CHAPTER 2. Engine oil Drain.
Page 183: Engine Assembly
ENGINE ASSEMBLY È: 7 Nm (0.7 m kg, 5.1 ft • • È È Q’ty Remarks Order Job name/Part name Exhaust pipe/muffler assembly Refer to “EXHAUST PIPE AND MUFFLER”. Water pump Refer to “WATER PUMP” in CHAPTER 6. Battery Refer to “BATTERY INSPECTION” in CHAP- TER 2.
Page 184 ENGINE ASSEMBLY ENGINE ASSEMBLY È: kg, 5.1 ft 7 Nm (0.7 m • • É: 23 Nm (2.3 m kg, 17 ft • • Ê: kg, 18 ft 25 Nm (2.5 m • • Ë Ë: kg, 22 ft 30 Nm (3.0 m •...
Page 185: Removal
ENGINE ASSEMBLY REMOVAL 1. Remove: • Rear engine mounting nut • Front engine mounting nuts • Washers NOTE: Do not remove the engine mounting bolts. 2. Remove: • Engine assembly Removal steps: • Screw in the engine mounting bolt spacers (front and rear) using the engine mount spacer wrench 1 so that there is a gap between each engine mounting bolt spacer 2 and engine...
Page 186 ENGINE ASSEMBLY Installation steps: • Install the engine mounting bolt spacer (front left side). • Install the engine assembly, and then install the rear engine mounting bolt spacer. • Install the rear engine mounting bolt and front engine left mounting bolt. •...
Page 187: Camshafts
CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER È: 8 Nm (0.8 m kg, 5.8 ft • • È É: 10 Nm (1.0 m kg, 7.2 ft • • É Ê: 12 Nm (1.2 m kg, 8.7 ft • • Ë: kg, 9.4 ft 13 Nm (1.3 m •...
Page 188: Camshafts
CAMSHAFTS CAMSHAFTS È: kg, 6.5 ft 9 Nm (0.9 m • • È É: È kg, 8.7 ft 12 Nm (1.2 m • • Ê: kg, 17 ft 24 Nm (2.4 m • • Ê É Q’ty Remarks Order Job name/Part name Camshaft removal Remove the parts in the order listed below.
Page 189: Removal
CAMSHAFTS REMOVAL 1. Remove: • Timing accessing screw • Crankshaft end accessing screw 2. Align: • “I” mark a on the A.C. magneto rotor (with the stationary pointer b on the A.C. magneto cover) NOTE: • Turn the crankshaft counterclockwise. •...
Page 190: Inspection
CAMSHAFTS 6. Remove: • Intake camshaft sprocket 1 (Use the special tool 2) Rotor holding tool: 90890-01235, YU-01235 INSPECTION 1. Inspect: • Camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: • Camshaft lobe dimensions a and b Out of specification → Replace the camshaft. Camshaft dimensions: Intake: <Limit>:...
Page 191 CAMSHAFTS 4. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft journal diameter. Camshaft-journal-to-camshaft-cap clearance: 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in) Measurement steps: • Install the camshaft into the cylinder head (with- out the dowel pins and camshaft caps). ®...
Page 192 CAMSHAFTS 7. Inspect: • Decompression system Inspection steps: • Check that the decompressor lever pins 1 projects from the camshaft. • Check that the decompressor cams 2 moves smoothly. 8. Inspect: • Timing chain guide (top side) Damage/wear → Replace the timing chain guide.
Page 193 CAMSHAFTS Assembly steps: • Install the timing chain tensioner spring, timing chain tensioner spring seat, and timing chain tensioner rod 1. • Squeeze the timing chain tensioner clip 2, and then push the timing chain tensioner rod 3 into the timing chain tensioner housing. NOTE: Do not release the timing chain tensioner clip while pushing the rod into the housing, otherwise the rod...
Page 194: Installation
CAMSHAFTS INSTALLATION 1. Install: • Intake camshaft sprocket 1 (with the special tool 2) Rotor holding tool: 90890-01235, YU-01235 • Camshaft sprocket bolts Camshaft sprocket bolt: 24 Nm (2.4 m · kg, 17 ft · lb) NOTE: Make sure that the position to the cylinder #1 cam a and marks b and c on the camshaft sprockets are in the position shown in the illustration.
Page 195 CAMSHAFTS 3. Install: • Dowel pins • Intake camshaft cap • Exhaust camshaft cap NOTE: Install the camshaft caps with the arrow mark a pointing towards the right side of the engine. 4. Install: • Camshaft cap bolts Camshaft cap bolt: 9 Nm (0.9 m ·...
Page 196 • Apply bond TB1541 1 onto the mating surfaces of the cylinder head cover and cylinder head cover gasket. • Apply Yamaha bond No. 1215 2 onto the mating surfaces of the cylinder head cover gasket and cylinder head. • Tighten the cylinder head cover bolts stages and in a crisscross pattern.
Page 197: Cylinder Head
CYLINDER HEAD CYLINDER HEAD Ê È É È: kg, 7.2 ft 10 Nm (1.0 m • • É: kg, 8.7 ft 12 Nm (1.2 m • • Ê: kg, 18 ft 25 Nm (2.5 m • • kg, 18 ft 25 Nm (2.5 m •...
Page 198: Removal
CYLINDER HEAD REMOVAL 1. Remove: • Cylinder head bolts NOTE: Loosen each bolt 1/2 of a turn at a time. After all of the bolt are fully loosened, remove them. INSPECTION 1. Eliminate: • Combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching:...
Page 199: Installation
CYLINDER HEAD INSTALLATION 1. Install: • Dowel pins 1 • Gasket 2 2. Install: • Cylinder head NOTE: Pass the timing chain through the timing chain cav- ity. 3. Tighten: • Cylinder head bolts (M10) NOTE: The tightening procedure of the cylinder head bolts is angle controlled, therefore tighten the bolts using the following procedure.
Page 200 CYLINDER HEAD • Tighten the cylinder head bolts further to reach the specified angle 180° in the proper tightening sequence as shown. Cylinder head bolt (M10): Final: Specified angle 175 ~ 185° WARNING When the bolts are tightened more than the specified angle, do not loosen the bolt and then retighten it.
Page 201 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Q’ty Remarks Order Job name/Part name Valves and valve springs removal Remove the parts in the order listed below. Cylinder head Refer to “CYLINDER HEAD”. Valve lifter Valve pad Valve cotter Upper spring seat Valve spring Exhaust valve Intake valve...
Page 202: Valves And Valve Springs
VALVES AND VALVE SPRINGS REMOVAL The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: •...
Page 203: Inspection
VALVES AND VALVE SPRINGS 4. Remove: • Upper spring seat 1 • Valve spring 2 • Valve 3 • Valve stem seal 4 • Lower spring seat 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. INSPECTION 1.
Page 204 VALVES AND VALVE SPRINGS • After installing the valve guide, bore the valve guide with the valve guide reamer 3 to obtain the proper valve-stem-to-valve-guide clearance. NOTE: After replacing the valve guide, reface the valve seat. Valve guide remover (ø4): 90890-04111, YM-04111 Valve guide installer (ø4): 90890-04112, YM-04112...
Page 205 VALVES AND VALVE SPRINGS 9. Measure: • Valve seat width a Out of specification → Replace the cylinder head. 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) Measurement steps: •...
Page 206 VALVES AND VALVE SPRINGS • Install the valve into the cylinder head. • Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.
Page 207: Installation
VALVES AND VALVE SPRINGS 12. Measure: • Compressed valve spring force a Out of specification → Replace the valve spring. b Installed length Compressed valve spring force (installed): Intake: 120.7 ~ 138.9 N at 30.13 mm (12.3 ~ 14.2 kg at 30.13 mm, 27.1 ~ 31.2 lb at 1.19 in) Exhaust: 150.6 ~ 173.2 N at 30.50 mm...
Page 208 VALVES AND VALVE SPRINGS 2. Lubricate: • Valve stem 1 • Valve stem seal 2 (with the recommended lubricant) Recommended lubricant: Molybdenum disulfide oil 3. Install: • Lower spring seat 1 • Valve stem seal 2 • Valve 3 • Valve spring 4 •...
Page 209 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. CAUTION: Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve pad •...
Page 210: A.c. Magneto Rotor And Starter Clutch
A.C. MAGNETO ROTOR AND STARTER CLUTCH A.C. MAGNETO ROTOR AND STARTER CLUTCH È: Ê: kg, 5.1 ft kg, 8.7 ft 7 Nm (0.7 m 12 Nm (1.2 m • • • • É: Ë: kg, 7.2 ft kg, 94 ft 10 Nm (1.0 m 130 Nm (13.0 m •...
Page 211: Removal
A.C. MAGNETO ROTOR AND STARTER CLUTCH REMOVAL 1. Remove: • A.C. magneto rotor bolt • Washer NOTE: • While holding the A.C. magneto rotor 1 with the sheave holder 2, loosen the magneto rotor bolt. • Do not allow the sheave holder to touch the pro- jection on the A.C.
Page 212: Inspection
A.C. MAGNETO ROTOR AND STARTER CLUTCH 3. Remove: • Starter clutch NOTE: • While holding the magneto rotor with the sheave holder, remove the starter clutch bolts 1. • Do not allow the sheave holder to touch the pro- jection on the magneto rotor. Sheave holder: 90890-01701, YS-01880-A INSPECTION...
Page 213: Installation
A.C. MAGNETO ROTOR AND STARTER CLUTCH 4. Inspect: É • Starter clutch operation Installation steps: • Install the starter clutch gear onto the starter clutch and hold the starter clutch. È • When turning the starter clutch gear clockwise È, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced.
Page 214 • Do not allow the sheave holder to touch the pro- jection on the magneto rotor. Sheave holder: 90890-01701, YS-01880-A 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 A.C. magneto cover bolt: 12 Nm (1.2 m ·...
Page 215: Oil Pan And Oil Pump
OIL PAN AND OIL PUMP OIL PAN AND OIL PUMP Ì É È (13) Ë Ì Ê È: kg, 7.2 ft 10 Nm (1.0 m • • É: kg, 8.7 ft 12 Nm (1.2 m • • Ê: 15 Nm (1.5 m kg, 11 ft •...
Page 216 OIL PAN AND OIL PUMP Ì É È (13) Ë Ì Ê È: kg, 7.2 ft 10 Nm (1.0 m • • É: 12 Nm (1.2 m kg, 8.7 ft • • Ê: 15 Nm (1.5 m kg, 11 ft •...
Page 217 OIL PAN AND OIL PUMP È: kg, 3.6 ft 5 Nm (0.5 m • • È È Q’ty Remarks Order Job name/Part name Oil pump disassembly Remove the parts in the order listed below. Oil pump housing cover 1 Spring Relief valve Oil pump inner rotor 1 Oil pump outer rotor 1...
Page 218: Removal
OIL PAN AND OIL PUMP REMOVAL 1. Remove: • Oil pan NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. INSPECTION 1.
Page 219: Installation
OIL PAN AND OIL PUMP 4. Inspect: • Relief valve body 1 • Relief valve 2 • Spring 3 Damage/wear → Replace the defective part(s). 5. Inspect: • Oil pump driven sprocket Cracks/damage/wear → Replace. 6. inspect: • Oil pump drive chain Damage/stiffness →...
Page 220 OIL PAN AND OIL PUMP 3. Install: • Oil pump driven sprocket shaft 1 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 •...
Page 221: Balancer
BALANCER BALANCER Ê È Ê Ë È: 10 Nm (1.0 m kg, 7.2 ft • • É: kg, 8.7 ft 12 Nm (1.2 m • • Ê: kg, 36 ft 50 Nm (5.0 m • • É Ë: kg, 54 ft 75 Nm (7.5 m •...
Page 222 BALANCER Ê È Ê Ë È: kg, 7.2 ft 10 Nm (1.0 m • • É: kg, 8.7 ft 12 Nm (1.2 m • • Ê: kg, 36 ft 50 Nm (5.0 m • • É Ë: 75 Nm (7.5 m kg, 54 ft •...
Page 223: Removal
BALANCER REMOVAL 1. Straighten the lock washer tab. 2. Loosen: • Right balancer weight nut 1 CAUTION: The right balancer weight nut has left-handed threads. To loosen the nut, turn it clockwise. NOTE: Place an aluminum plate 2 between the teeth of the balancer shaft drive gear 3 and balancer shaft driven gear 4.
Page 224: Inspection
BALANCER INSPECTION 1. Inspect: • Bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement → Replace. 2. Inspect: • Balancer shaft drive gear • Balancer shaft driven gear Damage/wear → Replace. 3. Inspect: •...
Page 225 BALANCER 3. Install: • Balancer shaft driven gear 1 • Lock washers • Balancer shaft driven gear nut • Right balancer weight nut • Balancer shaft drive gear bolt NOTE: • Align the punch mark a on the balancer shaft driven gear with the shorter spline b on the bal- ancer shaft end.
Page 226 BALANCER 5. Tighten: • Primary sheave drive shaft cover bolt Primary sheave drive shaft cover bolt: 12 Nm (1.2 m · kg, 8.7 ft · lb) ® LOCTITE NOTE: ® Apply LOCTITE to the bolts (black) indicated by the “ ” marks on the primary sheave drive shaft cover.
Page 227: Crankcase
CRANKCASE CRANKCASE CRANKCASE È: kg, 8.7 ft 12 Nm (1.2 m É • • É: kg, 11 ft 15 Nm (1.5 m • • kg, 11 ft 15 Nm (1.5 m • • Specified angle 65 ~ 70˚ Final È È...
Page 228: Connecting Rods And Pistons
CRANKCASE CONNECTING RODS AND PISTONS È È: kg, 14 ft 20 Nm (2.0 m • • Specified angle 120 ~ 130˚ Order Job name/Part name Q’ty Remarks Connecting rods and pistons removal Remove the parts in the order listed below. Connecting rod cap Big end bearing Piston pin clip...
Page 229: Crankshaft
CRANKCASE CRANKSHAFT Order Job name/Part name Q’ty Remarks Crankshaft removal Remove the parts in the order listed below. Crankshaft Crankshaft journal bearing Upper crankcase For installation, reverse the removal proce- dure. 5-60...
Page 230: Removal
CRANKCASE REMOVAL È 1. Remove: • Crankcase bolts NOTE: • Loosen the bolts in decreasing numerical order of the embossed numbers on the crankcase. • Loosen each bolt 1/4 of a turn at a time. After all of the bolts are fully loosened, remove them. È...
Page 231 CRANKCASE 5. Remove: • Piston pin clips 1 • Piston pin 2 • Piston 3 • Connecting rod 4 CAUTION: Do not use a hammer to drive the piston pin out. NOTE: • For reference during installation, put identification marks on the piston crown. •...
Page 232: Inspection
CRANKCASE INSPECTION 1. Inspect: • Piston wall • Cylinder wall Vertical scratches → Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: • Piston-to-cylinder clearance Measurement steps: 1st step: • Measure cylinder bore “C” with the cylinder bore gauge 1.
Page 233 CRANKCASE 3rd step: • Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance: 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) <Limit>: 0.120 mm (0.0047 in) • If out of specification, replace the cylinder, and the piston and piston rings as a set.
Page 234 CRANKCASE 5. Measure: • Piston ring end gap Out of specification → Replace the piston rings as a set. NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is excessive, replace all three piston rings. Piston ring end gap: Top ring: 0.15 ~ 0.25 mm (0.006 ~ 0.010 in)
Page 235 CRANKCASE 9. Calculate: • Piston pin to piston pin bore clearance Out of specification → Replace the piston pin and piston as a set. Piston pin to piston pin bore clearance = Piston pin bore size – Piston pin outside diameter Piston pin to piston pin bore clear- ance: 0.002 ~ 0.022 mm...
Page 236 CRANKCASE 12. Measure: • Crankshaft-journal-to-crankshaft-journal- bearing clearance Out of specification → Replace the crankshaft journal bearings. Crankshaft-journal-to-crankshaft- journal-bearing clearance: 0.020 ~ 0.044 mm (0.0008 ~ 0.0017 in) Measurement steps: CAUTION: Do not interchange the crankshaft journal bear- ings. To obtain the correct crankshaft-journal- to-crankshaft-journal-bearing clearance prevent engine damage, the crankshaft journal...
Page 237 CRANKCASE • Install the crankshaft journal lower bearings 1 into the lower crankcase and assemble the crankcase halves. NOTE: • Align the projections a of the crankshaft journal lower bearings with the notches b in the crank- case. • Do not move the crankshaft until the clearance measurement has been completed.
Page 238 CRANKCASE 13. Select: • Crankshaft journal bearings (J1 ~ J3) NOTE: • The numbers È stamped into the crankshaft web and the numbers É stamped into the lower crankcase are used to determine the replace- ment crankshaft journal bearing sizes. •...
Page 239 CRANKCASE Measurement steps: CAUTION: Do not interchange the big end bearings and connecting rods. To obtain the correct crank- shaft-pin-to-big-end-bearing clearance and pre- vent engine damage, the big end bearings must be installed in their original positions. • Clean the big end bearings, crankshaft pins, and bearing portions of the connecting rods.
Page 240 CRANKCASE • Tighten the connecting rod bolts. Connecting rod bolt: 1st: 20 Nm (2.0 m · kg, 14 ft · lb) Final: Specified angle 120 ~ 130° • Replace the connecting rod bolts with new ones. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method.
Page 241 CRANKCASE 15. Select: • Big end bearings (P1 ~ P2) NOTE: • The numbers È stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bear- ing sizes. • “P1” ~ “P2” refer to the bearings shown in the crankshaft illustration.
Page 242: Installation
CRANKCASE INSTALLATION 1. Install: • Crankshaft journal upper bearing (into the upper crankcase) • Crankshaft journal lower bearing (into the lower crankcase) NOTE: • Align the projections a on the crankshaft journal bearings with the notches b in the crankcase. •...
Page 243 CRANKCASE 5. Offset: È • Piston ring end gaps 90˚ a Top ring b 2nd ring c Upper oil ring rail d Oil ring expander 90˚ e Lower oil ring rail È Exhaust side 6. Lubricate: • Piston 45˚ • Piston rings •...
Page 244 CRANKCASE 9. Install: • Big end bearings • Connecting rod assembly 1 (into the cylinder and onto the crankshaft pin). • Connecting rod cap (onto the connecting rod) NOTE: • Align the projections on the big end bearings with the notches in the connecting rods and connect- ing rod caps.
Page 245 CRANKCASE 11. Tighten: • Connecting rod bolts Connecting rod bolt: 1st: 20 Nm (2.0 m · kg, 14 ft · lb) Final: Specified angle 120 ~ 130° • Replace the connecting rod bolts with new ones. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method.
Page 246 CRANKCASE 13. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215: 90890-85505 ® (Three Bond No.1215 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2 ~ 3 mm (0.08 ~ 0.12 in) of the crankshaft journal bearings.
Page 247 CRANKCASE 17. Install: È • Crankcase bolts NOTE: • Lubricate the bolt threads with engine oil. • Tighten the bolts in the order of the embossed numbers on the crankcase. Crankcase bolt: Bolt 1: 1st: 15 Nm (1.5 m · kg, 11 ft · lb) 2nd: 15 Nm (1.5 m ·...
Page 248: Chapter 6. Cooling System
COOL RADIATOR AND HEAT EXCHANGER COOLING SYSTEM RADIATOR AND HEAT EXCHANGER È: 8 Nm (0.8 m kg, 5.8 ft É • • É: kg, 7.2 ft 10 Nm (1.0 m • • È É Ê É Ê: kg, 19 ft 27 Nm (2.7 m •...
Page 249 COOL RADIATOR AND HEAT EXCHANGER È: 8 Nm (0.8 m kg, 5.8 ft É • • É: kg, 7.2 ft 10 Nm (1.0 m • • È É Ê É Ê: kg, 19 ft 27 Nm (2.7 m • • É...
Page 250: Inspection
COOL RADIATOR AND HEAT EXCHANGER INSPECTION 1. Inspect: • Coolant hoses • Heat exchanger • Oil cooler • Coolant pipes Cracks/damage → Replace. 2. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor.
Page 251: Installation
COOL RADIATOR AND HEAT EXCHANGER INSTALLATION 1. Install: • Heat exchanger Use the rivet gun. 2. Install: • O-ring • Oil cooler 1 Oil cooler bolt: 10 Nm (1.0 m · kg, 7.2 ft · lb) ® LOCTITE NOTE: Install the oil cooler with the manufacturer’s mark a facing down.
Page 252: Thermostat
COOL THERMOSTAT THERMOSTAT È È: kg, 7.2 ft 10 Nm (1.0 m • • É: kg, 17 ft 23 Nm (2.3 m • • Order Job name/Part name Q’ty Remarks Thermostat disassembly Remove the parts in the order listed below. Coolant temperature sensor coupler Disconnect.
Page 253: Inspection
COOL THERMOSTAT INSPECTION 1. Inspect: • Thermostat Does not open at 80 ~ 84 °C (176 ~ 183 °F) → Replace. Inspection steps: • Suspend the thermostat in a container filled with water. • Slowly heat the water. Place a thermometer in the water. •...
Page 254 COOL THERMOSTAT 3. Install: • Coolant temperature sensor (to the thermostat housing) Coolant temperature sensor: 23 Nm (2.3 m · kg, 17 ft · lb) CAUTION: Use extreme care when handling the coolant temperature sensor. Replace any part that was dropped or subjected to a strong impact.
Page 255: Water Pump
COOL WATER PUMP WATER PUMP È: kg, 8.7 ft 12 Nm (1.2 m • • È Order Job name/Part name Q’ty Remarks Water pump removal Remove the parts in the order listed. Oil tank Refer to “OIL TANK” in CHAPTER 5. Radiator Refer to “RADIATOR AND HEAT EXCHANGER”.
Page 256 COOL WATER PUMP Q’ty Remarks Order Job name/Part name Water pump disassembly Remove the parts in the order listed below. Water pump housing cover Gasket Circlip Impeller shaft assembly Water pump seal Oil seal Bearing Water pump housing For assembly, reverse the disassembly pro- cedure.
Page 257: Disassembly
COOL WATER PUMP DISASSEMBLY 1. Remove: • Impeller • Water pump seal 1 NOTE: Remove the water pump seal 1 from the inside of the water pump housing 2. 2. Remove: • Bearing 1 • Oil seal 2 NOTE: Remove the bearing 1 and oil seal 2 from the inside of the water pump housing 3.
Page 258: Assembly
• 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. Mechanical seal installer: 90890-04145, YM-04145...
Page 259: Installation
COOL WATER PUMP 4. Install: • Rubber damper holder 1 • Rubber damper 2 NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. 5. Measure: • Impeller shaft tilt Out of specification → Repeat steps (4) and (5).
Page 260 COOL 6-13...
Page 261: Chapter 7. Fuel Injection System
FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Battery 7 Cylinder identification D Oil pressure switch I Intake air temperature 2 ECU (engine control E Coolant temperature sensor sensor 8 Cylinder-#1 ignition coil J Grip/thumb warmer unit) sensor 3 Fuel injection system 9 Cylinder-#1 intake air F Crankshaft position...
Page 262 FUEL INJECTION SYSTEM...
Page 263 FUEL INJECTION SYSTEM 1 Crankshaft position sensor 4 Main switch 5 Main fuse 6 Load control relay 7 Fuel injection system fuse 0 Battery A Diode B Engine stop switch C Throttle switch E Grip warmer F Thumb warmer G Oil pressure switch H Drive position switch *1 I Reverse position switch *1 J ECU (engine control unit)
Page 264: Ecu Self-Diagnostic Function
FUEL INJECTION SYSTEM ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operat- ing normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and the warning light and self-diagnosis warning indicator come on to alert the rider that a malfunction has occurred in the system.
Page 265 FUEL INJECTION SYSTEM Fault code Able/unable Able/unable Item Symptom to start to drive Cylinder-#2 ignition coil (faulty ignition) Open circuit detected in the primary lead of Able Able the cylinder-#2 ignition coil. (depending (depending on the num- on the num- ber of faulty ber of faulty cylinders)
Page 266: Troubleshooting Chart
FUEL INJECTION SYSTEM TROUBLESHOOTING CHART and self-diagnosis warning indicator flash Engine operation is not normal or the warning light and self-diagnosis warning indicator may * Warning light not flash even if the engine operation is not normal. and self-diagnosis warning indi- self-diagnosis The warning light The warning light and...
Page 267: Diagnostic Mode
FUEL INJECTION SYSTEM DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators without connecting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode. Setting the diagnostic mode 1.
Page 268 FUEL INJECTION SYSTEM 6. Verify the operation of the sensor or actuator. • Sensor operation The data representing the operating condi- tions of the sensor appears on the odometer/ tripmeter LCD. • Actuator operation Push the grip warmer side of the grip/thumb warmer adjustment switch to operate the actuator.
Page 269 FUEL INJECTION SYSTEM Fault code table Fault Symptom Probable cause of malfunction Diagnostic code No. code No. No normal signals are • Open or short circuit in wire harness. received from the cylinder • Defective cylinder identification sensor. — identification sensor. •...
Page 270 FUEL INJECTION SYSTEM Fault Symptom Probable cause of malfunction Diagnostic code No. code No. Power supply to the fuel • Malfunction in the charging system. (Refer to “CHARGING SYS- injection system is not nor- — TEM” in CHAPTER 8.) mal. Faulty ECU memory.
Page 271 FUEL INJECTION SYSTEM Diagnostic mode table Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “DIAG- NOSTIC MODE”. NOTE: • Check the intake air temperature and coolant temperature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively.
Page 272 FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code No. (reference value) Cylinder-#1 ignition coil Actuates the cylinder-#1 ignition coil five times at 1-sec- After pushing the switch, check ond intervals and displays the self-diagnosis warning the spark five times.
Page 273 FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code No. (reference value) Headlight relay Actuates the headlight relay for five cycles of 5 seconds After pushing the switch, check and displays the self-diagnosis warning indicator 1 sec- the operating sound of the ond after the grip warmer side of the grip/thumb warmer headlight relay five times.
Page 274: Troubleshooting Details
FUEL INJECTION SYSTEM TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part have been completed, reset the meter display accord- ing to the reinstatement method.
Page 275 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft position sensor. Diagnostic code No. – – Order Item/components and probable cause Check or maintenance job Reinstatement method Installed condition of crankshaft position Check for looseness or pinching. Cranking the sensor.
Page 276 FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#1 intake air pressure sensor: open or short circuit detected. Diagnostic code No. 03 (cylinder-#1 intake air pressure sensor) Order Item/components and probable cause Check or maintenance job Reinstatement method Connections Check the couplers for any pins that may have Turning the Cylinder-#1 intake air pressure sen- pulled out.
Page 277 FUEL INJECTION SYSTEM Cylinder-#1 intake air pressure sensor: hose system malfunction (clogged Fault code No. Symptom or detached hose). Diagnostic code No. 03 (cylinder-#1 intake air pressure sensor) Order Item/components and probable cause Check or maintenance job Reinstatement method Cylinder-#1 intake air pressure sensor Repair or replace the sensor hose.
Page 278 FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. Diagnostic code No. 01 (throttle position sensor) Order Item/components and probable cause Check or maintenance job Reinstatement method Installed condition of throttle position Check for looseness or pinching. Starting the sensor.
Page 279 FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#2 intake air pressure sensor: open or short circuit detected. Diagnostic code No. 04 (cylinder-#2 intake air pressure sensor) Order Item/components and probable cause Check or maintenance job Reinstatement method Connections Check the couplers for any pins that may have Turning the Cylinder-#2 intake air pressure sen- pulled out.
Page 280 FUEL INJECTION SYSTEM Cylinder-#2 intake air pressure sensor: hose system malfunction (clogged Fault code No. Symptom or detached hose). Diagnostic code No. 04 (cylinder-#2 intake air pressure sensor) Order Item/components and probable cause Check or maintenance job Reinstatement method Cylinder-#2 intake air pressure sensor Repair or replace the sensor hose.
Page 281 FUEL INJECTION SYSTEM Fault code No. Symptom Open circuit detected in the primary lead of the cylinder-#1 ignition coil. Diagnostic code No. 30 (cylinder-#1 ignition coil) Order Item/components and probable cause Check or maintenance job Reinstatement method Connections Check the couplers for any pins that may have Starting the Cylinder-#1 ignition coil coupler pulled out.
Page 282 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the speed sensor. Diagnostic code No. 07 (speed sensor) Order Item/components and probable cause Check or maintenance job Reinstatement method Connections Check the couplers for any pins that may have Starting the Speed sensor coupler pulled out.
Page 283 FUEL INJECTION SYSTEM Fault code No. Symptom ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Diagnostic code No. 09 (fuel system voltage) Order Item/components and probable cause Check or maintenance job Reinstatement method Connections...
Page 284 FUEL INJECTION SYSTEM Fault code No. Symptom Error is detected while reading or writing on EEPROM (CO adjustment value). Diagnostic No. 60 (EEPROM improper cylinder indication) Order Item/components and probable cause Check or maintenance job Reinstatement method Malfunction in ECU. Execute the diagnostic mode (code No.
Page 285 FUEL INJECTION SYSTEM Fault code No. Symptom Knock sensor: open or short circuit detected. Diagnostic code No. – – Order Item/components and probable cause Check or maintenance job Reinstatement method Installed condition of knock sensor Check for looseness or pinching. Starting the engine and Connections...
Page 286 FUEL INJECTION SYSTEM Fault code No. Symptom Oil pressure switch: open circuit detected. Diagnostic code No. – – Order Item/components and probable cause Check or maintenance job Reinstatement method Connections Check the couplers for any pins that may have Starting the Oil pressure switch coupler pulled out.
Page 287 FUEL INJECTION SYSTEM Er-1 Symptom No signals are received from the ECU. Er-2 Symptom No signals are received from the ECU within the specified duration. Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Er-4 Symptom Non-registered data has been received from the meter.
Page 288: Oil Pressure Switch
FUEL INJECTION SYSTEM OIL PRESSURE SWITCH 1. Disconnect: • Oil pressure switch coupler 1 2. Connect: • Pocket tester (between the engine ground and oil pressure switch terminal) 3. Check: • Oil pressure switch continuity No continuity → Replace the oil pressure switch.
Page 289: Throttle Body
THROTTLE BODY THROTTLE BODY Q’ty Remarks Order Job name/Part name Throttle body removal Remove the parts in the order listed below. Air filter case assembly Refer to “COWLINGS” in CHAPTER 3. Throttle position sensor coupler Disconnect. Fuel hose Fuel return hose Disconnect.
Page 290: Injectors
THROTTLE BODY INJECTORS Order Job name/Part name Q’ty Remarks Injector removal Remove the parts in the order listed below. Negative pressure hose Idle adjusting screw Throttle position sensor Pressure regulator hose Pressure regulator Fuel strainer seat Fuel strainer Fuel rail Injector Throttle body heater hose Air screw...
Page 291: Inspection
THROTTLE BODY INSPECTION 1. Inspect: • Injectors Damage → Replace. 2. Inspect: • Throttle body Cracks/damage → Replace the throttle body. 3. Check: • Fuel passages Obstructions → Clean. NOTE: • Use a petroleum based solvent for cleaning. • Blow out all passage with compressed air. 4.
Page 292: Inspection And Adjustment
THROTTLE BODY • Use the mity vac set to adjust the fuel pressure in relation to the vacuum pressure as described below. NOTE: The vacuum pressure should not exceed 100 kPa (760 mmHg). Increase the vacuum pressure → Fuel pressure is decreased Decrease the vacuum pressure →...
Page 293 THROTTLE BODY 2. Adjust: • Throttle position sensor angle Adjusting steps: • Connect the throttle position sensor coupler to L B/L Y the wire harness. • Connect the digital circuit tester to the throttle position sensor. Positive tester probe → yellow terminal 1 Negative tester probe →...
Page 294 7-34...
Page 295: Chapter 8. Electrical
– ELEC SWITCH INSPECTION ELECTRICAL SWITCH INSPECTION SWITCH INSPECTION Use a pocket tester to check the terminals for conti- nuity. If the continuity is faulty at any point, replace the switch. Pocket tester: 90890-03112, YU-03112-C NOTE: • Set the pocket tester to “0” before starting a test. •...
Page 296: Ignition System
– ELEC IGNITION SYSTEM...
Page 297: Circuit Diagram
– ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT 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...
Page 298: Troubleshooting
– ELEC IGNITION SYSTEM TROUBLESHOOTING NO SPARK OR WEAK SPARK. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or ignition fuse. Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace and/or charge the battery.
Page 299 – ELEC IGNITION SYSTEM T.O.R.S. OPERATES. Is self-diagnosis code 15, 16, or 42 displayed? Check the affected item(s). Has throttle body icing occurred or is foreign material stuck in the throttle body? Perform throttle body maintenance. Is the throttle switch malfunctioning? Repair or replace the throttle switch.
Page 300: Ignition Spark Gap
– ELEC IGNITION SYSTEM IGNITION SPARK GAP È 1. Remove: • Ignition coil 2. Measure: • Ignition spark gap Out of specification → Replace the ignition coil. Measurement steps: • Disconnect the ignition coil 1 from the spark plug. É •...
Page 301: Crankshaft Position Sensor
– ELEC IGNITION SYSTEM CRANKSHAFT POSITION SENSOR 1. Disconnect: • 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...
Page 302: Throttle Override System (T.o.r.s.)
– ELEC IGNITION SYSTEM THROTTLE OVERRIDE SYSTEM (T.O.R.S.) If the throttle bodies or throttle cable malfunctions during operation, the T.O.R.S. will operate when the throttle lever is released. The T.O.R.S. is designed to interrupt the fuel injec- tion and keep the engine speed between 2,800 and 3,000 r/min if the throttle valves fail to return to the idle position when the throttle lever is released.
Page 303: Engine Stop Switch
– ELEC IGNITION SYSTEM ENGINE STOP SWITCH 1. Disconnect: • Engine stop switch coupler Ω × 1 2. Connect: • Pocket tester – 3. Check: • Engine stop switch continuity Br Br/W Faulty → Replace the right handlebar switch. Switch position Continuity RUN (pulled out) OFF (pushed in)
Page 304: Main Switch
– ELEC IGNITION SYSTEM MAIN SWITCH 1. Disconnect: • Main switch coupler Ω × 1 2. Connect: • Pocket tester – 3. Check: • Main switch continuity Br/W Faulty → Replace. Color code Switch position Br/W START Continuity 8-10...
Page 305: Electrical Starting System
– ELEC ELECTRICAL STARTING SYSTEM 8-11...
Page 306: Troubleshooting
– ELEC ELECTRICAL STARTING SYSTEM TROUBLESHOOTING STARTER MOTOR DOES NOT OPERATE. 1. Connect: • Starter relay terminals (battery side and starter motor side) Check the battery and connectors. Refer to “BATTERY INSPECTION” in CHAPTER Charge and/or replace the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2.
Page 307 – ELEC ELECTRICAL STARTING SYSTEM FAULTY Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse and/or ignition fuse. FAULTY Check the engine stop switch and main switch. Refer to “IGNITION SYSTEM”. Replace the right handlebar switch and/or main switch.
Page 308: Starter Motor
– ELEC ELECTRICAL STARTING SYSTEM STARTER MOTOR È: kg, 8.7 ft 12 Nm (1.2 m • • : 1 ESSO beacon 325 grease or Aeroshell grease #7A È Order Job name/Part name Q’ty Remarks Starter motor removal Remove the parts in the order listed below. Engine assembly Refer to “ENGINE ASSEMBLY”...
Page 309 – ELEC ELECTRICAL STARTING SYSTEM È: kg, 8.7 ft 12 Nm (1.2 m • • : 1 ESSO beacon 325 grease or Aeroshell grease #7A È Q’ty Remarks Order Job name/Part name Brush holder Armature assembly Starter motor yoke For assembly, reverse the disassembly pro- cedure.
Page 310 – ELEC ELECTRICAL STARTING SYSTEM Inspection 1. Inspect: • Commutator (outer surface) Dirty → Clean with #600 grit sandpaper 1. Hold the armature in a vise 2 and copper or aluminium plate 3. CAUTION: Lightly grip the armature with a vise. 2.
Page 311 – ELEC ELECTRICAL STARTING SYSTEM 5. Measure: • Brush length a Out of specification → Replace the starter motor. Brush length wear limit: 3.65 mm (0.14 in) 6. Measure: • Brush spring pressure Fatigue/out of specification → Replace as a set.
Page 312 – ELEC ELECTRICAL STARTING SYSTEM 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. 8-18...
Page 313 CHARGING SYSTEM CIRCUIT DIAGRAM 2 A.C. magneto È È 3 Rectifier/regulator 5 Main fuse G/B R/L B/L G/W G L/R Br/R Sb W/L Br/R 0 Battery Gy/R Gy/R B O/B FUEL PUMP GEAR MOTOR HEADLIGHT SUB-WIRE SUB-WIRE SUB-WIRE SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS WIRE HARNESS...
Page 314: Charging System
– ELEC CHARGING SYSTEM TROUBLESHOOTING BATTERY IS NOT CHARGED. 1. Connect: • Pocket tester (to the battery terminals) 2. Measure: OUT OF SPECIFICATION • Battery voltage Battery voltage: more than 12 V at 20 °C (68 °F) • Check the battery. •...
Page 315: Battery
– ELEC CHARGING SYSTEM BATTERY Inspection 1. Inspect: • Battery condition Refer to “BATTERY INSPECTION” in CHAP- TER 2. Battery Storage The battery should be stored if the machine is not going to be used for a long period. 1. Remove: •...
Page 316 LIGHTING SYSTEM CIRCUIT DIAGRAM È È R/G R/W G/B R/L B/L G/W G L/R Br/R Sb W/L Br/R Gy/R Gy/R B O/B FUEL PUMP GEAR MOTOR HEADLIGHT O R/W SUB-WIRE SUB-WIRE SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS WIRE HARNESS SUB-WIRE WIRE HARNESS R/L L/R WIRE HARNESS...
Page 317: Lighting System
– ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM 2 A.C. magneto 3 Rectifier/regulator 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...
Page 318: Troubleshooting
– ELEC LIGHTING SYSTEM TROUBLESHOOTING HEADLIGHT AND/OR HIGH BEAM INDICATOR LIGHT AND/OR METER LIGHT DO NOT COME ON. Check the headlight bulb(s). NO CONTINUITY Replace the bulb(s). Check the main fuse, ignition fuse, and headlight fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse, and/or head- light fuse.
Page 319 – ELEC LIGHTING SYSTEM TAIL LIGHT DOES NOT COME ON. Check the main fuse, ignition fuse, and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse, ignition fuse, and/or signal FAULTY fuse. Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace and/or charge the battery.
Page 320: Bulb(S)
– ELEC LIGHTING SYSTEM BULB(S) NOTE: Do not check any of the lights that use LEDs. 1. Remove: • Headlight bulb 2. Connect: • Pocket tester (to the bulb terminals) WARNING Keep flammable products and your hands away from the bulb while it is on; it will be hot. Do not touch the bulb until it cools down.
Page 321: Headlight Relay
– ELEC LIGHTING SYSTEM HEADLIGHT RELAY 1. Remove: • Headlight relay (with the black coupler) Inspection steps: • Connect the pocket tester (Ω × 1) to the head- light relay terminals as shown. Positive tester probe → Blue/White 1 Negative tester probe → Green 2 •...
Page 322 SIGNAL SYSTEM CIRCUIT DIAGRAM È È R/G R/W G/B R/L B/L G/W G L/R Br/R Sb W/L Br/R Gy/R Gy/R B O/B FUEL PUMP GEAR MOTOR HEADLIGHT O R/W SUB-WIRE SUB-WIRE SUB-WIRE WIRE HARNESS WIRE HARNESS R/L L/R WIRE HARNESS WIRE HARNESS SUB-WIRE WIRE HARNESS...
Page 323: Signal System
– ELEC SIGNAL SYSTEM SIGNAL SYSTEM CIRCUIT DIAGRAM 2 A.C. magneto 3 Rectifier/regulator 4 Main switch 5 Main fuse 6 Load control relay 0 Battery B Engine stop switch D DC back buzzer H Drive position switch I Reverse position switch J ECU (engine control unit) S Speed sensor W Knock sensor...
Page 324: Troubleshooting
– ELEC SIGNAL SYSTEM TROUBLESHOOTING BRAKE LIGHT DOES NOT COME ON. Check the main fuse, ignition fuse, and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse, and/or signal fuse. Check the battery. Refer to “BATTERY INSPECTION”...
Page 325 – ELEC SIGNAL SYSTEM LOW COOLANT TEMPERATURE INDICATOR LIGHT, COOLANT TEMPERATURE WARNING INDICATOR AND/OR WARNING LIGHT DO NOT COME ON. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or ignition fuse. Check the battery.
Page 326 – ELEC SIGNAL SYSTEM FUEL METER AND/OR FUEL LEVEL WARNING INDICATOR AND/OR WARNING LIGHT DO NOT COME ON. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or ignition fuse. Check the battery.
Page 327 – ELEC SIGNAL SYSTEM OIL LEVEL WARNING INDICATOR AND/OR WARNING LIGHT DO NOT COME ON. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse and/or ignition fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION”...
Page 328 – ELEC SIGNAL SYSTEM KNOCK CONTROL SYSTEM INDICATOR LIGHT DO NOT COME ON. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse and/or ignition fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace and/or charge the battery.
Page 329 – ELEC SIGNAL SYSTEM DRIVE POSITION INDICATOR LIGHT AND/OR REVERSE POSITION INDICATOR LIGHT DO NOT COME ON. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or ignition fuse. Check the battery. Refer to “BATTERY INSPECTION”...
Page 330 – ELEC SIGNAL SYSTEM SPEEDOMETER DOES NOT OPERATE. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse and/or ignition fuse. FAULTY Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace and/or charge the battery.
Page 331 – ELEC SIGNAL SYSTEM BACK BUZZER DOES NOT SOUND. (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) Check the main fuse, ignition fuse, and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse, ignition fuse, and/or signal FAULTY fuse. Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace and/or charge the battery.
Page 332: Brake Light Switch
– ELEC SIGNAL SYSTEM BRAKE LIGHT SWITCH 1. Disconnect: • Brake light switch coupler 2. Connect: • Pocket tester (to the brake light switch coupler) 3. Check: • Brake light switch continuity Faulty → Replace. Switch position Continuity Brake lever operates Brake lever does not operate DRIVE POSITION SWITCH AND REVERSE...
Page 333: Coolant Temperature Sensor
– ELEC SIGNAL SYSTEM COOLANT TEMPERATURE SENSOR 1. Remove the coolant temperature sensor. CAUTION: Handle the coolant temperature sensor with special care. Never subject it to shock or allow it to be dropped. If it is dropped, it must be replaced.
Page 334: Oil Level Switch
– ELEC SIGNAL SYSTEM OIL LEVEL SWITCH 1. Remove: • Oil level switch Ch R/B 2. Connect: • Pocket tester (to the oil level switch coupler) 3. Check: • Oil level switch continuity É Faulty → Replace. È Good Switch position Bad condition condition Down...
Page 335: Speed Sensor
– ELEC SIGNAL SYSTEM SPEED SENSOR 1. Inspect: • Speed sensor Inspection steps: • Connect the pocket tester (DC 20 V) to the speed sensor coupler (wire harness side) as shown. Positive tester probe → White/Yellow Negative tester probe → Black/Blue Positive battery terminal →...
Page 336 GRIP WARMER SYSTEM CIRCUIT DIAGRAM È È R/G R/W G/B R/L B/L G/W G L/R Br/R Sb W/L Br/R Gy/R Gy/R B O/B FUEL PUMP GEAR MOTOR HEADLIGHT O R/W SUB-WIRE SUB-WIRE SUB-WIRE WIRE HARNESS WIRE HARNESS R/L L/R WIRE HARNESS WIRE HARNESS SUB-WIRE WIRE HARNESS...
Page 337: Grip Warmer System
– ELEC GRIP WARMER SYSTEM GRIP WARMER SYSTEM CIRCUIT DIAGRAM 2 A.C. magneto 3 Rectifier/regulator 4 Main switch 5 Main fuse 6 Load control relay 0 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...
Page 338: Troubleshooting
– ELEC GRIP WARMER SYSTEM TROUBLESHOOTING GRIP WARMER AND THUMB WARMER DO NOT OPERATE. Check the main fuse and ignition fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse and/or ignition fuse. Check the battery. Refer to “BATTERY INSPECTION” in CHAPTER 2. OUT OF SPECIFICATION Replace and/or charge the battery.
Page 339 – ELEC GRIP WARMER SYSTEM PASSENGER GRIP WARMER DOES NOT OPERATE. (PZ50VT) Check the main fuse, ignition fuse, and signal fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. Replace the main fuse, ignition fuse, and/or signal FAULTY fuse. Check the battery. Refer to “BATTERY INSPECTION”...
Page 340: Grip And Thumb Warmer
– ELEC GRIP WARMER SYSTEM GRIP AND THUMB WARMER 1. Disconnect: • Grip warmer coupler • Thumb warmer coupler 2. Connect: • Pocket tester Ω × 1 (to the grip warmer coupler and/or thumb – warmer coupler) 3. Measure: • Grip warmer resistance 1 •...
Page 341: Passenger Grip Warmer (Pz50Vt)
– ELEC GRIP WARMER SYSTEM PASSENGER GRIP WARMER (PZ50VT) 1. Disconnect: • Passenger grip warmer coupler Ω × 1 2. Connect: • Pocket tester – (to the passenger grip warmer coupler) 3. Measure: • Passenger grip warmer resistance Out of specification → Replace. Passenger grip warmer resistance (high): 8.82 ~ 10.78 Ω...
Page 342: Passenger Grip Warmer Relay (Pz50Vt/Pz50Mp)
– ELEC GRIP WARMER SYSTEM PASSENGER GRIP WARMER RELAY (PZ50VT/PZ50MP) 1. Remove: • Passenger grip warmer relay Inspection steps: • Connect the pocket tester (Ω × 1) and battery (12 V) to the passenger grip warmer relay termi- nals as shown. Positive battery terminal →...
Page 343 – ELEC 8-49...
Page 344 COOLING SYSTEM (PZ50M/PZ50VT/PZ50MP) CIRCUIT DIAGRAM È È R/G R/W G/B R/L G L/R Br/R Sb W/L B/L G/W Br/R Gy/R Gy/R B O/B FUEL PUMP GEAR MOTOR HEADLIGHT O R/W SUB-WIRE SUB-WIRE SUB-WIRE WIRE HARNESS WIRE HARNESS R/L L/R WIRE HARNESS WIRE HARNESS SUB-WIRE WIRE HARNESS...
Page 345: Cooling System (Pz50M/Pz50Vt/Pz50Mp)
– ELEC COOLING SYSTEM (PZ50M/PZ50VT/PZ50MP) COOLING SYSTEM (PZ50M/PZ50VT/ PZ50MP) CIRCUIT 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...
Page 346: Troubleshooting
– ELEC COOLING SYSTEM (PZ50M/PZ50VT/PZ50MP) TROUBLESHOOTING THE RADIATOR FAN MOTOR DOES NOT MOVE Check the main fuse, ignition fuse, and radiator fan motor fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse, and/or radia- tor fan motor fuse.
Page 347: Radiator Fan Motor
– ELEC COOLING SYSTEM (PZ50M/PZ50VT/PZ50MP) RADIATOR FAN MOTOR 1. Disconnect: • Radiator fan motor coupler 2. Connect: • Battery 3. Inspect: • Radiator fan motor Positive battery terminal → Blue 1 Negative battery terminal → Black 2 Does not move → Replace the radiator fan motor.
Page 348: Drive/Reverse Selecting System (Pz50Gt/Pz50Fx/Pz50M/Pz50Vt/Pz50Mp)
DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) CIRCUIT DIAGRAM È È R/G R/W G/B R/L B/L G/W G L/R Br/R Sb W/L Br/R Gy/R Gy/R B O/B FUEL PUMP GEAR MOTOR HEADLIGHT O R/W SUB-WIRE SUB-WIRE SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS WIRE HARNESS SUB-WIRE WIRE HARNESS R/L L/R...
Page 349: Circuit Diagram
DRIVE/REVERSE SELECTING SYSTEM – ELEC (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) DRIVE/REVERSE SELECTING SYSTEM (PZ50GT/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...
Page 350: Troubleshooting
DRIVE/REVERSE SELECTING SYSTEM – ELEC (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) TROUBLESHOOTING CANNOT SHIFT TO DRIVE OR REVERSE. Check the main fuse, ignition fuse, and gear motor fuse. Refer to “FUSE INSPECTION” in CHAPTER 2. FAULTY Replace the main fuse, ignition fuse, and/or gear motor fuse. Check the battery.
Page 351: Gear Motor
DRIVE/REVERSE SELECTING SYSTEM – ELEC (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) GEAR MOTOR 1. Remove: • Gear motor Refer “SECONDARY SHAFT REVERSE GEAR CASE” in CHAPTER 4. NOTE: Since the pinion gear is in the drive position when the gear motor is removed, be sure to perform the reverse position inspection first.
Page 352: Gear Motor Relay 1
DRIVE/REVERSE SELECTING SYSTEM – ELEC (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) GEAR MOTOR RELAY 1 1. Remove: • Gear motor relay 1 (with the black coupler) Inspection steps: • Connect the pocket tester (Ω × 1) to the gear Br/R Br/B motor relay 1 terminals as shown. Positive tester probe →...
Page 353: Gear Motor Relay 3
DRIVE/REVERSE SELECTING SYSTEM – ELEC (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) • Connect the pocket tester (Ω × 1) and battery (12 V) to the gear motor relay 2 terminals as shown. Positive battery terminal → Red/Green 3 Negative battery terminal → Sky blue/White 4 Positive tester probe →...
Page 354: Chapter 9. Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Model code number: 8GC1 (PZ50 “USA/Canada”) 8GC2 (PZ50 “Europe”) 8GK1 (PZ50GT “USA/Canada”) 8GK2 (PZ50GT “Europe”) 8GN1 (PZ50FX “USA/Canada”) 8GN2 (PZ50FX “Europe”) 8GP1 (PZ50M “USA/Canada”) 8GP2 (PZ50M “Europe”) 8GJ1 (PZ50VT “USA/Canada”) 8GJ2 (PZ50VT “Europe”) 8GR1 (PZ50MP “Canada”) 8GR2 (PZ50MP “Europe”) Dimensions:...
Page 355 SPEC GENERAL SPECIFICATIONS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Engine: Engine type Liquid-cooled, 4-stroke, DOHC Cylinder type Backward-inclined parallel 2-cylinder Displacement 499 cm (30.45 cu.in) Bore × stroke 77.0 × 53.6 mm (3.03 × 2.11 in) Compression ratio 12.4 : 1 Maximum hose power r/min 58.8 kw (80.0 PS)/11,250 r/min Maximum torque r/min 51.0 Nm (5.2 kgf)/9,000 r/min...
Page 356 SPEC GENERAL SPECIFICATIONS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Transmission: Primary reduction system V-Belt Primary reduction ratio 3.80 ~ 0.95 : 1 Clutch type Automatic centrifugal engagement Secondary reduction system Chain Secondary reduction ratio 2.28 (41/18) (PZ50/PZ50FX) 2.05 (41/20) (PZ50GT) 2.41 (41/17) (PZ50M “USA/Canada”) 2.16 (41/19) (PZ50M “Europe”) 2.37 (45/19) (PZ50VT “USA/Canada”) 2.50 (45/18) (PZ50VT “Europe”/PZ50MP)
Page 357 SPEC GENERAL SPECIFICATIONS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Headlight bulb type: Halogen bulb Bulb wattage × Quantity: 12 V, 60/55 W × 2 Headlight Tail/brake light Meter light Warning light High beam indicator light Low coolant temperature indicator light Knock control system indicator light Drive position indicator light LED (PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP) Reverse position indicator light...
Page 358: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Cylinder head: Volume (with spark plug) 13.82 ~ 14.62 cm (0.84 ~ 0.89 cu.in) <Warpage limit> 0.10 mm (0.0039 in) Lines indicate straight edge measurement. Cylinder: Material Aluminum alloy with dispersion coating Bore size 77.000 ~ 77.010 mm (3.0315 ~ 3.0319 in) <Taper limit>...
Page 359 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Valves, valve seats, valve guides: Valve clearance (cold) Intake 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) Exhaust 0.21 ~ 0.25 mm (0.0083 ~ 0.0098 in) Valve dimensions Valve head diameter A Intake 23.4 ~ 23.6 mm (0.9213 ~ 0.9291 in) Exhaust 24.9 ~ 25.1 mm (0.9803 ~ 0.9882 in) Valve face width B...
Page 360 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Valve spring: Free length Intake 36.51 mm (1.44 in) <Limit> 34.68 mm (1.37 in) Exhaust 37.92 mm (1.49 in) <Limit> 36.02 mm (1.42 in) Installed length (valve closed) Intake 30.13 mm (1.19 in) Exhaust 30.50 mm (1.20 in) Compressed spring force (installed) Intake 120.7 ~ 138.9 N (12.3 ~ 14.2 kg, 27.1 ~ 31.2 lb)
Page 361 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Piston ring: Sectional sketch Top ring Ring type Barrel Dimensions (B × T) 0.90 × 2.75 mm (0.035 × 0.108 in) 2nd ring Top ring (same or no) Ring type Taper Dimensions (B × T) 0.80 ×...
Page 362 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Throttle body: Type × Quantity TSK43 × 1 Manufacturer KEIHIN I.D. mark 8GC1 00 Throttle valve (Th.V) N503-89A00 (θ = 8°) Throttle cable free play 2.0 ~ 3.0 mm (0.08 ~ 0.12 in) Engine idle speed 1,700 ~ 1,900 r/min Fuel pump: Type...
Page 363: Power Train
SPEC MAINTENANCE SPECIFICATIONS POWER TRAIN Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Transmission: Type V-belt automatic Range of ratio 3.80 ~ 0.95 : 1 Engagement speed r/min 3,700 ~ 4,100 r/min (PZ50/PZ50GT/PZ50FX) 4,100 ~ 4,500 r/min (PZ50M “USA/Canada”) 3,900 ~ 4,300 r/min (PZ50M “Europe”) 3,300 ~ 3,700 r/min (PZ50VT “USA/Canada”) 2,900 ~ 3,300 r/min (PZ50VT “Europe”/PZ50MP) Shift r/min 10,800 ~ 11,800 r/min...
Page 364 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Free length 72.1 mm (2.84 in) (PZ50/PZ50GT/PZ50FX) 74.1 mm (2.92 in) (PZ50M) 73.4 mm (2.89 in) (PZ50VT “USA/Canada”) 72.9 mm (2.87 in) (PZ50VT “Europe”/PZ50MP) Set length 65.4 mm (2.57 in) Primary sheave weight arm: Part number (with bush) 8GC-17605-00 (PZ50/PZ50GT/PZ50FX/PZ50VT/PZ50MP) 8DN-17605-30 (PZ50M) Weight (without bush and rivets)
Page 365 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Secondary sheave spring: Part number 90508-55007 (PZ50/PZ50GT/PZ50FX/PZ50M) 90508-58007 (PZ50VT/PZ50MP) Color code Red (PZ50/PZ50GT/PZ50FX/PZ50M) Blue (PZ50VT/PZ50MP) Outside diameter 66.0 mm (2.598 in) Wire diameter 5.5 mm (0.217 in) (PZ50/PZ50GT/PZ50FX/PZ50M) 5.8 mm (0.228 in) (PZ50VT/PZ50MP) Hole position Sheave side-spring seat side (twist angle) A-1 (45°) (PZ50/PZ50GT/PZ50FX) B-1 (55°) (PZ50M)
Page 366 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Track: Part number 8GK-47110-00 (PZ50/PZ50FX) 8GN-47110-00 (PZ50GT) 8GP-47110-00 (PZ50M) 8ET-47110-10 (PZ50VT) 8GR-47110-00 (PZ50MP) Width 355.6 mm (14.0 in) (PZ50/PZ50GT/PZ50FX/PZ50M) 381.0 mm (15.0 in) (PZ50VT) 406.4 mm (16.0 in) (PZ50MP) Length 3,072.4 mm (120.96 in) (PZ50/PZ50GT/PZ50FX) 3,648.5 mm (143.64 in) (PZ50M/PZ50VT/PZ50MP) Pitch 64.0 mm (2.52 in)
Page 367 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Suspension wire diameter Front 8.8 mm (0.346 in) (PZ50/PZ50FX) 7.8 mm (0.307 in) (PZ50GT “USA/Canada”) 7.5 mm (0.295 in) (PZ50GT “Europe”/PZ50M/PZ50VT “Europe”) 8.2 mm (0.322 in) (PZ50VT “USA/Canada”/PZ50MP) Rear 11.2 mm (0.441 in) (PZ50/PZ50FX/PZ50VT “Europe”/ PZ50MP) 10.9 mm (0.429 in) (PZ50GT) 10.3 mm (0.406 in) (PZ50M)
Page 368 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Rear Extension 3,170.0 N/0.3 m/s (323.2 kg/0.3 m/s, 712.6 lb/0.3 m/s) (PZ50) 1,450.0 N/0.3 m/s (147.9 kg/0.3 m/s, 326.0 lb/0.3 m/s) (PZ50GT “USA/Canada”) 1,710.0 N/0.3 m/s (174.4 kg/0.3 m/s, 384.4 lb/0.3 m/s) (PZ50GT “Europe”) 3,070.0 N/0.3 m/s (313.0 kg/0.3 m/s, 690.1 lb/0.3 m/s) (PZ50FX) 1,430.0 N/0.3 m/s (145.8 kg/0.3 m/s, 321.5 lb/0.3 m/s) (PZ50M)
Page 369: Chassis
SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Frame: Frame material Monocoque (Aluminum and Steel) Seat height 719 mm (28.31 in) (PZ50/PZ50GT/PZ50FX/PZ50M) 724 mm (28.50 in) (PZ50VT/PZ50MP) Luggage box location Not available Steering: Lock-to-lock angle (left) 32.4° (R ski) 37.6° (L ski) (right) 37.6°...
Page 370 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Wire diameter 8.8 mm (0.346 in) (PZ50) 7.8 mm (0.307 in) (PZ50GT/PZ50VT “Europe”) 8.5 mm (0.335 in) (PZ50FX) 8.2 mm (0.323 in) (PZ50M) 9.8 mm (0.386 in) (PZ50VT “USA/Canada”) 8.0 mm (0.315 in) (PZ50MP) Shock absorber: Damping force Extension 2,260 N/0.3 m/s (230.4 kg/0.3 m/s, 508.0 lb/0.3 m/s) (PZ50)
Page 371: Electrical
SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Voltage 12 V Ignition system: Ignition timing (B.T.D.C.) 5° at 1,800 r/min Advanced type Digital type Ignition coil: Model/Manufacturer F6T567/MITSUBISHI Ignition spark gap 6.0 mm (0.24 in) 1.19 ~ 1.61 Ω at 20 °C (68 °F) Primary coil resistance Secondary coil resistance 8.5 ~ 11.5 kΩ...
Page 372 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP T.P.S. (throttle position sensor): Model/Manufacturer 8GC/KEIHIN Resistance 4 ~ 6 kΩ at 20 °C (68 °F) (Blue – Black/Blue) Oil level switch: Model/Manufacturer 8GC/ASTI Fuel sender: Model/Manufacturer 8GC/NIPPON SEIKI 10 ~ 12 Ω at 20 °C (68 °F) Sender resistance Full 179 ~ 185 Ω...
Page 373 SPEC MAINTENANCE SPECIFICATIONS Model PZ50/PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP Speed sensor: Model/Manufacture 8FP/NIPPON SEIKI Cylinder identification sensor: Model/Manufacture 8GC/NIPPON SEIKI Crankshaft position sensor: Model/Manufacture 8GC/MITSUBISHI 189 ~ 231 Ω at 20 °C (68 °F) (Gray – Black) Resistance Intake air pressure sensor: Model/Manufacture 5PS/DENSO Intake air temperature sensor: Model/Manufacture 8FP/MITSUBISHI...
Page 374: Tightening Torque
SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE Tightening torque Parts to be tightened Remarks m · kg ft · lb Spark plug Cylinder head bolt (M10 × 1.25) See NOTE.*1 Cylinder head bolt Camshaft cap and cylinder head Apply the engine oil. Cylinder head cover Cylinder identification sensor Ignition coil...
Page 375 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m · kg ft · lb ® Bearing retainer Apply LOCTITE Right balancer weight Connecting rod and cap See NOTE.*3 A.C. magneto rotor 13.0 Apply the engine oil. A.C. magneto rotor cover bolt (M6 × 1.0) × 7 A.C.
Page 376: Power Train
SPEC TIGHTENING TORQUE POWER TRAIN Tightening torque Parts to be tightened Remarks m · kg ft · lb Primary sheave See NOTE. Apply engine oil. Spider and sliding sheave 20.0 Left-hand thread. ® Apply LOCTITE Primary sheave cap and sliding sheave Roller and weight (primary sheave) Secondary sheave Bushing stopper bolt (secondary sheave)
Page 377 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m · kg ft · lb Front pivot arm and connecting arm (PZ50VT/PZ50MP) Front pivot arm and sliding frame Front suspension bracket and connecting arm ® Sliding frame and wheel bracket Apply LOCTITE (PZ50M) Suspension wheel...
Page 378 SPEC TIGHTENING TORQUE CHASSIS Tightening torque Parts to be tightened Remarks m · kg ft · lb Front bumper Wind shield bracket (PZ50GT/PZ50FX/PZ50M) Mirror (PZ50VT/PZ50MP) Headlight bracket (PZ50/PZ50GT/PZ50FX/PZ50M) Side panel (PZ50/PZ50GT/PZ50FX/PZ50M) Lower cover Seat rail assembly bolt (PZ50/PZ50GT/PZ50FX/PZ50M) Seat rail assembly nut (PZ50/PZ50GT/PZ50FX/PZ50M) Seat (PZ50/PZ50GT/PZ50FX/PZ50M)
Page 379 SPEC TIGHTENING TORQUE Tightening torque Parts to be tightened Remarks m · kg ft · lb Shock absorber (upper) Shock absorber (lower) Upper arm ball joint and upper arm Upper arm and frame Upper arm ball joint and steering knuckle Lower arm and frame Lower arm and steering knuckle Stabilizer and stabilizer joint...
Page 380: General Torque Specifications
GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS GENERAL TORQUE General torque SPECIFICATIONS specifications (nut) (bolt) This chart specifies torque for standard fasteners m · kg ft · lb with standard I.S.O. pitch threads. Torque specifi- 10 mm 6 mm cations for special components or assemblies are 12 mm 8 mm included in the applicable sections of this book.
Page 381 GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS 9-28...
Page 382: Cable Routing
SPEC CABLE ROUTING 9-29...
Page 383 SPEC CABLE ROUTING CABLE ROUTING PZ50/PZ50M/PZ50FX/PZ50GT 1 To the coolant temperature sen- 2 To the knock sensor 3 Route the fuel hose over the wire harness and fuel tank breather hose. 4 Wire harness 5 Bundle the slack in the wire har- ness and fasten it with the plastic band.
Page 384 SPEC CABLE ROUTING 9-31...
Page 385 SPEC CABLE ROUTING M Parking brake cable N Brake hose O Route the fuel tank breather hose along the steering gate. P Speed sensor coupler Q Auxiliary DC jack (PZ50GT/ PZ50FX/PZ50M) R Install the frame ground lead ter- minal and the Rectifier/regulator using the same nut.
Page 386 SPEC CABLE ROUTING 9-33...
Page 387 SPEC CABLE ROUTING PZ50VT/PZ50MP 1 To the coolant temperature sen- 2 To the knock sensor 3 Pass the plastic band through the hole in the frame front cross member, and then fasten the wire harness with the band. Posi- tion the buckle of the plastic band on top of the leads, with the end facing to the left.
Page 388 SPEC CABLE ROUTING 9-35...
Page 389 SPEC CABLE ROUTING O Install the fuel tank breather hose to the fuel tank with the hose clamp. Be sure to connect the hose end that does not have a paint mark to the fuel tank. P Parking brake cable Q Brake hose R Auxiliary DC jack S Route the fuel tank breather...
Page 390 SPEC CABLE ROUTING 9-37...
Page 391 SPEC CABLE ROUTING 1 Injector coupler 2 Cylinder head breather hose 3 Reverse position switch coupler (PZ50GT/PZ50FX/PZ50M/ PZ50VT/PZ50MP) 4 Drive position switch coupler (PZ50GT/PZ50FX/PZ50M/ PZ50VT/PZ50MP) 5 Fasten the sub-wire harness to the coolant reservoir with the plastic band, making sure to route the harness to the front of the gear motor.
Page 392 SPEC CABLE ROUTING 9-39...
Page 393 SPEC CABLE ROUTING G Cylinder #2 ignition coil lead H Speed sensor lead coupler I To the speed sensor J Frame ground lead K Connect the sub-wire harness coupler to the wire harness cou- pler. L To the handlebar switch M Throttle position sensor coupler N Oil pressure switch coupler O Wire harness...
Page 394 SPEC CABLE ROUTING 9-41...
Page 395 SPEC CABLE ROUTING 1 To the oil pressure switch 2 Throttle position sensor coupler 3 Fuel hose 4 Fasten the corrugated tube and sub-wire harness to the frame front cross member with the plas- tic band. (PZ50/PZ50GT/ PZ50FX/ PZ50M) 5 Brake light switch (PZ50/ PZ50GT/PZ50FX/PZ50M) 6 Sub-wire harness coupler 7 Fasten the corrugated tube to the...
Page 396 SPEC CABLE ROUTING 9-43...
Page 397 SPEC CABLE ROUTING L Cylinder identification sensor M Ignition coil N Fasten the sub-wire harness to the frame front 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.
Page 398 SPEC CABLE ROUTING PZ50 PZ50VT/PZ50MP PZ50GT/PZ50FX/PZ50M 9-45...
Page 399 SPEC CABLE ROUTING 1 To the main switch 2 To the main switch 3 To the fuel pump 4 Route the wire harness over the frame rear cross member. 5 To the multi-function meter unit 6 Brake hose 7 Coolant reservoir breather hose 8 Wire harness 9 Fasten the wire harness at the white tape to the frame rear...
Page 400 SPEC CABLE ROUTING PZ50 PZ50VT/PZ50MP PZ50GT/PZ50FX/PZ50M 9-47...
Page 401 SPEC CABLE ROUTING I Oil tank inlet hose J Oil tank outlet hose K Place the end of the coolant res- ervoir breather hose to the inside of the frame rear cross member. L Fasten the starter motor lead and negative battery lead to the radi- ator joint pipe with the plastic band.
Page 402 SPEC CABLE ROUTING PZ50 PZ50VT/PZ50MP PZ50GT/PZ50FX/PZ50M 9-49...
Page 403 SPEC CABLE ROUTING [ Fasten the tail/brake light lead and brake hose to the frame rear cross member with the plastic band. Install the plastic band with its buckle positioned towards the front of the machine and its end facing to the right. \ 40 ~ 50 mm (1.6 ~ 2.0 in) ] Parking brake cable _ Gear motor lead coupler...
Page 404 SPEC CABLE ROUTING 9-51...
Page 405 SPEC CABLE ROUTING PZ50/PZ50GT/PZ50FX/PZ50M 1 Corrugated tube (engine stop switch lead, throttle switch lead, right grip warmer lead, and thumb warmer lead) 2 Right grip warmer lead 3 Right handlebar switch 4 Route the throttle cable over the handlebar. 5 Multi-function meter unit lead 6 Parking brake cable 7 Route the brake hose over the top rod of the windshield bracket.
Page 406 SPEC CABLE ROUTING 9-53...
Page 407 SPEC CABLE ROUTING P Route the A.C. magneto lead behind the idling adjusting screw remote adjustment cable. Q Fasten the idling adjusting screw and oil pressure switch lead at the white tape with the plastic band. Install the plastic band with its buckle positioned towards the rear of the machine and its end facing to the right.
Page 408 SPEC CABLE ROUTING 9-55...
Page 409 SPEC CABLE ROUTING f Fasten the corrugated tube (engine stop switch lead, throttle switch lead, right grip warmer lead, and thumb warmer lead), corrugated tube (left grip warmer lead, grip/thumb warmer adjust- ment switch lead, brake light switch lead, and headlight beam switch lead), parking brake cable, throttle cable, speedome- ter unit lead, and brake hose with...
Page 410 SPEC CABLE ROUTING 9-57...
Page 411 SPEC CABLE ROUTING PZ50VT/PZ50MP 1 Corrugated tube (engine stop switch lead, throttle switch lead, right grip warmer lead, and thumb warmer lead) 2 Right grip warmer lead 3 Right handlebar switch 4 Route the throttle cable over the handlebar. 5 Multi-function meter unit lead 6 Parking brake cable 7 Route the brake hose in front of the handlebar.
Page 412 SPEC CABLE ROUTING 9-59...
Page 413 SPEC CABLE ROUTING P Fasten the idling adjusting screw and oil pressure switch lead with the plastic band. Install the plas- tic band with its buckle posi- tioned towards the rear of the machine and its end facing to the right.
Page 414 SPEC CABLE ROUTING 9-61...
Page 415 SPEC CABLE ROUTING e Fasten the corrugated tube (engine stop switch lead, throttle switch lead, right grip warmer lead, and thumb warmer lead), corrugated tube (left grip warmer lead, grip/thumb warmer adjust- ment switch lead, brake light switch lead, and headlight beam switch lead), parking brake cable, throttle cable, speedome- ter unit lead, and brake hose with...
Page 416 SPEC CABLE ROUTING 9-63...
Page 417 SPEC CABLE ROUTING PZ50VT/PZ50MP 1 Headlight unit 2 Headlight lead coupler 3 Headlight lead 4 Fasten the headlight 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...
Page 418 SPEC CABLE ROUTING PZ50/PZ50GT/PZ50FX/PZ50M PZ50VT/PZ50MP 9-65...
Page 419 SPEC CABLE ROUTING 1 Tail/brake light lead 2 Fasten the tail/brake light lead with the plastic band. Face the end of the plastic band down- ward. 3 Fasten the tail/brake light lead at the white tape with the plastic band. Face the end of the plastic band downward.
Page 420 WIRING DIAGRAM PZ50 2007 8GC-0F001-00 R/G R/W G/B R/L B/L G/W Gy/R Gy/R FUEL PUMP SUB-WIRE SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS WIRE HARNESS HARNESS 2 HARNESS 1 HARNESS O R/W R/L L/R (BLACK) Gy/R R/W Gy/R B R/B (BLACK) Br/L B G/B Gy/R R/L R/B...
Page 421 WIRING DIAGRAM PZ50 2007 8GC-0F001-00 1 Crankshaft position sensor COLOR CODE 2 A.C. magneto B ....Black 3 Rectifier/regulator Br.....Brown 4 Main switch Ch....Chocolate 5 Main fuse G .....Green 6 Load control relay Gy....Gray 7 Fuel injection system fuse L ....Blue 8 Starter relay Lg ....Light green 9 Starter motor...
Page 422 WIRING DIAGRAM PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 2007 8GK-0F001-00/8GN-0F001-00/8GJ-0F001-00 È È R/G R/W G/B R/L B/L G/W G L/R Br/R Sb W/L Br/R Gy/R Gy/R B O/B FUEL PUMP GEAR MOTOR O R/W HEADLIGHT SUB-WIRE SUB-WIRE SUB-WIRE WIRE HARNESS WIRE HARNESS R/L L/R WIRE HARNESS WIRE HARNESS SUB-WIRE WIRE HARNESS...
Page 423 WIRING DIAGRAM PZ50GT/PZ50FX/PZ50M/PZ50VT/PZ50MP 2007 8GK-0F001-00/8GN-0F001-00/8GJ-0F001-00 1 Crankshaft position COLOR CODE warmer relay d Frame ground sensor B ....Black 2 A.C. magneto e Passenger grip Br.....Brown 3 Rectifier/regulator warmer switch Ch....Chocolate 4 Main switch f Passenger grip G....Green 5 Main fuse warmer Gy....Gray 6 Load control relay...
Page 424 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN U.S.A. 2006.07 CR...

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Yamaha PZ50W Service Manual

Chapter 1. General Information

Machine Identification

Important Information

Special Tools

Chapter 2

Periodic Inspection and Adjustment

Introduction

Periodic Maintenance Chart for the Emission Control System

General Maintenance and Lubrication Chart

Engine

Power Train

Chassis

Electrical

Tuning

Chapter 3

Chassis

Cowlings

Steering

Ski

Front Suspension

Chapter 4. Power Train

Primary Sheave and Drive V-Belt

Secondary Sheave

Drive Chain

Secondary Shaft

Secondary Shaft and Reverse Gear Case

Brake

Slide Rail Suspension

Front Axle and Track

Chapter 5. Engine

Seat and Fuel Tank

Backrest and Passenger Seat

Rider Seat and Fuel Tank

Exhaust Pipe and Muffler

Oil Tank

Engine Assembly

Camshafts

Cylinder Head

Valves and Valve Springs

A.C. Magneto Rotor and Starter Clutch

Oil Pan and Oil Pump

Balancer

Crankcase

Chapter 6. Cooling System

Radiator and Heat Exchanger

Thermostat

Water Pump

Chapter 7. Fuel Injection System

Fuel Injection System

Throttle Body

Chapter 8. Electrical

Switch Inspection

Ignition System

Electrical Starting System

Charging System

Lighting System

Signal System

Grip Warmer System

Cooling System (Pz50M/Pz50Vt/Pz50Mp)

Drive/Reverse Selecting System (Pz50Gt/Pz50Fx/Pz50M/Pz50Vt/Pz50Mp)

Chapter 9. Specifications

General Specifications

Maintenance Specifications

Tightening Torque

General Torque Specifications

Definition of Units

Cable Routing

Quick Links

Troubleshooting

Related Manuals for Yamaha PZ50W

Summary of Contents for Yamaha PZ50W